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User`s Manual Wave Rider 1

1. 2025 792 240 2025 791 2P 35A 2025 765 actioo 2025 786 22 60 2025 73 50 aczoson 2025 792 2 504 2025 767 EDz150L 2025 760 99 2025 796 2025 794 2 54 2060 2025 768 ED24175L 2025 099 OC2100H 2025 797 2000 2025 706 2 50 2025 770 ED2500L 2025 541 ED2425L 2025 759 ED2128 2025 750 100A oun 2025 772 ED2500L 2025 641 5 128 2025 759 2 128 2025 759 2 99 2025 772 ED2500L 2025 541 ED2125L 2025 759 y ED2125L 2025 759 GHC2100 2025 772 HIGHER KAIC 1 PH UPS INPUT CIRCUIT BREAKERS as 1204 INPUT 208V INPUT 240V INPUT 277V INPUT UNIT RATING RATING C H P N RATING P N CIH PIN RATING CIR PIN PN 1P 50A 2P 30A jJQHCX1050 2025 800 2025 764 GHC2025 2025 763 2P 80 42KA 2 100A QHCX2080 2025 802 2025 767 GHC2040 2025 766 k GHC2100 2025 772 2025 768 GHC2050 2025 767 rth X TT ED2150L 2025 760 d i 2025 769 ED2175L 2025 999 leote i 2025 771 Re ED2200L 1 2025 541 2025 759 2125 2025 759 2P ED2200L 2025 541 d 2025 759 2125 2025 750 ED2200L 2025 541
2. Cara Power User s Manual Wave Rider 1 Central Lighting Inverter 3 20 kva 2 1 17 kw Doc 6002 1394 Revision J Installation and Operating Documentation Due to continuous product improvement this document is subject to change without prior notice Crucial Power Products TABLE OF CONTENTS SECTION PAGE REVISIONIHISTORY 2 X PROPRIETARY cc tela A buste ots bt EAE utto d SECTION 1 SAFETY EE 1 1 SECTION 2 INSTALLATION ae ae ee 2 1 2 1 SITE PLANNING AND PREPARATION 22222 anaa 2 1 Illustration 2 1 48 Cabinet Cable Access and Mounting 88 2 2 Illustration 2 2 68 Cabinet Cable Access and Mounting 2 3 Illustration 2 3 Oversize Cabinet Cable Access and Mounting 2 4 2 2 EQUIPMENT UNPACKING _________________________________________ 2 5 Illustration 2 4 Fork Inge 2 5 2 3 UNIT ANSTALISAT IG NI ne e vua centers Wik oct e men tiki eot EEN 2 6 Illustration 2 5 Wave Rider 1 Customer s Connection Input Terminal Block 2 7 Illustration 2 6 Customer s Connection Terminal Block for 120 208 240 277V Output 2 8 Illustration 2 7 Customer s Connection Terminal Block for 208 240 277V Output 2 8 Illustration 2 8 Customer Connections Same Input Output Voltage 120V Unit 2 9 Illustration 2 9 Customer Connections Same Input Output Volt
3. 4 1 7 Atthis time the Wave Rider 1 should be providing AC line power If the Wave Rider 1 is not operating in the normal mode turn off the input circuit breaker Contact Crucial Power at 800 797 7782 for technical assistance 4 1 8 Recheck that the output voltage is 120 208 240 or 277 VAC If the output voltage is approximately the same as the nameplate turn on the loads 4 1 9 Verify battery operation and the inverter test switch To place the Wave Rider 1 in battery operation simulate loss of input power press and hold yellow Inverter Test Push Button With Push Button in the hold position the Wave Rider 1 should be running on its internal batteries Verify that the LCD panel displays is as below where xx is the kVA of this unit Line 1 UPS ALARM XX kVA Line 2 INPUT BAD CHRGR ON Line 3 BATTERY OK DC OK Line 4 ON INVERTER OUT Release the yellow Inverter Push Button and Verify that the LCD PANEL displays INPUT OK CHRGR ON Caution Be sure to release the Push Button after the test so it will not deplete the ate ate e batteries 4 1 10 The Wave Rider 1 is now fully functional providing clean sine wave power to the load with battery back up in case of an input power failure This concludes the start up procedures 6002 1394 REV J 4 2 Crucial Power Products 42 OPERATION 4 2 1 Turning On the Wave Rider 1 4 2 2 4 3 4 3 1 4 3 2 1 Apply input power
4. 4 indicators or alarms operate abnormally or continuously 5 Any other abnormal function of the system occurs 6 If any abnormal battery condition is detected 7 When you are unsure of what action to take 6 3 STEPS TO TAKE If any of the above occur 1 Consult Appendix C LCD Display Menu and Troubleshooting Guide Record information on the LCD Display to relay to Crucial Power Customer Service and Support 2 Call Crucial Power Customer Support at 1 800 797 7782 or 1 800 PWR SRVC Danger LETHAL VOLTAGES ARE PRESENT INSIDE THE EQUIPMENT EVEN WHEN THERE APPEARS TO BE NO INPUT POWER TO THE UNIT PROTECT YOURSELF FROM THE RISK ELECTROCUITION BY REFERRING SERVICE TO QUALIFIED PERSONNEL ONLY 6 4 PREVENTATIVE MAINTENANCE Unit Operator Maintenance consists of the basic tasks listed in this section Other maintenance functions require Crucial Power Service personnel 6 4 1 Maintaining an Operator s Log Careful record keeping will ensure proper maintenance of the Unit and assist in the correction of any abnormal conditions The operator s log should contain the following information Date of system start up Dates that battery maintenance was performed Dates that input output and battery status readings were checked and the values displayed for these readings Dates and summaries of all communications with Crucial Power Service Personnel 6002 1394 REV J 6 3 Crucial Power Products 6 4 2 Periodi
5. GND GND o GND ILLUSTRATION 2 5 WAVE RIDER 1 CUSTOMER S CONNECTION INPUT TERMINAL BLOCK INPUT POWER VOLT TERMINAL 1 2 3 120 H N GND 208 H H GND 240 H H GND 277 H N GND B Output Load Connection by Customer Connect the critical load to one output terminal TB2 as shown in the voltage connection diagram with the main output circuit breaker However when any aux output CBs are used follow the instructions below 1 No main output CB but only aux output CBs are used Connect critical loads to aux CBs directly not TB2 Do Not Use 2 Both main output CB and aux output CBs are used Connect the main load to TB2 as shown in the voltage connection diagram and connect other aux load directly to aux output CBs Locate the aux output CBs Neutral and grounding terminals are provided 6002 1394 REV J 2 7 Crucial Power Products For 120 208 240 277V output verify jumper between TB2 2 and TB2 3 120V output is connected at TB2 1 Neutral TB2 2 120VAC Hot 208V output is connected at TB2 1 Hot TB2 4 208 Hot 240V output is connected at TB2 1 Hot TB2 5 240VAC Hot 277 output is connected at TB2 1 Neutral TB2 6 277 Hot From External Battery Cabinet To Customer s Load BATTERY INPUT TB1 OUTPUT TB2 CONNECTION TB3 1 2 3 1 2 3 4 5 6 7 1 2 3
6. 2 With input power available turn on the main input circuit breaker 3 Wait until you hear the input contactor closing and fan running 4 Close the battery circuit breaker only after the LCD display is lit and displays screens per Appendix D 5 Verify that all parameters on the LCD display panel are proper See Appendix D for display details 6 Close the output circuit breaker 7 Turn On the auxiliary output circuit breakers Turning Off the Wave Rider 1 Turn off the Output Breaker s Battery Breaker and Input Breaker FIELD REPLACEABLE UNITS FRUS Refer to Table 4 1 for ordering the replacement parts from the factory Supply the information from the units nameplate including the serial number model number KVA P F input output battery voltages and date of manufacture when ordering parts from factory Call Toll Free 800 PWR SRVC in North America Replacement parts must be replaced by qualified factory trained service personnel only A Circuit boards and IGBTs contain ESDS ElectroStatic Discharge Susecptable components Handle and package ATTENTION ESDS devices in accordance with standard JESD625 OBSERVE PRECAUTIONS A Use a grounded ESD wrist strap when handling the devices ELECTROSTATIC and circuit boards Always package components and circuit ences boards in static dissipative plastic bags before transporting sna am even if a device has failed Failure to do so could result in further damage compl
7. 2 continued B 208V Unit INPUT CONNECTION 208V OUTPUT CONNECTION 208VAC oP r gt 12 4 OUTPUT CB OPTIONAL 0 lt gt 2P Aux Output CBs option o INPUT IO 23 Customer connect loads O to these Aux output CB When both main output CB and Aux output CB option are used notice these jumpers Customer can turn on off each CB individually This is factory standard To locate all Aux Output CBs after the main output CB move these jumpers to CB3 2 and CB3 4 ILLUSTRATION 2 9 208V UNIT 6002 1394 REV J 2 10 Crucial Power Products 2 continued C 240V Unit OUTPUT CONNECTION 240 21 1314151617 GND H TB2 H 174 OUTPUT CB cast I OPTIONAL l 4 0 I lt gt 2P Aux Output CBs option INPUT 0 LOP 2 Customer connect loads O to these Aux Output CB When both main output CB and Aux output CB option are used notice these jumpers Customer can turn on off each CB individually This is factory standard To locate all Aux Output CBs after the main output CB move these jumpers to CB3 2 and CB3 4 ILLUSTRATION 2 10 240V UNIT 6002 1394 REV J 2 11 Crucial Power Products 2 continued D 277 Unit INPUT CONNECTION 277V OUTPUT CONNECTION GND 277VAC Neutral and Gnd are ee tied Jumper from TB2 7 and TB2 1 for 277V unit 1P
8. 800 797 7782 Do not use a questionable battery under any circumstances even temporarily 6002 1394 REV J D 1 Crucial Power Products 96 Volt Nominal Typical 1 Strings of 8 Battery system Maximum 4 Strings of 8 Battery system are available in maximum 2 Cabinets depend upon Battery Run Time requirement Consult Factory for detail UPS ELECTRONICS 2 STRING __ 3 STRING 4 STRING 6002 1394 REV J D 2 Crucial Power Products Maximum 4 Strings of 10 Battery system e Depend upon Battery Run Time requirement 1 20 Volt Nom batteries can be in UPS cabinet separate maximum of 2 Cabinets Typical 1 Strings of 10 Battery system Consult Factory Tor BATT UPS ELECTRONICS 120 VDG 23 E 2 0 oF o v 1 B 2 STRING 3 STRING 4 STRING 6002 1394 REV J D 3 Crucial Power Products 192 Volt Nominal Typical 1 Strings of 16 Battery system Maximum 4 Strings of 16 Battery system Depend upon Battery Run Time requirement batteries can be in UPS cabinet or separate maximum of 3 Cabinets Consult Factory for detail UPS ELECTRONICS O oe 192 VDC 2 STRING 3 STRING 4 STRING 6002 1394 REV J D 4 Crucial Power Products 240 Volt Nominal Maximum 4 Strings 20 Battery system Typical 1 Strings of 20 Battery system Depend upon Battery Run Time requirement batteries can
9. 9100 1363 01 Audio Alarms with Silence Switch 9100 1020 06 Remote UNIT Status Display 9100 1362 01 Form C N O Contacts for Alarms 9100 1401 02 12 13 TVSS Transient Voltage Surge Suppressor 9100 1343 01 thru 16 Normally ON OFF Output Aux Circuit Breakers 9100 1439 01 thru 03 External Output Aux Circuit Breakers in Panel Board 9100 1429 xx Stackable Rack 1 rack per 2 cabinets N A System Input CB Standard Higher KAIC N A System Output CB Standard Higher KAIC 9100 1434 31 thru 86 Higher KAIC Norm ON OFF Output Circuit Breaker Molded case 208 240 9100 1435 01 26 61 86 Higher KAIC Norm ON OFF Output Circuit Breaker 1 Phase Din rail 277V 9100 1317 02 Seismic Mounting Bracket Left and Right set per cabinet 9100 1493 01 Power Flow Mimic GMS Global Monitoring System 9800 005 xx Local on PC via RS232 9800 006 01 Local on PC via RS485 9800 007 01 Basic NetAgent SNMP 9800 007 02 Basic NetAgent SNMP with WIFI HUB 9800 008 01 Advanced NetAgent SNMP 9800 008 02 Advanced NetAgent SNMP with WIFI HUB 9800 008 03 Advanced NetAgent SNMP with mobile GPRS modem 9800 008 04 Advanced NetAgent SNMP with Dial up modem 9100 1501 ECC EMERGENCY CIRCUIT CONVERTER 9100 1502 ECM EMERGENCY CONTROL MODULE 6002 1394 REV J 5 1 Crucial Power Products 5 1 Optional External Maintena
10. GND ov 120V ov 88V 1200 157V GND GND N JUMPER L J FOR 208V 240V l 277 OUTPUT 240V 277V lt F TVT Yr gt ILLUSTRATION 2 6 CUSTOMER S CONNECTION OUTPUT TERMINAL BLOCK 120 208 240 277V For 208V 240 277V output INPUT POWER OUTPUT POWER VOLT TERMINAL VOLT TB2 NEUTRAL BUS GND BUS 1 2 3 TERMINAL NO MOVE TO MOVE TO 1 TO 2 120 V E 120 H N GND 120 240 2 TO 5 120 V TB2 2 2 3 208 H H GND 208 1 4 7 240 H H GND 240 1TO5 7 277 H N GND 277 1TO6 TB2 1 TB2 1 120 1 TO 2 TB2 1 TB2 1 From External Battery Cabinet To Customer s Load BATTERY INPUT TB1 OUTPUT TB2 CONNECTION TB3 1 2 3 1 2 3 4 5 6 7 1 2 3 HOT HOT GND ov 120V ov 88 120V 1577 GND GND N ILLUSTRATION 2 7 CUSTOMER S CONNECTION OUTPUT TERMINAL BLOCK 120 208 240 277V If there are no requirements for remote signaling section 2 4 may be skipped 6002 1394 REV J 2 8 Crucial Power Products 2 Same input voltage and output voltage unit A 120V Unit INPUT 120VAC OUTPUT GND 120V 2 1 1 i 1 CB from CC LC I OPTIONAL 2 1 to TB2 7 l I for 120V In Out unit INPUT CB OPTIONAL Aux Output CBs option Customer connect load to the Aux CB and Neutral for Aux CB option ILLUSTRATION 2 8 120V UNIT 6002 1394 REV J 2 9 Crucial Power Products
