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1. A ai CR 24 4052 3REAK YIN um Figure 3 1 Front view of the ELI M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3 2 Rear view SPRINKLER HOOD REAR ACCESS COVER Figure 3 2 Rear view of the ELI M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3 3 Rear View Cover Removed Removal of the rear access cover exposes personnel to dangerous voltages and shock hazards that may cause damage injury or death BATTERY BREAKER MAINTENANCE SWITCH TERMINAL BLOCK Figure 3 3 Rear cover removed 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3 4 Battery Cabinets Some battery cabinets feature slide out shelves Prior to installation of the BBU the side panels should have
2. 11 gt 13 d Gohtrol Panel 13 1 6 AUDIE AIA 13 5 COMMUNICATION MEN ACES ia bs 14 22 RE UT T Tm 15 0 2 Ao 400 amp Relay CONTACT GA A EE APA W 15 Oe RY CONAC RA 17 54 Emergency POWE Ol 18 5 5 Emergency Lighting 19 OBIONALFEGUICS UU Ur 20 6 1 Simple Network Management Protocol SNMP 20 6 2 Monitoring and Optional Control Software 20 M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 vili WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 6 35 Normally OMF UNCION qt tm 20 Ke ODETAUON EET 21 em 21 122 OCC 6 Cada oc R W 21 Tice asa O A A A EM UM mE UM 22 7 4 Maintenance Bypass 22 TROUBLESHOOTING ssi et tad ze _ _ _ ____ _ 24 Oe Layout Adda a A O O ES 25
3. EMI RFI L PFC CIRCUNL INVERTER _ OUTPUT m UAC OUTPUT MA 3 M GIRL 45 T 2W G 4 FILTER P Us FILTER ATLAS t STATIC OUTPUT TRANSFORMER BYPASS ISOLATION TRANSFORMER BATTERY INTERNAL y CHARGER 1 Y BATTERY CABINET NL Figure 2 1 ELI Block Diagram M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 2 2 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER ELI Subsystems e Input Transformer A transformer is factory installed in the ELI Cabinet and connected to the AC input power supply e Input Breaker The input breaker prevents the main distribution panel breaker from tripping when a ELI fault or over current condition occurs It also acts as a test switch for performing back up mode tests e Input EMI RFI Filter This filter attenuates any electrical noise in the input AC power supply e Input surge protector Provides protection to the ELI and equipment from power surges and transients such as lightning and phase to phase faults e Rectifier Power Factor Correction During normal operation the rectifier circuit converts the utility power AC power to DC power The inverter uses the DC power to generate the AC output waveform At the same time the Rectifi
4. Always On UPS Systems Aurora Series Single Phase ELI System 3 KW 7 5 KW Service Manual M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER NOTE The instructions contalned in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred directly to Always On Any electrical or mechanical modifications to this equipment without prior written consent of Always On will void all warranties and may void UL cUL listing Unauthorized modifications may also result in personal injury death and damage to the equipment Dear Customer Thank you for selecting our emergency lighting inverter ELI We are pleased to include you as one of our valued Always On customers We are confident that this emergency lighting inverter system developed and manufactured in our ISO 9001 certified facilities will provide the quality and satisfaction you demand Please read
5. computing device Operation of this equipment in a residential area may cause interference to radio and TV reception requiring the operator to take whatever steps necessary to correct the interference CAUTION Do not put option control wiring in the same conduit as the ELI input or output power cables M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 vi WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER THIS SAFETY NOTICE IS ADDRESSED TO THE ALWAYS ON CUSTOMER ENGINEERS WHO PERFORM MAINTENANCE OF THE UNINTERRUPTIBLE POWER SUPPLY ELI SYSTEMS Electrical Safety Maintenance work to be performed by a factory trained customer engineers or qualified personnel Extremely dangerous voltage levels can exist within the ELI system Extreme caution must be used Ensure system is in maintenance bypass mode or external wrap around bypass mode before work is started This manual is designed as an aid tool in diagnosing problems that may arise Always On does not assume responsibility if information causes injuries Apart from the front door do not open any other part of the ELI without consulting the factory first Before removing the protection screens be sure that the unit is completely powered off Be aware that dangerous voltage can be supplied by the internal battery or ele