11. See more detail on Section 5 OO 3 9 SECTION 4 OPERATION 7 7 ue 4 1 4 1 START UP PROCEDURES e a 4 1 4 2 OPERATION ire hana 4 3 4 3 FIELD REPLACEABLE UNITS 11110100 4 3 Illustration 4 1 Heat Sink Assembly FRU _______________________________ 4 4 4 4 RENEWAL PARTS 4 5 6002 1394 REV J Crucial Power Products SECTION SECTION 5 SYSTEM OPTIONS 5 1 OPTIONAL EXTERNAL MANUAL BYPASS SWITCH Illustration 5 1 Manual Bypass Switch 222222222222 20 Illustration 5 2 Manual Bypass Switch Diagram 2 1 5 2 OPTIONAL INTERNAL MANUAL BYPASS SWITCH 5 3 OPTIONAL AUDIO ALARM WITH SILENCE SWITCH 54 OPTIONAL REMOTE UNIT STATUS PANEL P N 9100 1020 06 00 5 5 OPTIONAL FORM CONTACTS FOR ALARMS P N 9100 1362 01 5 6 OPTIONAL TVSS P N 9100 1440 02 _________________________________ 5 7 OPTIONAL NORMALLY ON NORMALLY OFF OUTPUT AUX CIRCUIT BREAKERS P N 9100 1343 01 THRU 16 sss 5 8 OPTIONAL EXTERNAL OUTPUT AUX CB S IN PANEL BOARD P N 9100 1439 01 THRU 03 5 9 OPTIONAL HIGHER KAIC NORM ON OFF OUTPUT CR 5 10 OPTIONAL INPUT CB STANDARD HIGHER KAIC 511 OPTIONAL OUTPUT CB STANDARD HIGHERKAIC 2 5 12 OPTIONAL SEISMIC MOUNTING BRACKET P N 9100 1317 02 2 5 13 OPTIONAL STACKABLE CABINET RACK P N9100 1429 XX _____________ 5 14 OPTIONAL POWER FLOW MIMIC 9100 1493 01 ________________
12. Terminal Block to remove heat sink assembly TB4 14 Fan Transformer T3 15 Control Power Transformer T2 16 Control Transformer Fuse F1 17 Fan Fuse F2 18 19 20 ONO O1 10 11 12 13 KS SE WY a Heat Sink Fan s Optional Output Isolation Transformer 1 21 Breaker Panel 22 Input Breaker CB2 23 Battery Breaker CB1 24 Output Breaker CB3 25 Output Distribution Breakers CB4 and on 26 Maintenance Free Lead Acit Battery s 27 Inverter Test Switch S2 28 Rectifier Block BR1 ILLUSTRATION 3 2 COMPONENT LAYOUT 6002 1394 REV J 3 4 Crucial Power Products 3 4 3 4 1 3 4 2 3 4 3 3 4 4 3 4 5 3 4 6 3 4 7 3 4 8 3 4 9 FUNCTIONAL DESCRIPTION Illustrations 3 3 depict FUNCTIONAL block diagrams of the Wave Rider 1 These diagrams provide an excellent tool for identifying the major building blocks within the Wave Rider 1 Main input circuit breaker optional The main input circuit breaker provides Wave Rider 1 with incoming power isolation and input over current protection Input Contactor Input contactor controls power applied to the unit The microprocessor control circuit verifies that the unit is in hormal and not at a fault condition and that the input voltage and frequency are within an acceptable range Only then it energizes the contactor closing coil via control transformer and fuse Input Induc
13. Aux Output CB If 1P Aux CB option is called out neutral is brought out as shown here When both main output CB and Aux Output CB option are used notice these jumpers Customer can turn on off each CB individually This is factory standard ILLUSTRATION 2 11 277V UNIT 6002 1394 REV J 2 12 Crucial Power Products 3 Customer Connection Output connection with output transformer The following Illustrations 2 12 to 2 18 are standard Aux CB Output CB s connections Note When desire to locate all Aux Output CBs after the main output CB move Aux CB wiring to CB3 2 amp CB3 4 For multiple output unit and different input output voltage application There is an output transformer Input power connections are same as 1 refer to each voltage l B C D A 120 Output connection 120V Load GND Output CB3 is sometimes 120V Cn 1P CB not 2P for low current unit amp 120VAC unit Output XFMR Aux output CBs O Customer Connections 3 wires each 1P CB for L N G 6002 1394 REV J 2 13 Crucial Power Products 3 continued B 208V Output connection T1 157V 120V 9 CB3 Aux output CB Customer Connections 2P CB ILLUSTRATION 2 13 208V Output Customer Connections w Output XFMR 6002 1394 REV J 2 14 Crucial Power Products 3 continued 240V Output connection output Customer Connection
14. ELECTROCUTION FIRE EXPLOSION OR EQUIPMENT FAILURE Danger READ THIS MANUAL ITS ENTIRETY BEFORE PERFORMING THE INSTALLATION START UP OPERATION OR MAINTENANCE OF THE UNIT Uninterruptible Power System OR BATTERY SYSTEMS FAILURE TO DO SO COULD RESULT IN ELECTROCUTION FIRE EXPLOSION OR EQUIPMENT FAILURE If you require assistance call toll free 800 PWR SRVC 800 797 7782 Please have the following information from your unit s nameplate available to speed assistance Serial Number kVA Power Rating Input Voltage Output Voltage Manufacturer Date 6002 1394 REV J 1 1 Crucial Power Products Danger ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT WIRING MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL ELECTRICAL CODES WIRING MAY CAUSE DAMAGE TO THE EQUIPMENTS INJURY OR DEATH OF PERSONNEL VERIFY THAT ALL HIGH AND LOW VOLTAGE INPUT POWER CIRCUITS ARE DE ENERGIZED AND LOCKED OUT BEFORE INSTALLING CABLES OR MAKING ANY ELECTRICAL CONNECTIONS Danger EXERCISE EXTREME CARE WHEN HANDLING UNIT AND BATTERY CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL CABINETS WEIGH SEVERAL HUNDRED POUNDS Danger TEST LIFT AND BALANCE THE CABINETS BEFORE MOVING MAINTAIN MINIMUM TILT FROM VERTICAL AT ALL TIMES THE BOTTOM STRUCTURE WILL SUPPORT THE UNIT ONLY IF THE FORKLIFT FORKS ARE COM
15. Electronic Circuit Breaker NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal Block OUTPUT RATING KVA KW 3 3 5 5 7 517 5 10 10 12 5 12 5 15 15 17 17 VOLTAGE VAC Single Phase 120 208 240 277 VOLTAGE REGULATION 3 No Load to Full Load 3 High Line to Low Line FREQUENCY Hz 60 Hz 0 25 Hz When on Inverter WAVESHAPE Sine Wave HARMONIC DISTORTION lt 5 THD lt 3 Single Harmonic CREST FACTOR Up to 3 to 1 POWER FACTOR 0 65 Lagging or Leading to Unity STEADY STATE CURRENT 25 14 13 1 42 24 21 1 63 36 31 2 83 48 42 36 104 60 52 45 125 72 63 54 142 82 91 61 Normal Mode Emergency Mode 1 8 7 OVERLOAD 125 for One 1 minutes surge 150 96 PROTECTION Electronic Circuit Breaker NOISE REJECTION 120 dB Common Mode 60 dB Normal Mode NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal Block 6002 1394 REV J Crucial Power Products POWER RATING KW 3 3 5 5 7 5 7 5 10 10 12 5 12 5 15 15 17 BATTERY BATTERY RUN TIME 90 Minutes Minimum BATTERY TYPE Sealed Maintenance Free AGM VRLA type NOMINAL DC VOLTAGE 96 VDC 120 VDC 120 VDC 192 VDC 192 VDC 240 VDC 240 VDC OVERCURRENT PROTECTION Circuit Breaker PACKAGING Batteries Housed in Same Enclosure and or additional battery cabinet See Table 2 2 MONIT
16. Listed below are the environmental specifications for the Wave Rider 1 Adequate clearance in the front of the equipment MUST be provided for service access Operating Environment AMBIENT TEMPERATURE 0 to 40 32 to 104 F OPERATING ALTITUDE 1 829 M 6 000 FT DERATE 1096 FOR EACH ADDITIONAL 305 M 1 000 FT UP TO 2 744 m 9 000 FT RELATIVE HUMIDITY 096 to 9596 non condensing Operating the Wave Rider 1 and batteries at either extreme of the temperature range may affect the long term reliability of the system This is especially true of the sealed maintenance free batteries Sealed maintenance free batteries are designed to operate at normal room temperatures 72 to 77 F 2 1 2 Storage Environment Provide a storage environment which meets the following conditions AMBIENT TEMPERATURE 20 C to 68 4 to 154 F RELATIVE HUMIDITY 0 to 9596 non condensing NOTE System should be stored in its original packaging 6002 1394 REV J 2 1 Crucial Power Products 2 1 3 Location Considerations 39 A 1 5 2 75 or 1 y Y Conduit knockouts 2 1 5 or 2 Conduit knockouts 1 Air Exhaust gt 39 lt 1 Air Exhaust Clearance Clearance 2 1 5 or 2 Conduit knockouts 2 75 or 1 Conduit knockouts Front View Side View Both Sides Typ 34 75 4 0 69 Dia Typ Floor Mounting Holes 15 Bottom View ILLUSTRATION 2 1 48 CABINET CABLE ACCESS AND MOUNTI
17. MATCHS THE BATTERY CONNECTION DIAGRAM IN THE BATTERY CABINET REFER TO A SAMPLE NAMEPLATE BELOW Gi SHADOW P WAVERIDER Serial No 1 Model No 2 Rating KVA PF 3 Frequency Hz Phase Input Voltage Volts Input Current Amps against the nameplate information on Verify the following items 1 thru 7 Output Voltage AC Volts front of the unit Output Current Battery Volt 4 Battery Current Amps max Back up Time Minutes 5 Battery Quantity 1 12 VDC each Battery P N 6 All Values are Nominal Mfg Date Dwg No 6002 7 Battery Connection Diagram ILLUSTRATION 2 19 2 4 REMOTE SIGNALING CONNECTIONS OPTION The Wave Rider 1 includes the feature of providing dry relay contacts for remote signaling capabilities Signals available for remote annunciation are INPUT FAILURE N O contact that closes upon loss of input power LOW BATTERY N O contact that closes when the unit is on battery operation and the batteries approach inadmissible discharge status BYPASS ON N O contact that closes when the unit transfers the load to static by pass SUMMARY ALARM N O contact that closes when the unit has any one of the following alarm conditions Internal Failure System Overheat Battery Under voltage 6002 1394 REV J 2 20 Crucial Power Products 2 4 1 Dry relay contacts for remote signaling are provided via connector P2 on Control Board A2 l
18. WAY FOR QIFFERENT VOLTAGE 2677 ANa CASE OF DUTPUT OI Aux OUTPUT BOTH USED WES ux Cli 10 MES OUTPUT AN THORPE ORT W AT RT ASESOR matte Ai ILLUSTRATION 3 3 FUNCTIONAL BLOCK DIAGRAM 6002 1394 REV J 3 7 Crucial Power Products 3 5 3 5 1 3 5 2 3 5 3 3 5 4 3 5 5 THEORY OF OPERATION Standby Mode After power is applied the system is placed in STANDBY mode and a self check starts During this period the start subroutine checks for the input voltage and proper operation of the inverter and bypass SCR s After the routine is completed and check confirmed OK the system goes into the NORMAL mode Normal Mode The input contactor K1 receives a closing signal connecting input power to the DC supply transformer The DC rectifier supplies the battery charger Control Board and the DC AC inverter circuit The battery charger is then activated allowing the batteries to be continuously charged The on line DC AC inverter converts the DC voltage to a pulse width modulation PWM waveform This waveform is filtered and reconstructed back to a desired AC output Response To Input Power Failure If the system controller senses a change in input frequency of more than 3 Hz or an out of range input voltage it will consider it an input failure and will immediately open the input contactor isolating the unit from the facility At the same time the charger is turned off and the
19. be in UPS cabinet or separate maximum of 3 Cabinets Consult Factory for detail UPS ELECTRONICS urere I oN GJ 240 VDC 2 STRING 3 STRING 4 STRING 6002 1394 REV J D 5 Crucial Power Products APPENDIX E DRAWINGS FOR SINGLE PHASE UNIT All drawings are downloadable from Website www crucialpower com 1 Unit amp Battery Cabinet Installations 1 Phase UPS with 90 Min Battery Backup 3 5 7 5 10 12 5 15 and 20 kVA 2 1 3 3 5 5 5 25 7 7 5 8 8 5 10 10 5 14 15 kW 6001 033 01 2 UPS amp Battery Cabinet Layout 1 Phase UPS with 90 Min Battery Backup 3 5 7 5 10 12 5 15 and 20 2 1 3 35 5 5 25 7 7 5 8 8 5 10 10 5 14 15 kW 6001 033 02 1 Phase UPS Functional Block Diagram Single Line Diagram Dwg 6001 033 03 UPS amp Battery Cabinet Seismic Certification Drawing Dwg 6002 1658 09 0319 A Single Phase UPS with Load Center Dwg 6001 032 19 Single Phase External Wrap around by pass Panel 3KVA TO 20 KVA Dwg 6001 032 31 amp 6001 032 31S TABLES 1 Single Phase Unit Chart for recommended output input protective device rating BTU HR and Floor Loading Table XXX 1 and XXX 2 2 Allowable Ampacities of Insulated Conductors Rated 0 2000 V 60 to 90 deg C 140 194 deg F Table 310 16 of National Electrical Code Connection Type Wire Size Range Torque Specifications Unless Otherwise Labeled Unit In
20. if unit is so equipped and then rotate the maintenance bypass switch to the maintenance position Refer to the operation label on the unit After repair or periodic maintenance the MBS must be switched to UPS position in cases where the toggle switch has been incorporated with the switch be sure not to leave the switch in the middle position as this will not provide any output power when the unit is off Caution STOPPING ROTATION OF THE MAINTENANCE BYPASS SWITCH BETWEEN POSITIONS WILL RESULT IN THE REMOVAL OF OUTPUT VOLTAGE Fan Transformer The Fan transformer provides 120 VAC to the fans s with taps to match unit output voltages Fuse F2 protects fans amp transformer Efficiency Optimizer Function OFF Line Inverter Mode When Input Power is available the batteries shall be charged and AC output from inverter thru inverter static switch supports to the critical load In this Normal Mode Operation the inverter static switch is closed and bypass static switch is opened The bypass static switch is closed only upon inverter faults or upon manual operation and then output power thru bypass static switch supports critical load This is normal operation for true double convention UPS However there is demand for higher efficiency UPS in industry to reduce cost of electricity and want to use as off line inverter which means that normal operating mode is reversed such that bypass static switch is closed normally as long as i
21. minutes that will allow safe and orderly evacuation from the facility When input power to the Wave Rider 1 is lost during a power outage the system will automatically draw power from its internal battery supply without any interruption The critical load will receive only clean sine wave power The optional output transformer allows multiple output voltages as well as input voltages that are different than output voltages The internal VRLA valve regulated lead acid maintenance free batteries provide 90 minutes of backup power Upon restoration of input power the Wave Rider 1 automatically resumes normal operation and immediately begins to recharge the batteries The Wave Rider 1 has an internal bypass circuit which maintains the power to the load in case of internal unit failure The Wave Rider 1 provides comprehensive monitoring capabilities In addition to the LCD display it provides five dry relay contacts for remote monitoring capabilities Wave Rider 1 contains as standard features an AS 400 RS 232 protocol interface RS485 data transmission ports and many other communication options The Wave Rider 1 is an on line single phase PWM inverter available in output rating of 3 5 7 5 12 5 15 20 kVA and 3 5 7 5 12 5 15 17 KW The Wave Rider 1 is listed for compliance to UL1778 UL924 UL924A and CSA107 1 standards The Wave Rider 1 is available with an input or output voltages of 120 208 240 or 277 VAC single phase This
22. 0 208 240 277 VAC VOLTAGE REGULATION 3 No Load to Full Load 3 High Line to Low Line FREQUENCY Hz 60 Hz 0 25 Hz When on Inverter WAVESHAPE Sine Wave HARMONIC DISTORTION 596 THD 396 Single Harmonic CREST FACTOR Up to3 to 1 POWER FACTOR 0 65 Lagging or Leading to Unity STEADY STATE CURRENT 18 10 9 8 29 17 15 13 44 25 22 19 58 34 29 25 73 4236 32 88 50 44 38 96 83 72 OVERLOAD 125 96 for One 1 minutes surge 150 PROTECTION Electronic Circuit Breaker NOISE REJECTION 120 dB Common Mode 60 dB Normal Mode NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal Block 6002 1394 REV J A 1 Crucial Power Products POWER RATING KVA 3 2 1 5 3 5 7 5 525 10 7 12 5 8 75 15 10 5 20 14 BATTERY BATTERY RUN TIME 90 Minutes Minimum BATTERY TYPE Sealed Maintenance Free AGM VRLA type NOMINAL DC VOLTAGE 96 VDC 120 VDC 120 VDC 192 VDC 192 VDC 240 VDC OVERCURRENT PROTECTION Circuit Breaker PACKAGING Batteries Housed in Same Enclosure and or additional battery cabinet See Table 2 1 MONITORING AND COMMUNICATIONS LCD SCREEN Input Voltage Battery Charger UPS Output On Battery Low Battery Summary Alarm INDICATORS LCD Display Panel RELAY INTERFACE Dry Contacts for UPS On N C On Inverter N O Loss of Input Power N O Low Battery N O CONTACT RATING 125 Volts AC or DC Maximum 1 25 Ampe
23. 0 A Ballast load 1800 W Tungsten Lamp load 20 A 1 5 HP Operating Temperature 20to 150 F Flame rating UL 94V O Size 2 75 W x 4 75 x 1 75 D overall Low profile recessed portion is only 1 5 deep Color White Weight 8 oz EMERGENCY POWER TEST SWITCH UTILITY POWER ILLUSTRATION 5 10 ECC EMERGENCY CIRCUIT CONVERTER 6002 1394 REV J 5 12 Crucial Power Products 5 17 5 17 1 5 17 2 5 17 3 5 18 OPTIONAL ECM EMERGENCY CONTROL MODULE P N 9100 1502 INSTALLATION Indoor use only ECM is a universal mount unit simple and fast installation in ceiling or wall mounted standard single gang E box recommended box size 4 Installation must be performed by a qualified electrician per Installation Operation and dMaintenance Instructions provided with the EMC Operation The emergency power is provided from a central lighting inverter that is automatically switched over to 24 hour emergency power distribution panel The room switch turns on and off both regular and emergency lights simultaneously This is accomplished by having the room switch leg power activate the Emergency Control Module Wire input 1 is connected internally to a sensing circuit During a power interruption this circuit causes contact X to drop into a N C position Please review wiring schematics Specification Description ECM EMERGENCY CONTROL MODULE Part Number 9100 1502 01 120 VAC 9100 1502 02 277 VAC Rati
24. 2 RR MA if 1P CB is used QA O i one side of 240V is O E connected without Output 2 disconnecting mean XFMR 1P CB is not recommended for 240V output ILLUSTRATION 2 14 240V Output Customer Connections w Output XFMR 6002 1394 REV J 2 15 Crucial Power Products 3 continued D 277V Output connection Aux output CB 1P CB Option Customer connects load to these aux CB 3 wires CB H N and G The output aux CB can be 2 pole CB wire neutral T1 14 to second pole of CB ILLUSTRATION 2 15 277V Output Customer Connections w Output XFMR 6002 1394 REV J 2 16 Crucial Power Products 3 continued E 120 240V Dual Output connection Load 240V GB 120V 120 gt Ti 157V E SE OO 120V O Output 21010 1 3 Aux output CB 6 for 120 output 50 Directly connect load to 120V 2 each OV p 3 wires CB CAP p N and G Output O XFMR 22 qty up to Loe If qty is more than 3 for balance loading ILLUSTRATION 2 16 120 240V Dual Output Customer Connections 6002 1394 REV J 2 17 Crucial Power Products 3 continued F 120V 208V Dual Output connections Load 208V GND T1 Aux output CB for 120V output Connect load directly to each aux CB Output XFMR NOTE For 120V
25. 2 Part Number 9800 005 XX PC system requirements 98 and higher Windows OS serial port Viewing software Lab View included RS232 cable 25 thru 15 ft as specified included Local On PC Via RS 485 P N 9800 006 01 Installation Operation Specification as above except RS 485 cable 6002 1394 REV J 5 11 Crucial Power Products 5 16 OPTIONAL ECC EMERGENCY CIRCUIT CONVERTER P N 9100 1501 5 16 1 5 16 2 5 16 3 Installation Indoor use only Simple and fast installation in ceiling or wall mounted standard single gang E box Installation must be performed by a qualified electrician per Installation Operation and Maintenance Instructions provided with the ECC Operation When used with an inverter system the ECC is designed to allow you the ability to turn off ALL of the lighting in a given area via the local switch and still provide emergency lighting during a power failure The device will provide single phase power from the emergency source to the designated emergency fixtures regardless of their current status on or off thereby insuring safe egress from the facility at all times The automatic Diagnostic feature will confirm the emergency system is ready to provide back up power Specification Description ECC EMERGENCY CIRCUIT CONVERTER OPTION Part Number 9100 1501 01 120 VAC 9100 1501 02 277 VAC Rating 120 20 A Ballast load 1000 W Tungsten Lamp load 20 A 1 HP 277 VAC 2
26. 2025 759 ED2125L HB 101 REV X3 6002 1394 REV J C 1 Crucial Power Products STANDARD KAIC 1PH UPS OUTPUT CIRCUIT BREAKERS 120V OUTPUT 208V OUTPUT 240V amp 240 120 OUTPUT 480V 277V OUTPUT 1P 30A 2 20A i i 1 QC2015H 2025 787 iQc2030Hi 2025 790 47 i QC2025H 2025 789 Boss EM Mee E e EEN Lh Aa a B 2025 795 2025 792 QC2040H 2025 791 GHC2035 2025 765 i 7 5KVA 7 5 QC2080 TOKVANIO KW Ka 1 2025 786 jQc2060H 2025 793 42001 0 GHC2050 2025 767 12 5KVA 12 5 xa ED2135L 2025 759 15 15 0 02150 2025 760 2025 795 ED2200L 21251 2025 759 i 3 PP 3258 H 65KA ED2125L 2025 759 HIGHER KAIC 1 PH UPS OUTPUT CIRCUIT BREAKERS 1201 OUTPUT AD TP 30 P 202 IQHCX1030D1 2025 79 1 2020 2025 762 s G C2015 7 HFD2015L 2025 773 i 2025 764 HFD2025L 2025 775 2025 776 2025 767 49 HFD2035L 2100 2025 803 KA ED2125L 1 2025 759 len HE 65 HFD2080L 2025 778 JE ED2150L 2025 760 i i 2025 770 lt HFD2207L 2025 ED2200L EE 65 KA u 2025 759 HB 101 REV X3 6002 1394 REV J C 2 Crucial Power Products APPENDIX D BATTERY CONNECTIONS For the actual battery connection diagram for your system refer to the diagram on each unit The drawings below a
27. ASE 60HZ INTERNAL CABLE B5A 8 AWG 60A 110 82 AWG 140 TERMINALS ARE SIZED FOR PROPER APPLICATION ILLUSTRATION 5 2 MAINTENANCE BYPASS SWITCH WIRING DIAGRAM 5 1 1 Installation Allow front access to the MBS box at all times for maintenance and servicing Electrical codes require that the MBS box be installed with no less than 3 feet at the front of the cabinet Side and rear panels do not require service clearance however side vents must not be blocked ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT WIRING MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL ELECTRICAL CODES IMPROPER WIRING MAY CAUSE DEATH INJURY EXPLOSION FIRE OR DAMAGE TO THE EQUIPMENT VERIFY THAT ALL INCOMING HIGH AND LOW VOLTAGE POWER CIRCUITS ARE DE ENERGIZED AND LOCKED OUT BEFORE INSTALLING CABLES OR MAKING ANY ELECTRICAL CONNECTIONS Refer to Section 2 1 Site Planning and Preparation Verify the following connections have been made per wiring diagrams 6001 032 31 S Wiring Inspection 1 Verify all power connections are tight 2 Verify all control wire terminations are tight 6002 1394 REV J 5 3 Crucial Power Products 3 Verify all power wires and connections have proper spacing between exposed surfaces phase to phase and phase to ground 4 Verify that all control wires are run in individual separate steel conduit 5 1 2 Operation
28. ATTERIES RELEASED ELECTROLYTE IS HARMFUL TO THE SKIN AND EYES AND MAY BE TOXIC A BATTERY CAN HAVE A HIGH SHORT CIRCUIT CURRENT AND PRESENT A RISK OF ELECTRICAL SHOCK THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED WHEN WORKING ON BATTERIES REMOVE WATCHES RINGS OR OTHER METAL OBJECTS USE TOOLS WITH INSULATED HANDLES WEAR RUBBER GLOVES AND BOOTS DO NOT LAY TOOLS OR METAL PARTS ON TOP OF BATTERIES DISCONNECT CHARGING SOURCE PRIOR TO CONNECTING OR DISCONNECTING BATTERY TERMINALS DETERMINE IF BATTERY IS INADVERTENTLY GROUNDED IF SO REMOVE THE SOURCE OF THE GROUND CONTACT WITH ANY PART OF A GROUNDED BATTERY CAN RESULT IN ELECTRICAL SHOCK THE LIKELIHOOD OF SUCH SHOCK WILL BE REDUCED IF SUCH GROUNDS ARE REMOVED DURING INSTALLATION AND MAINTENANCE LEAD ACID BATTERIES CAN PRESENT A RISK OF FIRE BECAUSE THEY GENERATE HYDROGEN GAS THE FOLLOWING PROCEDURES SHOULD BE FOLLOWED 1 DO NOT SMOKE WHEN NEAR BATTERIES 2 DO NOT CAUSE FLAME OR SPARK IN BATTERY AREA DISCHARGE STATIC ELECTRICITY FROM YOUR BODY BEFORE TOUCHING BATTERIES BY FIRST TOUCHING A GROUNDED SURFACE 6002 1394 REV J 1 4 Crucial Power Products 2 1 SECTION 2 INSTALLATION SITE PLANNING AND PREPARATION The Wave Rider 1 is designed for installation indoors and meets NEMA specifications for operating temperature humidity and utility voltage These cabinets are rugged and corrosion resistant The footprint of the Wave Rider 1 is less than 6 square feet
29. D BATTERY CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL CABINETS WEIGH SEVERAL HUNDRED POUNDS TEST LIFT AND BALANCE THE CABINETS BEFORE MOVING MAINTAIN MINIMUM TILT FROM VERTICAL AT ALL TIMES THE BOTTOM STRUCTURE WILL SUPPORT THE UNIT ONLY IF THE FORKLIFT FORKS ARE COMPLETELY UNDERNEATH THE UNIT Remove the equipment from the shipping carton Since the Wave Rider 1 is designed for pad mounting installations there are no casters It is suggested that a forklift be used to remove the Wave Rider 1 from its shipping pallet See Illustration 2 4 for the location of forklift slot P 2 5 5 7 A Forklift Forks ILLUSTRATION 2 4 FORKLIFTING 6002 1394 REV J 2 5 Crucial Power Products 2 3 UNIT INSTALLATION 2 31 Mechanical Installation Preparing to Install Unit 1 Before placing the Wave Rider 1 onto the mounting bolts where it will be installed the conduit knockouts need to be removed The conduit knockouts are located on the sides and top of the cabinet See illustration 2 1 2 2 and 2 3 NOTE If site restrictions prevent routing of conduit to the locations where conduit knockouts are located do not drill holes in the cabinet without first consulting Crucial Power at 800 PWR SRVC 800 797 7782 The conduit knockouts provided are positioned to prevent airflow disruptions that could cause the unit to overheat Our engineers will be happy in assisting you in locatin
30. IS EQUIPMENT AS INSTRUCTED Danger BE CONSTANTLY AWARE THAT THE UNIT SYSTEM CONTAINS HIGH DC AS WELL AS AC VOLTAGES WITH INPUT POWER OFF AND THE BATTERY DISCONNECTED HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS HOWEVER POWER CIRCUIT FAILURES CAN OCCUR SO YOU SHOULD ALWAYS ASSUME THAT HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN VERIFY THAT POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING CONTACT Danger SOME COMPONENTS WITHIN THE CABINETS ARE NOT CONNECTED TO CHASSIS GROUND ANY CONTACT BETWEEN FLOATING CIRCUITS AND THE CHASSIS IS A LETHAL SHOCK HAZARD 6002 1394 REV J 1 3 Crucial Power Products Danger INTERNAL BATTERY STRAPPING MUST BE VERIFIED BY THE CUSTOMER PRIOR TO MOVING THIS UNIT THIS UNIT CONTAINS NON SPILLABLE BATTERIES THE UNIT UPRIGHT DO NOT STACK DO NOT TIP ALWAYS FOLLOW THE BATTERY MANUFACTURER S SAFETY INFORMATION LOCATED IN A POCKET ATTACHED TO THE INSIDE OF THE LEFT DOOR OF YOUR UNIT TO PREVENT AN ACCIDENT THAT COULD RESULT IN INJURY OR DEATH Danger LEAD ACID BATTERIES CONTAIN HAZARDOUS MATERIALS BATTERIES MUST BE HANDLED TRANSPORTED AND RECYCLED OR DISCARDED IN ACCORDANCE WITH FEDERAL STATE AND LOCAL REGULATIONS BECAUSE LEAD IS A TOXIC SUBSTANCE LEAD ACID BATTERIES SHOULD BE RECYCLED RATHER THAN DISCARDED DO NOT DISPOSE OF BATTERIES IN A FIRE THE BATTERIES MAY EXPLODE DO NOT OPEN OR MUTILATE THE B