6. 14 31 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 9 3 3 Left Side of 5kW and 7 5kW Unit M a ELECTRONICS all 5 Figure 9 13 5kW and 7 5kW Left Side View M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 32 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Top Left of Unit CONTROL BOARD INVERTER HEAT SINK ASSEMBLY Figure 9 14 5kW and 7 5kW Top Left View Bottom Left of Unit aj k FALTER INPUT TRANSEQRNER OUTP 4 Figure 9 15 5kW and 7 5kW Bottom Left View M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 33 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 9 3 4 Right Side of 5kW and 7 5kW Unit Figure 9 16 5kW and 7 5kW Right Side View M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 34 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPER
7. ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 9 LAYOUT DETAILS 9 1 Circuit Boards e LCD Control Panel O This is the front panel user interface O Displays data as received from the CPU Board O Provides interface to control the function of the ELI by front panel ON OFF STATUS ENTER and ESCAPE buttons e CPU Board O Contains the main microprocessor that provides monitoring and control of the main functions of the ELI system O Provides data display and user interface to LCD panel Provides communications to the 089 connector the RS232 and RX O Provides open collector dry contact status O Generates synchronizing and control signals for the inverter section of the ELI Sends status information to the AS400 PCB e Main Power Board O O Provides interface between various monitoring points within the ELI and the CPU Converts low level inverter drive signals from the control interface PCB to high level signals suitable for driving the inverter l G B T s Contains auxiliary DC switching power supply for the inverter section of the ELI e Charger Board O O O Designed for 240VDC battery system Capable of providing over 1200Watts of output power Provides float voltage of approximately 274VDC 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 25 WARNING ONL
8. Emergency Power Off M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 2 THEORY OF OPERATION The ELI uses a variety of technologies working in tandem to provide clean reliable power and protect the critical loads The first stage in the protection process uses a transformer to electrically isolate the unit from the AC source The input power is then passed through a surge and EMI RFI filter to remove fluctuations in high frequency and protect against power surges and transients The rectifier then takes over and converts the AC power to DC providing a constant voltage The charger circuit provides regulated DC power to the batteries The DC power is then fed to the inverter The inverter converts the supplied DC power into clean reliable AC power An output isolation transformer electrically isolates the ELI from the critical loads and an output filter provides protection from power fluctuations caused by equipment on the critical load circuit A switch allows for manual bypass An output breaker allows for output switching 2 1 Block Diagram MAINTENANCE BYPASS SWITCH INPUT UTILITY TEST OUTPUT BREAKER BREAKER SURGE amp RECTIFIER BREAKER O WE
9. display by pressing the STATUS or FUNC buttons 4 3 Button Operation There are three operating buttons on the front panel ON OFF button O Push the ON OFF button for at least seconds to turn on the O When ELI is running push the ON OFF button for at least seconds to turn off the ELI e FUNC button WARNING Factory settings authorized personnel only This button is used to check ELI configuration information O Push the FUNC button for at least 2 seconds to choose the function you want O Move between items by pressing the FUNC button once See Figure 4 1 O Each function can be displayed by pressing the button once and there are fourteen different settings to choose from O Push the ENTER button to choose the selected setting O Push the function button to select desired parameter O Push the ENTER button to save your setting O Push the ENTER button to confirm and enable the selected setting O If nothing has been pressed for 10 seconds the display will return to original status M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 11 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Settings LCD Display O P Wire Set O P Voltage Explanation nominal output PU MM Default _ Setti
10. frequency magnetic components The inverter uses PWM to generate and regulate the pure sine wave AC output with a very small tolerance 2 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Static by pass A static transfer switch and bypass circuit is provided as an integral part of the ELI The inverter has an overload rating of 150 rated load for 20 seconds 200 rated load for one and a half cycles The static bypass will auto transfer to bypass if these overload conditions are exceeded The static transfer switch control logic contains an automatic transfer control that senses the status of the inverter logic signals as well as operating and alarm conditions This control circuit provides an uninterrupted transfer of the load to a normal input source Transfers are also made when an overload or malfunction occurs within the ELI without exceeding the transient limits specified herein e Maintenance bypass switch The maintenance bypass switch is used to transfer the attached load without interruption from the inverter AC output to the bypass AC power source while electrically isolating the static bypass switch rectifier charger and inverter e Output Isolation Transformer An output isolation transformer factory installed in