31. Mimic allows unit power status verification at a glance It has 6 LED s indicating the following conditions GREEN Input OK GREEN Inverter On YELLOW On Battery YELLOW On Bypass RED Low Battery RED Summary Alarm The LED s are located on the pictogram below for quick status assessment UPS NORMAL 0 20KVA INPUT OK CHRG BATTERYOK DCOK ON INVERTER OUT OK INPUT O BATTERY ONGATTERY LOW BATTERY ILLUSTRATION 5 4 MIMIC PAD 5 14 2 Specification Description POWER FLOW MIMIC OPTION 1 PHASE Part Number 9100 1493 02 Color Blue with black lettering Dimensions 4 25 x 4 Mounting Self adhesive Scotch pad LED s Water clear lens 20 mA View Angle 140 Nicom ZU55W 05 Connectors Nicomatic 8 Pin Black 6002 1394 REV J 5 8 Crucial Power Products 5 15 OPTIONAL GMS GLOBAL MONITORING SYSTEM LOCAL ON UPS 5 15 1 Local On UPS EVENT LOG 5 15 1 1 Operation Control and Monitoring PCB acquires event data and displays up to 100 most recent Date and Time stamped events The default setting is a scroll of monitoring and alarm screens When the log is full the first oldest events is erased from the register System events are in Appendix B Key pad functions and resulting screens are presented below LOG Press one time to activate the event log display After approximately 5 seconds the screen will show the event log All stored events will be continuously scrol
32. N MAY STILL BE PRESENT THE BATTERY POWER TO THE UNIT MUST BE LOCKED AND TAGGED OFF BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT THE BATTERY MANUFACTURER S SAFETY INFORMATION AND MATERIAL SAFETY DATA SHEET IS LOCATED IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UNIT FAILURE TO FOLLOW THOSE INSTRUCTIONS AND THE INSTRUCTION LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION FIRE EQUIPMENT FAILURE OR ELECTROCUTION Danger BE CONSTANTLY AWARE THAT THE UNIT SYSTEM CONTAINS HIGH DC AS WELL AS AC VOLTAGES WITH INPUT POWER OFF AND THE BATTERY DISCONNECTED HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS HOWEVER POWER CIRCUIT FAILURES CAN OCCUR SO YOU SHOULD ALWAYS ASSUME THAT HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN VERIFY THAT POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING CONTACT 6002 1394 REV J 6 2 Crucial Power Products 62 WHEN CALL Call for service if you encounter any of the following conditions 1 Repeated start up attempts are unsuccessful 2 A UPS fault occurs which cannot be cleared 3 Normal operation of the critical load repeatedly causes an overload condition This is not a unit fault but a qualified person must analyze the total load connected to the unit to prevent unit failure Momentary overload conditions will be handled within the parameters of the Unit but sustained overloads will cause the Unit to fail
33. NG 3 KW 2 1 4 Cable Access Caution Blocking vents may cause equipment malfunction and failure The Wave Rider 1 Cabinet Installation Diagrams for 3 20 KVA models provide cable conduit openings on the top and sides of the cabinet Refer to Illustration 2 1 2 2 and 2 3 6002 1394 REV J 2 2 Crucial Power Products 2 75 or 1 Conduit knockouts 2 1 5 or 2 Conduit Top View knockouts 1 Air Exhaust gt pe 39 lt 1 Air Exhaust Clearance ___ Clearance A 2 1 5 or2 Conduit knockouts lew 2 75 or 1 Conduit knockouts 68 Y m Side View Both Sides Typ 4 0 68 Dia Typ Floor Mounting Holes ILLUSTRATION 2 2 68 CABINET CABLE ACCESS AND MOUNTING 6002 1394 REV J 2 3 Crucial Power Products L an AIR EXHAUST TOP VIEW KNOCK OUT na ME 4 AIR INTAKE CLEARANCE d 50 j E CLEARANCE NRINTAKE a ed e 8 i LEFT VIEW FRONT VIEW RIGHT VIEW NOTES UNLESS OTHERWISE SPECIFIED 15 225014885 125 185185 10 1600LBS 1 DIMENSIONS SHOWN ARE APPROXIMATE 2 CONSTRUCTION INDOOR NEMA 1 3 BATTERY RUN TIME 90 MINUTES 4 RATING amp WEIGHT CHARTED KW TOTAL WEIGHT BOTTOM VIEW ILLUSTRATION 2 3 OVERSIZE CABINET CABLE ACCESS AND MOUNTING 7 5 15 KW WITH BATTERY 6002 1394 REV J 2 4 Crucial Power Products Caution Each model of the Wave
34. O NOT GROUND BATTERY POSITIVE NEGATIVE 55555555 Lead acid batteries can present a risk of fire because they generate Caution hydrogen gas The following safety procedures must be followed DO NOT SMOKE when near batteries DO NOT cause flame or sparks in battery areas Discharge static electricity from your body before touching batteries by first touching a grounded metal surface 4 When replacing batteries use with the same number of batteries and Caution same manufacturer type and model that was supplied with the unit To avoid system failure replace all batteries if one or more batteries fail to perform to specifications 6002 1394 REV J 6 5 Crucial Power Products 6 44 Battery Cabinets Although the individual batteries are sealed and require minimal maintenance only the batteries should be given a periodic inspection and electrical check every six months Battery Service Agreements are available through Crucial Power Customer Service and Support at 1 800 PWR SRVC 800 797 7782 In order to qualify for battery warranty replacement you will need to show records of the battery maintenance history including battery numbers battery voltages individual cells terminal torque measurements and dates of maintenance 6 4 5 Power Connections Check for corrosion and connection integrity Visually inspect wiring for discolored or cracked insulation Clean and or re torque as requi
35. ORING AND COMMUNICATIONS LCD SCREEN Input Voltage Battery Charger UPS Output On Battery Low Battery Summary Alarm INDICATORS LCD Display Panel RELAY INTERFACE Dry Contacts for UPS On N C On Inverter N O Loss of Input Power N O Low Battery N O CONTACT RATING 125 Volts AC or DC Maximum 1 25 Amperes Maximum 30 Watts 50 VA Maximum INTERFACE CONNECTION Hard Wired Terminal Block ENVIRONMENTAL USRGE WITHSTANDABILITY ANSI C62 41 1980 Categories amp B OPERATING TEMPERATURE Meets NEMA Requirements OPERATING RELATIVE HUMIDITY 0 to 95 Non Condensing ALTITUDE Up to 6 000 Feet 1 829 Meters with No De Rating COOLING PHYSICAL Air Cooled Forced Fan SIZE HxWXxD in cm 70 x 39 x 20 177 8 x 99 1 x 50 8 WEIGHT Ibs kg with batteries 1066 485 1284 584 2350 1069 2870 1306 3777 1719 4512 2053 4512 2053 CONSTRUCTION Painted Steel Enclosure with 3 Point Double Locking Front Door and Full Length Door Hinge ENCLOSURE Designed for Inside Installations COLOR Natural finish ACCESSIBILITY Front All Servicing is Through the Front No Side or Rear Access is Required CABLE ENTRY Bottom or sides MOUNTING Four 4 Holes Provided to Anchor Enclosure to Pedestal Supplied by Others 6002 1394 REV J 4 Crucial Power Products APPENDIX B LCD DISPLAY MENU AND TROUBLESHOOTING GUIDE Two screens A B
36. PLETELY UNDERNEATH THE UNIT Danger OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION OR SERVICE OF THE UNIT OR BATTERIES EVEN WITH THE BATTERY CIRCUIT BREAKER IN THE POSITION THE DANGER OF ELECTROCUTION MAY STILL BE PRESENT THE BATTERY POWER TO THE UNIT MUST BE LOCKED AND TAGGED OFF BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT THE BATTERY MANUFACTURER S SAFETY INFORMATION AND MATERIAL SAFETY DATA SHEET IS LOCATED IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UNIT FAILURE TO FOLLOW THOSE INSTRUCTIONS AND THE INSTRUCTION LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION FIRE EQUIPMENT FAILURE OR ELECTROCUTION 6002 1394 REV J 1 2 Crucial Power Products Danger ALL POWER TO THE UNIT MUST BE LOCKED AND TAGGED OFF BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT FAILURE TO DO SO COULD RESULT IN ELECTROCUTION IN CASE FIRE INVOLVING ELECTRICAL EQUIPMENT ONLY CARBON DIOXIDE FIRE EXTINGUISHERS OR THOSE APPROVED FOR USE ON ELECTRICAL EQUIPMENT SHOULD BE USED USE OF WATER ON FIRES INVOLVING LIVE HIGH VOLTAGE ELECTRICAL CIRCUITS COULD PRESENT AN ELECTROCUTION HAZARD Danger EXTREME CAUTION IS REQUIRED WHEN PERFORMING MAINTENANCE LETHAL VOLTAGES EXIST WITHIN THE EQUIPMENT DURING OPERATION OBSERVE ALL WARNINGS AND CAUTIONS IN THIS MANUAL FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH OBTAIN QUALIFIED SERVICE FOR TH
37. RECT CONTACT WITH THE FLOOR EARTH GROUND AND SHOULD MAKE USE OF RUBBER MATS WHEN PERFORMING MAINTENANCE ON ANY PORTION OF THE UNIT WHILE IT IS UNDER POWER HIGH AC AND DC ELECTRICAL VOLTAGES ARE PRESENT THROUGHOUT THE UNIT S AND INCORRECT INSTALLATION OR SERVICING COULD RESULT IN ELECTROCUTION FIRE EXPLOSION OR EQUIPMENT FAILURE SPECIAL SAFETY PRECAUTIONS AND LOCKOUT TAGOUT PROCEDURES ARE REQUIRED FOR ALL OPERATIONS INVOLVING THE HANDLING INSTALLATION OR MAINTENANCE OF THE UNIT SYSTEM AND ANY ASSOCIATED BATTERY CABINETS FAILURE TO FOLLOW SAFETY PROCEDURES COULD RESULT IN DEATH INJURY OR DAMAGE TO EQUIPMENT 6002 1394 REV J 6 1 Crucial Power Products Danger THIS EQUIPMENT CONTAINS CIRCUITS THAT ARE ENERGIZED WITH HIGH VOLTAGES ONLY TEST EQUIPMENT DESIGNED FOR TROUBLESHOOTING HIGH VOLTAGES SHOULD BE USED PARTICULARLY FOR OSCILLOSCOPES AND PROBES ALWAYS CHECK WITH AN AC AND DC VOLTMETER TO ENSURE SAFETY BEFORE INITIATING CONTACT OR USING TOOLS EVEN WHEN THE POWER IS OFF DANGEROUSLY HIGH POTENTIAL VOLTAGES MAY EXIST AT CAPACITOR BANKS ALWAYS OBSERVE BATTERY PRECAUTIONS WHEN OPERATING NEAR ANY BATTERIES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN DEATH INJURY OR DAMAGE TO EQUIPMENT Danger OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION OR SERVICE OF THE UNIT OR BATTERIES EVEN WITH THE BATTERY CIRCUIT BREAKER IN THE POSITION THE DANGER OF ELECTROCUTIO
38. Rider 1 is designed to supply a maximum load which is determined by its kVA 1000 s of volt amperes and kW rating It is very important that the load is within the rating of this Wave Rider 1 to ensure that the connected loads will be properly supported Each electrical device to be powered by the Wave Rider 1 should have a specification sheet attached to it which specifies the amount of power it requires In addition this information should be listed in the manual supplied with each piece of equipment The device s nameplate should also list the electrical requirements of the device The total load to be powered by the Wave Rider 1 must not exceed its rating If the total load is exceeded the Wave Rider 1 monitoring will sense an overload condition and a summary alarm will occur 2 1 5 Pre Installation All customer connections are brought through knockouts located on the top or on the sides of the unit The Wave Rider 1 consists of one electronics and one or more battery cabinets Before unpacking the equipment inspect the exterior the shipping container and the equipment itself for damage that may have occurred during transit If the shipping container or equipment itself shows evidence of damage note the damage on the receiving document before signing for receipt of the equipment Damage claims should be filed directly with the carrier 2 22 EQUIPMENT UNPACKING Danger EXERCISE EXTREME CARE WHEN HANDLING UPS AN
39. SS SWITCH P N 9100 1359 01 THRU 04 5 2 1 Specifications Part Number Description 9100 1359 01 FOR 3 5 and 7 5 KVA UNITS SAME IN OUT VOLT UNIT 9100 1359 02 FOR 3 5 and 7 5 KVA UNITS DIFFERENT IN OUT VOLT UNIT 9100 1359 03 FOR 10 15 and 15 KVA UNITS 17KW SAME IN OUT VOLT UNIT 9100 1359 04 FOR 10 15 and 15 KVA UNITS 17 KW DIFFERENT IN OUT VOLT UNIT 5 2 2 Instruction for Internal Maintenance Bypass Switch UPS to BYPASS BYPASS to UPS 1 Turn Battery Breaker Off 1 Turn Battery Breaker Off 2 Switch Manual Bypass switch to BYPASS position 2 Switch Manual Bypass switch to UPS position Note Leave Battery Breaker Off except when set on 3 Turn on battery CB for Normal operation UPS position Manual Bypass Switch 5 3 OPTIONAL AUDIO ALARM WITH SILENCE SWITCH P N 9100 1363 01 6002 1394 REV J 5 4 Crucial Power Products 54 OPTIONAL REMOTE UNIT STATUS PANEL P N 9100 1020 06 5 4 1 Installation The Remote Unit Status Panel is available in a console mount style box in black finish It can also be wall mounted and comes with a 10 foot long DB connector signal cable or optional length cable that can be up to 1000 feet long 5 4 2 Operation Remote Status Panel comes with 10ft long cable SILENCE LED HORN test switches and includes following status LED s e INPUT OK Input power is within acceptable range e INVERTER ON Inverter is On e ON BYPASS Unit is on b
40. THE RESULTING LIQUID SHOULD BE FLUSHED WITH WATER AND THE AREA DRIED Danger DO NOT DISPOSE OF A BATTERY OR BATTERIES IN A FIRE THE BATTERIES MAY EXPLODE CAUSING DEATH OR SERIOUS INJURY 6002 1394 REV J 6 4 Crucial Power Products DO not substitute batteries from other manufacturers without the express Caution approval of Crucial Power Customer Service personnel Caution Caution Power Battery PRC 12xxx is one battery manufacturer used by Crucial Power with xxx representing the amp hour size of the battery Universal Battery UB12xxx is another battery manufacturer authorized by Crucial Power the xxx is the amp hour size of battery Lead acid batteries contain hazardous materials and must be handled transported and recycled or scrapped in accordance with federal state and local regulations Since lead is a toxic substance lead acid batteries should be recycled rather than scrapped A battery can present a risk of electrical short and high short circuit current The following precautions should be observed when working on or around batteries Remove watches rings necklaces or other metal objects Use only tools with insulated handles Wear rubber insulating gloves and boots Do not lay tools or metal parts on top of batteries Disconnect charging source prior to connecting or disconnecting battery terminals Verify that batteries are properly grounded D
41. TION IN A PANEL BOARD 1PH CB UP TO 24 QO 155 9100 1439 02 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD 1PH CB UP TO 30 QO 200 9100 1439 03 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD 1PH CB UP TO 42 QO BREAKER 225AMP 2025 125 10KAIC 9240 120 240V APPLICATION CB 1PH 20AMP QO BREAKER FOR 9100 1439 xx 5 9 OPTIONAL HIGHER KAIC NORM ON OFF OUTPUT CIRCUIT BREAKER HIGHER KAIC NORMALLY ON NORMALLY OFF OUTPUT AUX CBs OPTION 1 PHASE 20AMP Part Number Description 9100 1434 31 56 42 KAIC 120 240V Din Rail 9100 1434 61 86 65 KAIC 2208 240V ONLY Din Rail 9100 1435 01 26 14 KAIC 277V ONLY Molded Case 9100 1435 61 86 65 KAIC 277V ONLY Molded Case 5 10 OPTIONAL INPUT CB STANDARD HIGHER KAIC INPUT CIRCUIT BREAKER OPTION STANDARD AND HIGHER KAIC Refer to the separate table in Appendix C 6002 1394 REV J 5 7 Crucial Power Products 5 11 OPTIONAL OUTPUT CB STANDARD HIGHER KAIC OUTPUT CIRCUIT BREAKER OPTION STANDARD AND HIGHER KAIC Refer to the separate table in Appendix C 5 12 OPTIONAL SEISMIC MOUNTING BRACKET P N 9100 1317 02 Left Right seismic floor mounting bracket 1 set per cabinet 5 13 OPTIONAL STACKABLE RACK P N 9100 1429 Drawings 6001 033 02 One rack per 2 cabinets 5 14 OPTIONAL POWER FLOW MIMIC P N 9100 1493 02 illustration 5 4 5 14 1 Operation Power Flow
42. The external maintenance bypass switch in mounted in a box which is field installed on the unit cabinet This box includes a rotary switch to provide a single control for transferring to and from maintenance bypass For ratings wiring diagram enclosure dimensions and installation refer to drawings 6001 032 31 The operator control switch for external manual bypass switch can be accessed by opening the cabinet front door 9 The single control simplifies the operation of the external manual bypass Caution switch however operating instructions must be carefully observed before using the bypass switch The THREE Manual Bypass Switch Positions are 1 UPS Connects the critical load to the output of the Inverter and establishes normal operation 2 SBS Connects power to the critical load through Static Bypass Switch For 0 Phase angle synch 3 BYPASS Connects power to the critical load through the Bypass switch to bypass the Inverter 5 1 3 Specification Optional External Manual Bypass Switch Part Number Description 3000 044 EXTERNAL MANUAL BYPASS SWITCH MAKE BEFORE BREAK 55AMP 3 POLES LINE ONLY 14 W x 8 00 D x 16 00 H USE FOR 3 5 and 7 5 UNITS 3000 045 EXTERNAL MANUAL BYPASS SWITCH MAKE BEFORE BREAK 110AMP 3 POLES LINE ONLY 14 W x 8 00 D x 16 00 H USE FOR 10 15 20 KVA AND 17 KW UNITS 5 2 OPTIONAL INTERNAL MANUAL BYPA
43. _ Illustration 5 4 Power Flow 1 5 15 OPTIONAL GLOBAL MONITORING SYSTEM Localon UPS 5 15 1 Local On UPS Event Log P N 9100 1466 01 9100 1538 XX Illustration 5 5 Logged Events Illustration 5 6 Status Screen _ o O O aaaaaaaaaaa LLL Illustration 5 7 System scenes 5 15 2 Local On UPS AUX CBs Trip Monitor with Event Log P N 9100 1453 01 Illustration 5 8 Auxiliary CB Trip 5 15 3 Local on PC via RS 2322 LLL Illustration 5 9 Sample PC Screen 5 15 4 Local PO via RS 485 516 OPTIONAL ECC Emergency Circuit Converter a Illustration 5 10 ECC Emergency Circuit Converter 5 17 OPTIONAL Emergency Control Module 0 00 Illustration 5 11 ECM Emergency Control Module SECTION 6 MAINTENANCE 6 1 SAFETY PRECAUTIONS 6 2 WHEN TO CALL 6 3 STEPS TO TAKE 6 4 PREVENTIVE MAINTENANCE 65 CRUCIAL POWER CUSTOMER SERVICE AND SUPPORT APPENDICES 6002 1394 REV J APPENDIX A SPECIFICATIONS APPENDIX C OPTIONAL MAIN INPUT OUTPUT BREAKERS FOR VARIOUS MODELS APPENDIX D BATTERY CONNECTIONS 5 6 5 7 5 8 5 10 5 10 5 10 5 11 5 11 5 11 5 12 5 12 5 13 5 13 6 1 6 3 6 3 6 7 A 1 B 1 C 1 D 1 F 1 Crucial Power Products Crucial Power Products Inc Reproduction or Distribution forbidden NOTICE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION This document contains proprietary and confidential information of Crucial Power Produ
44. age 208V Unit 2 10 Illustration 2 10 Customer Connections Same Input Output Voltage 240V Unit 2 11 Illustration 2 11 Customer Connections Same Input Output Voltage 277V Unit 2 12 Illustration 2 12 Customer Connections Output Connection w Output XFMR 120V 2 13 Illustration 2 13 Customer Connections Output Connection w Output XFMR 208V 2 14 Illustration 2 14 Customer Connections Output Connection w Output XFMR 240V 2 15 Illustration 2 15 Customer Connections Output Connection w Output XFMR 277V 2 16 Illustration 2 16 Customer Connections Dual Output Connection w Output XFMR 120 240 2 17 Illustration 2 17 Customer Connections Dual Output Connection w Output XFMR 120 208V 2 18 Illustration 2 18 Customer Connections Dual Output Connection w Output XFMR 120 277 2 19 Illustration 2 19 Customer Connections Battery Connections aaa 2 20 24 REMOTE SIGNALLING CONNECTIONS OPTIONAL ss 2 20 2 5 BATTERY STORAGE ee eee us eb eee EE 2 21 SECTION GENERAL c ore cd p a 3 1 3 1 INTRODUCTION 3 1 Illustration 3 1 Wave Rider 1 ___ 3 1 BENERIIS eet 3 2 3 3 PRODUCT FEATURES e 3 3 Illustration 3 2 Unit Component Layout 3 4 3 4 FUNCTIONAL DESCRIPTIONS 0 0 0 0 82 3 444444444444442 3 5 Illustration 3 3 Functional Block Diagram n 3 7 35 THEORY OPERAATION A 3 8 3 6 OUTPUT LOADS eia sn so es 3 9 3 7 OPTIONS
45. and 208V dual output case TB2 1 or T1 14 can be treated as a neutral point and can be tied together neutral and ground If neutral and ground isolation is needed disconnect jumper ILLUSTRATION 2 17 120 208V Dual Output Customer Connections 6002 1394 REV J 2 18 Crucial Power Products 3 continued G 120V 277V Dual Output connections Load GND 1 157V Output 120V output and 277V output CBs can be combined as shown NOTE Neutral and Ground is tied together S CB 88V GO Option Aux output CB OV 120V output 120V Connect load directly to aux CB and N Aux output Output p O 277V output O ILLUSTRATION 2 18 120 2277V Dual Output Customer Connections C Battery Connections For battery connections please refer to the battery connection diagram for each sales order There are various configurations due to battery run time and battery bus voltages Appendix C 2 C 3 C 4 and C 5 show the maximum strings of each battery system as reference only 6002 1394 REV J 2 19 Crucial Power Products WARNING USE BATTERY CONNECTION DIAGRAM FROM THE ACTUAL UNIT EACH BATTERY CABINET SHOULD HAVE A COPY OF THE CONECCTION DIAGRAM EACH UNIT CABINET SHOULD HAVE A COPY OF CONNECTION DIAGRAM MAKE SURE THE BATTERY CONNECTION DIAGRAM NUMBER IN THE NAMEPLATE OF EACH UNIT
46. are updated continuously for units without optional output transformer Three screens A B C are updated continuously for units with optional output transformer Start up Screen When input power is applied for the unit LCD panel lights up and displays Crucial Power UNIT If LCD display panel is not lit the unit has problem Contact the factory service at 1 800 PWR SRVC 800 797 7782 Screen A The first default screen appears as below UNIT NORMAL XX KVA INPUT OK CHRG ON BATTERY OK DC OK ON INVERTER OUT OK The display may say Line 1 UPS NORMAL 15 KVA 5 KVA indicates the KVA rating STAND BY or NORMAL indicating normal operating modes STAND BY ALARM FAILURE indicates UPS alarm condition and FAILURE indicates unit failed or had persistent alarm condition This will require system reset by cycling power Shut if off and wait till LCD is dark Restart the unit Line 2 INPUT OK CHG ON INPUT OK INPUT BAD CHRG ON CHRG OFF Input within an acceptable range Input out of range Charger on The charger is off This will happen if the input capacitor is open or the system is in a failure mode UPS ALARM Line 3 BATTERY OK Q DC OK BATTERY OK BATTERY OV BATTERY LOW DC OK DC OV DC UV Battery voltage within an acceptable range Battery voltage high This is normal when the battery is charging Battery voltage low Recharge battery DC bus voltage within an acceptable ra
47. battery bank becomes a DC supply source to the inverter circuit maintaining an uninterrupted AC supply to the protected load The LCD screen will display a UPS ALARM message When the facility power returns stabilizes and is in phase with the backup power the system controller closes the input contactor and the system returns to NORMAL If the battery voltage drops below 16 of its nominal value and the facility power remains off then the system will assume a ALERT mode UPS ALERT The System controller will issue a ALERT message on the LCD screen if any of the following conditions happen Internal failure System overheats Battery bank under voltage During a ALERT the system stops its backup operation inverter SCRs are switched OFF and bypass SCRs are switched ON A summary alarm 5V signal is sent to the hardwired interface The system remains in this mode until power is cycled or system has been repaired when needed UPS ALARM The System controller will issue a UPS ALARM message on the LCD screen if any of the following conditions occur Input power failure Output overload During a ALARM mode inverter IGBTs remain on and an alarm signal may be sent to the signal interface The system will reset itself as soon as the problems disappear 6002 1394 REV J 3 8 Crucial Power Products 3 6 3 7 OUTPUT LOADS The Wave Rider 1 is designed to power any fluorescent or incandescent and HID lighting There are however certa
48. c Testing of Unit The Unit should be manually exercised on a periodic basis once every three months for example This forces the unit to transfer to the battery and return to main power This process activates self diagnostic testing which may reveal conditions that require attention 6 4 3 Maintaining the Batteries Danger BATTERY CIRCUIT BREAKER OPERATES AT THE RATED BATTERY VOLTAGES AT ALL TIMES TRIPPED BATTERY CIRCUIT BREAKER INDICATES A SERIOUS PROBLEM THAT MAY RESULT IN SERIOUS INJURY OR DAMAGE TO THE EQUIPMENT IF CLOSE THE CIRCUIT BREAKER WITHOUT KNOWING WHY IT FAILED CHECK SHORT IN BATTERY OR CALL CRUCIAL POWER PRODUCTS CUSTOMER SERVICE AND SUPPORT FOR ASSISTANCE AT 1 800 PWR SRVC Danger THE BATTERY ELECTROLYTE IS A DILUTED SULFURIC ACID THAT IS HARMFUL TO THE SKIN AND EYES IT IS ELECTRICALLY CONDUCTIVE AND CORROSIVE WEAR FULL EYE AND HAND PROTECTION ALONG WITH PROTECTIVE CLOTHING IF THE ELECTROLYTE CONTACTS THE SKIN WASH IT OFF IMMEDIATELY WITH WATER IF ELECTROLYE CONTACTS THE EYES FLUSH THOROUGHLY AND IMMEDIATELY WITH WATER SEEK IMMEDIATE MEDICAL ATTENTION SPILLED ELECTROLYTE SHOULD WASHED DOWN WITH A SUITABLE ACID NEUTRALIZING AGENT ONE COMMON PRACTICE IS TO USE A SOLUTION OF APPROXIMATELY ONE POUND 450 GRAMS OF BICARBONATE OF SODA TO APPROXIMATELY ONE GALLON 4 LITERS OF WATER THE BICARBONATE OF SODA SOLUTION SHOULD BE APPLIED TO THE SPILL UNTIL EVIDENCE OF CHEMICAL REACTION FOAMING HAS CEASED
49. circuit breaker and contact Crucial Power at 800 797 7782 for technical assistance Also use this number for any other questions or additional information The main input power and reserve input power should be available at same time when dual input power sources are used Caution 4 1 3 Apply input power to the Wave Rider 1 Input Circuit Breaker remains open Verify that the voltage measured on the input circuit breaker is 120 208 240 or 277 VAC and is the same as nameplate voltage rating If the voltage is not the same as on nameplate within 15 to 10 tolerance do not proceed any further Contact Crucial Power at 800 797 7782 for technical assistance Verify that there are no voltages measured on the output terminal block 4 1 4 Turn on the main input circuit breaker 4 1 5 After turning on the system wait one 1 minute while the Wave Rider 1 runs through its internal diagnostic routines Hear the sound of contactor closing See the fan s running See the LCD display screen showing UPS Normal message 6002 1394 REV J 4 1 Crucial Power Products Line 1 UPSNORMAL Line 2 INPUT OK CHRG ON Line 3 BATTERYOK DC OK Line 4 ONINVERTER OUT OK Verify that the LCD display panel indicates all correct parameters see Appendix D for details Verify that the output voltage is 120 208 240 277 VAC per the nameplate 4 1 6 Close battery breaker in the unit cabinet and in battery cabinet s
50. ctancy possibly causing unsafe operating condition Start Up Services Various start up services are available See your sales representative or telephone Crucial Power Customer Service at 1 800 PWR SRVC 800 797 7782 Maintenance Agreements Standard Full Service 24 7 Full Service and Extended On or OFF Site Maintenance agreements are available See your sales representative or telephone Crucial Power Customer Service at 1 800 PWR SRVC 800 797 7782 Warranties Contact Crucial Power Customer Service and Support at 1 800 PWR SRVC 800 797 7782 if you have any questions regarding the warranty on your unit system or batteries 6002 1394 REV J 6 7 Crucial Power Products APPENDIX SPECIFICATIONS SPECIFICATIONS FOR KVA 0 7PF UNITS POWER RATING KVA KW 3 2 1 5 3 5 7 5 5 25 10 7 12 5 8 75 15 10 5 20 14 INPUT VOLTAGE VAC Single Phase Single Phase 208 240 277 VAC 120 208 240 277 V AC MAXIMUM CURRENT 29 17 15 13 44 25 22 19 36 30 26 74 40 35 57 49 43 68 59 51 89 77 66 TOLERANCE 15 to 15 FREQUENCY Hz 60 396 POWER FACTOR 0 98 to 1 0 Typical OVERCURRENT PROTECTION Electronic Circuit Breaker NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal Block OUTPUT RATING KVA KW 3 2 1 5 3 5 7 515 25 10 7 12 5 8 75 15 10 5 20 14 VOLTAGE VAC Single Phase 12
51. cts Inc Crucial Power In consideration of the receipt of this document the recipient agrees not to copy any of its contents nor to disclose them to or allow them to be used by any person not currently an Crucial Power employee or an employee of the recipient having a need to know without the express written consent of Crucial Power and further agrees to surrender this document to Crucial Power when the reason for its receipt has terminated 2009 Crucial Power Products Inc All rights reserved 6002 1394 REV J Crucial Power Products Congratulations on selecting one of the fine products from Crucial Power the leader in power protection technology Our wide product offering includes UPS Uninterruptible Power Systems power conditioners automatic voltage regulators and specialty transformers e g computer grade medical grade Since our founding in 1972 Crucial Power has shipped many of these fine products to discerning customers around the world for use on sensitive equipment and critical applications One of our goals is to make our manuals both comprehensive and easy to use The new format of our user manual is the result of ideas and inputs from customers like you who have taken an active interest in our continued success We invite and appreciate your feedback on our products and documentation via e mail fax mail or telephone 6002 1394 REV J SALES Phone 800 244 4069 FAX No 800 246 2346 E mail in
52. der Note that the rear bracket attached to the heat sink slides under the bracket secured on to the back panel Slide the assembly back and reinstall 3 Phillips Screws Reinstall all the cables and connectors in the reverse order Verify per illustration 4 1 Verify connections prior to starting up the unit Phase C Q3 Q4 Phase A Q1 Q2 Phase B Q5 Q6 E2 Q7 Q8 E1 C2 Q7 Q8 RED PB1 1 P1 5 WHITE 1234 ILLUSTRATION 4 1 HEAT SINK ASSEMBLY FRU 6002 1394 REV J 4 4 Crucial Power Products 4 4 RENEWAL PARTS ITEM 6002 1394 REV J Table 4 1 System Parts aw DESCRIPTION 1 1 3 mgoen OO O O re 3 InputOutpuiBatery Terminal Block for customers use 181 TB TE 3 mue 3 Qe w 77717 Frequency Noise Filer Capacitors for output Power 056863 3 femas 3 3 mco 2 1 eisene E 3 12 723 lp 00 19 3 Jegen n 3 m T 1 Ouputisolaon Transformer 4 5 Crucial Power Products SECTION 5 SYSTEM OPTIONS This section describes options available with the Wave Rider 1 phase The following are available Part Number Options 3000 044 thru 056 External Manual Bypass Switch 9100 1359 01 thru 04 Internal Manual Bypass Switch
53. er The Power Board also contains the housekeeping power supplies and drivers for the IGBTs The entire assembly provides the landing place for all internal input output DC cables and metering devices for control and monitoring of the unit input and output currents Control Board Illustration 3 2 Item 10 The microprocessor with unit specific firmware and control circuitry is located on the Control Board The Control Board is mounted on the cabinet door and communicates with the Power Board A2 via a ribbon cable It monitors the input and output voltages and generates the command to close or open the input contactor and to sense and change the status of the bypass static switch The Control Board sends data to the LCD panel located on the door where actual status and parameters are displayed It additionally has AS400 RS232 and RS485 output capabilities and supports various communication including SNMP options Output Static Switch Illustration 3 2 Item 3 This SCR solid state switch connects the output of the inverter UPS to the load It is connected on the primary side of the optional output isolation transformer This switch shuts off in case of a problem or failure within the unit and transfers the load directly to the utility input via the bypass static switch It maintains it s status opposite to that of bypass switch LCD Display Panel Illustration 3 2 Item 11 The LCD Liquid Crystal Display panel provides all the input ou
54. er 1 is a self contained unit a simple solution for back up power for any fluorescent or incandescent lighting source such as overhead fixtures exit signs etc It has been specifically designed to maintain 90 minutes of lighting power and ensure a safe building evacuation It offers significant advantages over other alternatives For example just one Wave Rider 1 Central Lighting Inverter can replace 70 bug eyes to make service and maintenance much quicker and easier The convection cooled On line PWM inverter system is virtually silent and can be installed anywhere On line PWM technology provides switchover from utility to battery power without any interruption The Wave Rider 1 is designed to fit the needs of virtually all power conditioning and unit applications It has been designed to power all forms of modern data processing communication and process control equipment The Wave Rider 1 does not require any de rating as other products may when powering 100 electronic loads including switching mode power supplies The Wave Rider 1 protects sensitive electrical equipment such as computer servers telecommunication networks LANs multi user and instrumentation systems from electrical interference including problems associated with poor quality AC power sags and complete power outages 6002 1394 REV J 3 2 Crucial Power Products 3 3 3 3 1 3 3 2 3 3 3 3 3 4 3 3 5 3 3 6 PRODUCT FEATURES The following descr
55. fo crucialpower com Office Hours are 7 00 AM to 5 30 PM PST WARRANTY REGISTRATION AND WARRANTY CERTIFICATE REQUEST www 800pwrsrvc com SERVICE If you require assistance please call our 24 hour toll free hot line 800 PWR SRVC 800 797 7782 Please have the following information from your unit s nameplate available to speed assistance Serial Number kVA Power Rating Input Voltage Output Voltage Manufacturer Date Crucial Power Products IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS SECTION 1 SAFETY Following safety precautions is important when operating or servicing electrical equipment The symbols shown are used extensively throughout this manual Always heed these precautions since they are essential to the safe operation and servicing of this product Boxes labeled with the Danger symbol indicate that there is high risk of personal injury or death if instructions are not followed Warnings labeled with the Caution ee symbol indicate that there is a high probability of equipment failure damage or destruction if instructions are not followed Danger ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT TO INSTALL OR REPAIR THE UNIT OR ITS BATTERY SYSTEM IMPROPER INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT CAUSE OF START UP PROBLEMS HIGH AC AND DC ELECTRICAL VOLTAGES ARE PRESENT THROUGHOUT THE UNIT S AND INCORRECT INSTALLATION OR SERVICING COULD RESULT IN
56. g the conduit to maintain unit reliability 2 Determine which knockouts will be used to bring cables into and out of the unit Only remove the conduit knockouts that are to be used 3 Measure the locations for the conduits on the conduit knockouts 4 Punch holes in the conduit knockouts for the conduits 5 Anchor the Wave Rider 1 to the mounting pad at the four 4 mounting locations 6 Anchor the conduits to the conduit knockouts If equipment is not ready for normal operation it must be protected from dust to prevent damage to equipment This concludes the mechanical installation 2 3 2 Electrical Connection Arrangements Danger VERIFY THAT ALL CUSTOMER SUPPLIED WIRING IS DE ENERGIZED BEFORE PERFORMING ANY ELECTRICAL WORK FAILURE TO DO SO COULD RESULT IN ELECTROCUTION INJURY OR DAMAGE TO EQUIPMENT Danger EVEN WHEN THE WAVE RIDER 1 IS OFF THERE ARE POTENTIALLY DANGEROUS VOLTAGES WITHIN THE WAVE RIDER 1 UNIT DUE TO THE BATTERIES EXTREME CARE MUST BE TAKEN WHEN WORKING WITHIN THE WAVE RIDER 1 ENCLOSURE TO AVOID THE POSSIBILITY OF ELECTROCUTION INJURY OR DAMAGE TO THE EQUIPMENT 6002 1394 REV J 2 6 Crucial Power Products 2 33 Customer Connections A Input Power Connection by Customer Connect input Hot at TB 1 Connect input Hot Neutral at TB1 2 Connect input ground at TB1 3 To Customer s Load BATTERY INPUT TB1 OUTPUT TB2 CONNECTION TB3 1 2 3 2 3 4 5 7 1 2 3 HOT HOT N
57. ibes the major blocks within the Wave Rider 1 Please refer to lllustration 3 2 System Component Layout to find specific items Input Contactor K1 Illustration 3 2 Item 12 The input contactor is multifunctional First it provides connections for the input power to the unit Secondly the contactor disconnects the input line when an outage occurs so that there is no back feeding of power into the power line Finally the contactor allows for automatic unit operation upon a complete discharge of the batteries No operator intervention is required when power to the unit is restored after a complete battery discharge Battery Charger The battery charger maintains the batteries at full charge After a battery discharge the charger will automatically recharge the batteries upon restoration of input power This circuit is on the Power Board Power Board Assembly with IGBT s Illustration 3 2 Item 1 The Power Board is bolted onto the IGBT Insulated Gate Bipolar Transistor blocks that are mounted on heat sink The complete Heat Sink Assembly with IGBTs and Power Board is replaceable as a single part This FRU Field Replaceable Assembly converts all the power i e input AC power converted to DC bus battery power boosted to DC bus and finally DC bus power converted to output AC power using PWM technology for a smooth AC sine wave In case of a catastrophic failure the complete Heat Sink Assembly is easily replaceable using only a screwdriv
58. icating repair and failure analysis Control Board This Control Board is located on the inside right door at the top and mounted at 4 corners with screws and washers Verify that all connectors are matches with their designations and pins 1 2 etc Unplug P1 through P15 Install the new board Reconnect all plugs and connections maintain them with their original orientations Other Parts Verify that the cables are marked before disconnecting Replace the defective part with the new part Reconnect wiring the same way as it was disconnected 6002 1394 REV J 4 3 Crucial Power Products 4 3 3 Heat Sink Assembly Replacement Procedure 1 2 Disconnect and isolate all sources of power The Heat Sink Assembly is located on the right side of the top electronic shelf inside the unit cabinet Illustration 4 1 Verify that all cables and connectors have labels and are identified as shown This is important for reinstalling the assembly Disconnect connectors P7 P6 P4 P1 from the PCB A1 which is mounted horizontally on the big black heat sink Disconnect 5 power cables at 4 1 through TB4 5 using flat screw driver Verify and install label ID for each cable before disconnecting Loosen 3 Phillips head screws at front holding heat sink bracket Pull the complete assembly forward and up Remove it from tray gently making sure that no cables or wires are catching See illustration 4 1 Install new assembly in the reverse or
59. in types of loads that exhibit an excessive inrush current when first turned on or at other times during operation The capacity of the Wave Rider 1 may need to be greater than what would be estimated based on the nameplate requirements of loads previously discussed Contact your Crucial Power dealer or the factory directly if you have any questions about powering unusual loads from your Wave Rider 1 OPTIONS See Section 5 for details The following options are available with the Wave Rider 1 Internal External Manual Bypass Switch Audio Alarms with Silence Switch Remote UPS Status Display 1 phase Monitor Form C N O Contacts for Alarms TVSS Transient Voltage Surge Suppressor Normally ON OFF Output Aux Circuit Breakers External Output Aux Circuit Breakers in Panel Board Stackable Cabinet Rack System Input CB Standard Higher KAIC System Output CB Standard Higher KAIC Higher KAIC Norm ON OFF Output Circuit Breaker Molded case Higher KAIC Norm ON OFF Output Circuit Breaker 1 Phase Din rail Seismic Mounting Bracket Left and Right set per cabinet Power Flow Mimic GMS Global Monitoring System e Local via PC with RS232 e Localvia PC with RS485 e Basic NetAgent SNMP e Basic NetAgent SNMP with WIFI HUB application e Advanced NetAgent SNMP e Advanced NetAgent SNMP with WIFI HUB e Advanced NetAgent SNMP with GPRS mobile modem e Advanced NetAgent SNMP with dial up modem ECC Emergency Circuit Converter ECM Emergency Control Modu
60. information is provided on the nameplate located on the inside front door of the unit See Appendix A for a complete listing of the Wave Rider 1 specifications 68 High 48 High Cabinet Cabinet ILLUSTRATION 3 1 WAVE RIDER 1 6002 1394 REV J 3 1 Crucial Power Products 3 2 BENEFITS Electrical disturbances can come from practically anywhere from the incoming power lines and even from within a building Outside electrical disturbances include lightning strikes utility switching brown outs and accidents Electrical disturbances in a facility can be caused by load cycling elevators HVAC Systems etc fault conditions welders and other electrically noisy equipment Whether the electrical disturbances are generated outside or within the facility the following power problems can occur Complete power outages Brown outs including momentary sags Voltage surges Transients including common mode and transverse mode noise Frequency shifts and fluctuations Sensitive equipment needs protection from power problems Without power protection users of sensitive equipment may experience Loss of data Database corruption Rebuilding of files Equipment and component deterioration Premature equipment failures Unexpected equipment malfunctions Missed deadlines especially during batch processing Loss of real time transaction processing Loss of employee productivity The Wave Rid
61. le 6002 1394 REV J 3 9 Crucial Power Products SECTION 4 OPERATION 41 START UP PROCEDURES The unit s batteries are shipped directly from battery the manufacturer to insure brand new batteries and allow an opportunity for the installing contractor to schedule their arrival when they are ready to commission the system The battery cabinet and the interconnect cables are shipped with the electronics section of the inverter in a cardboard box located inside each battery cabinet Crucial Power service personnel must perform initial start up or a factory trained authorized representative To request start up fax a completed Request Turn On form 6002 1545 to 800 246 2346 or e mail it to info 800pwrsrvc com Form is now available in the web at www 800pwrsrvc com The start up procedure described in this manual is a reference only to a start up of the Wave Rider 1 for maintenance and shutdown Please be sure not to start up the unit without the assistance of a factory trained authorize personal as failure to do so may damage the unit and void the unit warrantee 4 1 1 Verify that the main input circuit breaker battery breaker and output circuit breaker s are in the OFF or down positions Refer to illustration 3 2 for the location of the circuit breakers 4 1 2 Check all cable connections are firmly secured If during the start up procedures anything unusual occurs immediately Caution gt turn off the input
62. led on display Press Log once again to return to the main menu 10 04 06 16 OVERTEMP 10 04 06 16 INP UV 10 04 06 08 INP UV 10 04 06 14 INP UV ESC LOG FREEZE INFO SILENCE ILLUSTRATION 5 5 LOGGED EVENTS FREEZE Press one time The display will freeze the default monitoring and alarms screen Press the Freeze key again to return the display to the initial menu with scrolling operation UPS NORMAL 20 KVA INPUT OK CHRG ON BATTERY OK DCOK ON INVERTER OUT OK ESC LOG FREEZE INFO RESET SILENCE ILLUSTRATION 5 6 STATUS SCREEN INFO Press the key one time System data appears on the screen after few seconds Pressing the key once again returns the display to default screen 6002 1394 REV J 5 9 Crucial Power Products 5 15 1 2 5 15 2 5 15 2 1 5 15 2 2 MINUTE ON BATT 00072 SYSTEMS HOUR 00256 BATT EVENT 00019 TEMPERATURE 32 ESC LOG FREEZE INFO RESET SILENCE ILLUSTRATION 5 7 SYSTEM INFO RESET Pressing the Reset and Info keys together clears Specification Description Local On UPS Event Log Part Number 9100 1466 01 9100 1538 XX Components Monitoring PCBA P N 1625 344 01 Power Supply P N 1625 339 5 12 VDC 25W Com Cable P N 7060 1187 01 Keypad Overlay P N 1250 070 Local On UPS Aux CB s Trip Monitor P N 9100 1453 01 Operation Trip signals coming from the breakers are displayed on the circuit breaker trip screen The circui
63. nce Bypass Switch P N 3000 044 thru 056 MOUNTING HoW H1 H H MOUNTING DIM 1 ENCLOSURE SIZE INCH PART NO AMP w H D W1 H1 3000 044 55 AMP 14 16 8 12 16 75 3000 045 110 AMP 14 16 10 12 16 75 ENCLOSURE DIM S SELECTION CHART FOR SINGLE PHASE UPS KWIKVA KW KVA KW KVA KW KVA kva kw FOR WIRING DIAGRAM 3 5 7 5 10 15 20A7 SEE DWG 3000 045 3000 044 3000 044 3000 045 3000 045 3000 045 6001 032 315 1 SWITCH CONTACTS ARE SINGLE PHASE L NEUTRAL MAKE BEFORE BREAK 2 CONTACTS MARKED UPS ARE CLOSED IN THE UPS POSITION 3 CONTACTS MARKED MAINT ARE CLOSED IN THE MAINT POSITION 4 WRAP AROUND BY PASS SWITCH SHOULD USED WITH SAME INPUT OUTPUT VOLTAGE 5 WRAP AROUND BY PASS SWITCH CAN ONLY BE USED WITHOUT ANY BUILT IN SECONDARY DISTRIBUTION CIRCUIT BREAKERS IN UPS ILLUSTRATION 5 1 EXTERNAL MAINTENANCE BYPASS SWITCH 6002 1394 REV J 5 2 Crucial Power Products FACILITY FEEDER CIRCUIT BREAKER SIZE CB FOR PROPER N APPLICATION 552001 SINGLE MAIN 1200 x 1 L INPUT Ta POWER 1 LEONE GND l L l 120 VOLT TB2 1 2 FOR 240 VOLT 2 5 1 FOR 277 VOLT 2 6 1 2 L3 NOT USED INCOMING POWER TO 600 VOLTS AC SINGLE PH
64. ng Maximum Ballast load 1500 W 120 and 277 VAC 20 A N C UL contact rating High Voltage surge protectors Approvals 01924 1104 2 4 1 OSHA NEC 700 thru 700 26 701 717 702 709 705 750 Operating Temperature 210 to 150 F Size 2 75 W x 1 5 1 25 D overall Color Black Weight 8 oz ILLUSTRATION 5 11 ECM EMERGENCY CONTROL MODULE OFF Line Inverter operation 5 18 1 Slow transfer unit P N 9100 1473 01 5 18 2 Fast transfer unit P N 9100 1634 01 thru 14 6002 1394 REV J 5 13 Crucial Power Products SECTION 6 MAINTENANCE 61 SAFETY PRECAUTIONS Danger READ AND UNDERSTAND THIS SECTION THOROUGHLY BEFORE PERFORMING ANY MAINTENANCE WORK ON OR AROUND THE UNIT READ THE BATTERY MANUFACTURER S MANUAL AND MATERIAL SAFETY DATA SHEETS BEFORE WORKING ON OR NEAR THE BATTERIES ONLY NORMAL SAFETY PRECAUTIONS ARE REQUIRED WHEN THE UNIT IS OPERATING WITH ALL CABINET DOORS CLOSED HOWEVER THE UNIT AND BATTERY CABINETS MUST BE KEPT FREE OF STANDING PUDDLES OF WATER EXCESS MOISTURE OR DEBRIS DEBRIS CAN CONSIST OF EXCESSIVE DUST IN AND AROUND THE UNIT AS THE COOLING FANS IN THE UNIT WILL PULL THIS DUST INTO THE UNIT Danger ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT TO INSTALL OR REPAIR THE UNIT OR ITS BATTERY SYSTEM IMPROPER INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT CAUSE OF START UP PROBLEMS SERVICE PERSONNEL SHOULD WEAR INSULATING SHOES FOR ISOLATION FROM DI
65. nge DC bus voltage too high UPS ALARM DC bus voltage too low UPS ALARM NOTE The typical DC buss voltage should be higher than the battery voltage 6002 1394 REV J 1 Crucial Power Products SCREEN B The second default screen appears as below OUTPUT INPUT DC BUS Line 1 Indicates output voltage and power in watts when an output transformer is not used It indicates primary voltage of the output transformer T1 208 VAC typically when T1 is used Line 2 Indicates input volts and Amps Line 3 Indicates internal DC bus condition for factory use Line 4 Indicates battery voltage The current in Amps indicates charging Amps while indicates discharging Amps SCREEN C When an optional output transformer is installed the multiple output voltages are displayed as follows OUTPUT 120 V OUTPUT 208 V OUTPUT 277 V OUTPUT 480 V Line 1 Indicates L N output voltage 1 Line 2 Indicates L N output voltage 2 Line 3 Indicates L N output voltage 3 Line 4 Indicates L N output voltage 4 6002 1394 REV J 2 Crucial Power Products APPENDIX C OPTIONAL MAIN INPUT amp MAIN OUTPUT BREAKERS FOR VARIOUS MODELS STANDARD KAIC 1PH UPS INPUT CIRCUIT BREAKERS RAUNG RATING CIM PIN 0 1050 2025 784 39 2025 700 25 6 2025 780 2 25 2025 2025 763 2080 2028 705 2P 50
66. nput voltage and input frequency are within 10 permissible windows of normal voltage and 3hz of normal frequencies and inverter static switch is opened The inverter static switch is only closed upon the failure of input power or upon out of voltage and frequency normal ranges This is called the off line inverter mode and system efficiency is higher as 9896 and reduces the total power loss The output AC voltage in the mode of operation follows proportionally to the input line voltage In another words there is no output voltage regulation within 10 window voltage range or 15 selectable window voltage range There are two versions one is fast transferring with a quarter of cycle 2 5 milli second another is slow transferring with 25 cycles 400 milli second second to 1second Fast transferring time is required when the loads are sensitive to voltages such as HID lights and other that any voltage disturbance effects their operation One must consider that higher efficiency of unit is only requirement and output voltage regulation is not critical as much Option part numbers refer to 5 18 options AC off line inverter operation with 2 version of transferring time 6002 1394 REV J 3 6 Crucial Power Products OUTPUT CIRCUIT BREAKER FOR FAST TRANSFER UNITE UPS CABINET BOTES UT Hee CAR DOTTED ARE OPTIONAL Nuse rO OF TERE ANPUT OUTPUT VOLTADE uus CONNECT TES
67. ocated on the inside of the right door of the enclosure See illustration 3 2 for location of Control PCB 2 4 2 Dry relay contacts have the following maximum ratings 125 volts AC or DC maximum 1 25 amperes maximum 30 watts 50 VA maximum It is imperative that the relay contact ratings are not exceeded Otherwise damage to the relays within the Wave Rider 1 will occur 2 4 3 Determine which signals will be used Connect wires customer supplied to the connector 2 4 4 See illustration 3 2 for location of dry C contacts terminal 2 5 2 5 1 This concludes the installation procedures Please proceed to Section 4 1 Start Up BATTERY STORAGE The Wave Rider 1 System can be placed in storage while not in use Provide a protected environment which meets the environmental parameters listed below AMBIENT TEMPERATURE 20 to 70 C 4 to 158 F e RELATIVE HUMIDITY 096 to 95 non condensing If the Wave Rider 1 will be stored for three months or longer it should be serviced by charging the batteries for 24 hours at regular three month intervals While in storage service the unit using the procedures in this section Battery Maintenance During long term storage the batteries are subject to aging and deterioration After visual inspection if the batteries need to be replaced contact your Crucial Power dealer or the Crucial Power factory directly to purchase new batteries Batteries matching sequence numbers used sh
68. ormation and tight regulation of the output voltage while the Wave Rider is operating from its internal inverter and it can be utilize to provide a different voltage than input source voltage Inverter Test Switch The SW 2 test momentary switch is a push button switch for testing the Wave Rider 1 and the batteries for proper operation When the Wave Rider 1 is running and Switch SW 2 is pushed and held in the Wave Rider 1 will automatically transfer to battery operation The Wave Rider 1 will continue to run on batteries until the switch is released When the switch is released the Wave Rider 1 returns to normal operation provided input power is present 6002 1394 REV J 3 5 Crucial Power Products 3 4 10 3 4 11 3 4 12 3 4 13 3 4 14 Power Supply Transformer This transformer with fuse F1 provides internal housekeeping DC power supply The primary of this transformer has taps to match with the input voltage Control Transformer T2 Transformer with 120 VAC secondary for control of the K1 contactor coil from the A1 control board Maintenance Bypass Switch This Maintenance Bypass Switch MBS allows the Wave Rider 1 to be switched off line for maintenance or troubleshooting when the inverter malfunctions or PM Periodic Maintenance is required The MBS transfers the input power directly to critical load without any break or power disruption Before switching the MBS to the maintenance position turn on toggle switch S1
69. ould be purchased to set up a string If the unit is stored in its original packaging unpack unit using unpacking procedures outlined in Equipment Unpacking Section 2 2 If the unit is not connected to a source of power first connect the unit to an appropriate power source using the procedures in Unit Installation Section 2 3 Then recharge batteries as follows 1 Unlock and open front doors Set AC input power source to ON Close input circuit breaker and wait for 1 minute Close battery circuit breaker only when UPS Normal is displayed on screen Pa 29 19 The unit automatically recharges batteries The LCD panel will indicate the battery voltage and charging current Allow unit to run for 24 hours to fully charge batteries When batteries have reached partial charge the battery charging current will be under 1 Amp on LCD panel 8 Open 2 Battery Breaker 9 Turn OFF input power to the unit 10 Close and lock front door 6002 1394 REV J 2 21 Crucial Power Products 3 1 SECTION 3 GENERAL INTRODUCTION The Wave Rider 1 Central Lighting Inverters are manufactured to provide critical power for lighting during a power outage The Wave Rider 1 meets or exceeds the life safety codes of UL924 and UL1778 These codes were established to allow the emergency lighting inverters to provide critical power to the lighting circuits during a power failure The emergency lighting inverter will then provide power for 90
70. re shown for electrical connection only and do not necessarily match the actual battery layout in your unit The arrangement may be different from drawings Caution Danger The use of a physically damaged battery can cause a catastrophic system failure and can even result in a fire or explosion that could endanger life and property Before accepting a battery shipment from the carrier please read and follow these instructions 1 Thoroughly inspect each battery for any signs of damage If there is any damage reject the shipment and notify the manufacturer at 800 PWR SRVC 800 797 7782 If possible photograph the damage for future reference As you unpack the pallet or container check each battery box for damage on all sides the top and bottom If there is any sign of damage photograph the damage if possible and contact Online Power at 800 PWR SRVC 800 797 7782 Before you install each battery in the cabinet remove it from its carton and thoroughly inspect it again on every side the top and bottom for any signs of physical damage including but not limited to cracks chips leaks bulges and so forth 4 If battery is dropped or makes hard contact with any abject inspect it again 5 Batteries are heavy so exercise care when lifting them to the shelves of a battery cabinet If at any time you have any questions regarding the condition of a battery set it aside and notify the manufacturer at 800 PWR SRVC
71. red All Battery terminal connections must be tighten with proper torque value set in accordance with the table or instructions provided by battery manufacturer Use the correct torque tool to tighten the terminal bolts as indicated in table below and use all hardware s provided with batteries Type Standard VRLA Battery Battery part Initial torque in LBS Annual re torque in Terminal Hardware number LBS Type PRC 12150 C T Copper Insert 150 120 IN LB 13 6 115 IN LB 13 6 NM Terminal 4 20 UNC Bolt 1 to 1 25 long bolt Z1 Z post w 14mm head 14mm UB 12750 88 5 IN LB 10 NM 84 IN LB 9 5 NM type terminal nut 8mm washer amp lock washer UB12900 88 5 IN LB 10 NM 84 IN LB 9 5 NM Same as above UB12110 88 5 IN LB 10 NM 84 IN LB 9 5 NM Same as above Type G Longer warranty battery Battery part SE 3 Annual re torque in Terminal number Initial torque in LBS LBS Type Hardware GSLF 10512 120 IN LB 13 6 NM 115 IN LB 13 0 NM Copper Insert GSLF 12012 120 IN LB 13 6 NM 115 IN LB 13 0 NM Copper Insert 1 4 Type N Nickel Cad battery only nickel plated copper cable lugs should be used Ni Cad P N Recommended Torque 112 138 66 IN LB 7 5 5 148 184 177 IN LB 20 M8 BM 195 231 277 266 IN LB 30 NM M10 NOTE For annual re torque reduce 5 IN LB from recommended torq
72. res Maximum 30 Watts 50 VA Maximum INTERFACE CONNECTION Hard Wired Terminal Block ENVIRONMENTAL USRGE WITHSTANDABILITY ANSI C62 41 1980 Categories A amp B OPERATING TEMPERATURE Meets NEMA Requirements OPERATING RELATIVE HUMIDITY 0 to 95 Non Condensing ALTITUDE Up to 6 000 Feet 1 829 Meters with No De Rating COOLING PHYSICAL Air Cooled Forced Fan SIZE HxWxD in cm 70 x 39 x 20 177 8 x 99 1 x 50 8 WEIGHT Ibs kg with patience 896 408 1191 533 1666 758 2042 929 3572 1625 3132 1425 215 CONSTRUCTION Painted Steel Enclosure with 3 Point Double Locking Front Door and Full Length Door Hinge ENCLOSURE Designed for Inside Installations COLOR Natural finish ACCESSIBILITY Front All Servicing is Through the Front No Side or Rear Access is Required CABLE ENTRY Bottom or sides MOUNTING Four 4 Holes Provided to Anchor Enclosure to Pedestal Supplied by Others 6002 1394 REV J A 2 Crucial Power Products SPECIFICATIONS FOR KW 1 0PF UNITS POWER RATING KW 3 3 5 5 7 5 7 5 10 10 12 5 15 15 17 12 5 20 14 VOLTAGE Single Phase Single Phase 208 240 277 120 208 240 277 VAC MAXIMUM CURRENT 51 41 36 64 56 48 79 69 59 95 83 71 107 94 80 TOLERANCE 15 to 15 FREQUENCY Hz 60 3 POWER FACTOR 0 98 to 1 0 Typical OVERCURRENT PROTECTION
73. signed for specific line configurations The device has two stage protection When protection components are damaged by absorbed transients the device will show a reserve flag indicating a need for replacement At this time the device is still operational due to redundant circuits After the second spike the device will show and alarm condition indicating replacement is mandatory Remote indication contacts TS allows remote control of the protection status 6002 1394 REV J 5 6 Crucial Power Products 5 7 OPTIONAL NORMALLY ON NORMALLY OFF OUTPUT AUX CIRCUIT BREAKERS P N 9100 1343 01 THRU 16 These circuit breakers are 1 pole 20A devices for protection of customer s circuits Normally ON C B Option Normally OFF C B Option Normally OFF Delay C B Option NORM ON OFF OUTPUT AUX CBS STANDARD KAIC CB Refer to the table for details in the separate attachment 10 KAIC 120 240 VOLT 6 KAIC 277 VOLT 5 8 OPTIONAL EXTERNAL OUTPUT AUX CIRCUIT BREAKERS IN PANEL BOARD P N 9100 1439 01 THRU 03 5 8 4 Description A matching external panel board with 1P 20A QO Square D circuit breakers is provided for power distribution from the unit output to critical loads The panel board accommodates up to 42 breakers A main circuit breaker is provided with each panel board See drawing 6001 03 15 for panel mounting arrangement 5 8 2 Specification Part Number Description 9100 1439 01 EXTERNAL OUTPUT AUX CBS OP
74. stallation Data Specifications 6002 1394 REV J E 1 Crucial Power Products APPENDIX F Connection Diagram using existing 3 pole panel board for dual output voltages H2 N 120V 208V NOT USE 88V 88V I N 208 120 m OUTPUT XFMR UPS OUTPUT PNL BD 1 1 H2 N 120V NOT USE HI H2 277V 157 OUTPUT XFMR UPS OUTPUT T B OUTPUT 2 010 H2 N 120V HI H2 240V HI N 120V OUTPUT XFMR UPS OUTPUT T B 6002 1394 REV J F 1
75. t breaker is a part of default monitoring and alarm display that scrolls continuously when the unit is in operation Below is an illustration of a typical circuit breaker trip screen AUX CB TRIP ESC LOG FREEZE INFO RESET SILENCE ILLUSTRATION 5 8 AUXILLIARY CB TRIP Specification Description Local On UPS Aux CB S Trip Monitor With Event Log Part Number 9100 1453 01 Components Event Log Option P N 9100 1466 01 Trip monitoring modules ABB S2C S H 6R DIN rail mount Monitored CBs only ABB MCB series 6002 1394 REV J 5 10 Crucial Power Products 5 15 3 Local On PC Via RS 232 P N 9800 01 25 THRU 150 25 150ft 5 15 3 1 5 15 3 2 5 15 3 3 5 15 4 Description This option requires a PC and LabView monitoring software The software is provided on a disc that is easily installed on any Windows platform An attached cable of a specified length plugs into a PC serial port and connector J6 on the Control PCB 1625 296 LabView software must selected for COM port 1 Operation LabView software translates data protocol coming to COM port from an active unit via the RS232 RS485 Interface and displays the parameters and active alarms on a PC monitor in the appropriate form Below is a sample of a PC screen with measured parameters and actual unit status 4 va X KR ILLUSTRATION 5 9 SAMPLE PC SCREEN Specification Description Local On PC Via RS 23
76. tors The input inductors are a single phase input filter Inverter When the AC input power is not available to power the load the inverter converts the energy stored in the battery bank to AC power to supply power to the load The pulse width modulated PWM inverter utilizes high speed high efficiency IGBT s for fast response sinusoidal power Battery charger The battery charger converts AC power into regulated DC power to re charge and to maintain the charge on the battery bank The charger is fully automatic with a current limiting feature so that battery damage will be prevented in case of a charger malfunction The charger is sized such that the batteries will be maintained at full charge even when the input voltage is at the low line limit for indefinite periods of time Battery The battery bank shall consist of 8 10 16 20 or 32 12 Volt batteries providing the reserve energy to sustain the load when suitable AC input power is not present The batteries are sealed maintenance free VRLA Valve Regulated Lead Acid construction DC Choke The DC choke helps boost battery voltage to a higher internal DC bus voltage while it reduces high frequency noise Output Transformer used only for multiple output voltage units The Output transformer performs two critical functions First it provides excellent common mode and normal mode noise isolation of the load from the input or inverter power Secondly it provides voltage transf
77. tput battery metering and alarm data and UPS status for customer use on a constantly scrolling set of 2 default screens with continuous update 6002 1394 REV J 3 3 Crucial Power Products 3 3 7 Optional Output Isolation Transformer Illustration 3 2 Item 20 The output isolation transformer provides isolation between the inverter and protected output The power to the primary of this transformer is received from unit and is transformed to required output voltage levels It will also add another screen to the main menu 3 3 8 Optional Maintenance Bypass Switch Illustration 3 2 Item 2 The MBS Maintenance Bypass Switch removes the critical load from the backup power and providing utility input directly to the load in case of a malfunction of the unit or during system maintenance 3 3 9 Battery Bank Illustration 3 2 Item 26 The battery bank consists of sealed maintenance free batteries The batteries provide emergency power during power outages The battery bank includes a breaker for over current protection and DC disconnect 3 3 10 System Component Layout Power Board A1 Bypass Static Switch PB1 Output Static Switch PB2 Input Output Battery Terminal Block for customer s use TB1 TB2 TB3 Input Choke L2 Output Choke L3 DC Choke L4 Input Choke L1 High Frequency Noise Filter Capacitors for Input C1 Output C2 and Battery C3 Power Control Board A2 LCD Display Board Input Contactor K1
78. ue value gt Caution Porque all connections accordance with the above tables unless Zeenen wees provided from battery manufacturer Failure to do so may create an unsafe condition or fire hazard 6002 1394 REV J 6 6 Crucial Power Products 6 4 6 6 5 6 5 1 6 5 2 6 5 3 Battery Terminals e Check for discoloration corrosion and connection integrity Clean and tighten as necessary e To access battery terminals remove the top strapping material located at the lower front of the battery shelf Pull the battery forward to access the battery connections Disconnect the cables connected to the battery Once disconnected insulate the cables to prevent accidental shorts Use a protective boot or electrical tape Before replacing the battery connections clean and re torque the connection hardware Crucial Power Customer Service personnel must approve use of non standard batteries Please call at 1 800 PWR SRVC 800 797 7782 CRUCIAL POWER CUSTOMER SERVICE AND SUPPORT Start up unit maintenance battery maintenance and preventative maintenance programs are available through your Crucial Power sales representative or through Crucial Power Customer Service and Support A program of periodic maintenance is recommended once every six months but is mandatory once every twelve months since heat and cold will effect the compression of the electrical connections and lack of maintenance will shorten the product s life expe
79. ypass mode e ONBATT Unit is running from Battery e LOW BATT Battery voltage is at low voltage before shutdown e SUM ALARM Unit is on critical alarm such as Over Temperature DC OV UV e HORN Audible warning for alarm condition e SILENCE SWITCH Silences the audible warning LED TEST Tests the LED s by push in Side Mount Provision REMOTE STATUS PANEL Back Mount Provision ON BYPASS e gan 6 1 E Zi gt OUTPUT O BATT DATT ALARM To UPS P100 Terminal Block See installation instruction shipped with the assembly LED TEST SILENCE t TC Use Bumpers for console install ILLUSTRATION 5 3 REMOTE STATUS PANEL 5 4 3 Specifications Unit Remote Status Panel Installation Drawing 9100 1020 06 revision A attached at the end of System Options Section 6002 1394 REV J 5 5 Crucial Power Products 5 5 5 5 1 5 5 2 5 6 5 6 1 OPTIONAL FORM C CONTACTS FOR ALARMS P N 9100 1362 01 Installation Terminal strip TB is provided on the optional alarm relay board for user connection to the individual alarm contacts Operation The Remote Contact Board includes isolated Form C contacts for the following alarm signals TB 1 LOW BATTERY TB 2 ON BYPASS TB 3 SUMMARY ALARM TB 4 NOT USED TB 5 INPUT FAIL TB 6 COMMON OPTIONAL TVSS P N 9100 1440 02 Operation TVSS contains energy absorbing components de

User`s Manual Wave Rider 1

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