11. manual please contact our Service Centre before proceeding This document may not be copied or reproduced without the explicit written permission of Always On Due to technical advancements and improvements some of the information contained in this manual may be changed or modified without prior notice M4003 Aurora 3 7 5 Service Manual V3 0 2012 06 14 iii WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Symbols The following symbols are used through out this manual Warning Information This symbol alerts you to important information Electrical Hazard A This symbol indicates an electrical hazard may be present Electrical Symbols Protective grounding terminal a terminal that must be connected to ground prior to making any other connection to the equipment A terminal to from which an alternating current or voltage may be applied supplied mp A terminal to from which a direct current or voltage may be applied supplied 7 This symbol indicates the word phase M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Sa
12. not exceed 40 C 1043 Optimal battery life is obtained if the ambient temperature does not exceed 25 77 F HIGH GROUND LEAKAGE CURRENT ground connection completed before connecting the AC voltage wires on the input owitching OFF the ELI does not isolate the ELI from the utility as the utility supply is still HOT at the input terminal strip Supply breaker needs to be opened It is important that air can move freely around and through the unit Do not block the air vents Avoid locations in direct sunlight or near heat sources gas or electric heaters STORAGE otore the ELI in a dry location free of contaminants Storage temperature must be within 25 C 13 F to 55 C 131 If the unit is stored for a period exceeding 3 months the batteries must be recharged periodically time depending on storage temperature WARNING LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT IS APPARENTLY NOT OPERATING OBSERVE ALL CAUTIONS AND WARNINGS IN THIS MANUAL FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH REFER UNIT TO QUALIFIED SERVICE PERSONNEL IF MAINTENANCE IS REQUIRED NO ONE SHOULD WORK ON THIS EQUIPMENT UNLESS THEY ARE FULLY QUALIFIED TO DO SO AN INSTALLER SHOULD NEVER WORK ALONE WARNING WHEN REMOVING POWER FROM THE ELI ALLOW FIVE MINUTES FOR CAPACITORS TO DISCHARGE BEFORE WORKING ON THE EQUIPMENT CAUTION This equipment complies with the requirements in Part 15 of FCC rules for a Class A
13. ATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Top Right of Unit STATIC CHARGER BYPASS BOARD Figure 9 17 5kW and 7 5kW Top Right View e Bottom Right of Unit IIli INPUT TRANSFORMER Figure 9 18 5kW and 7 5kW Bottom Right View M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 35 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 10 CONTACT INFORMATION Warranty Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 758 Phone 250 491 9777 Ext 209 Fax 250 491 9775 Email qa alwayson com Website www alwayson com Software Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 758 Phone 250 491 9777 Ext 204 Fax 250 491 9775 Email webmaster alwayson com Website www alwayson com Additional Purchases or Upgrades Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 758 Phone 250 491 9777 Ext 451 Fax 250 491 9775 Email sales alwayson com Website www alwayson com 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WAR
14. ING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 6 OPTIONAL FEATURES 6 1 6 2 6 3 Simple Network Management Protocol SNMP Adapter The Always On Simple Network Management Protocol SNMP adapter is a web based management product that uses multiple open standards such as Telnet HTTP and SNMP to provide full management of supported devices The SNMP Adapter is designed to connect directly to the network and allow network broadcasting of ELI conditions as well as remote access to the ELI system to monitor parameters and displays For set up instructions view the READ ME file provided with the set up disk Monitoring and Optional Control Software The optional power management software offers powerful features such as the ability to monitor local ELI s as well as remote units via a TCP IP network from your central location It can notify you of any problems automatically by sending email or by dialling your pager through a modem when an event such as a power outage occurs The software is capable of broadcasting messages to remote computers and can even send them commands to shutdown The GUI is a real time graphical display of ELI status including input output voltage frequency load temperature and capacity There is also a data logging feature included The software can b
15. ISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Dry Contact Dry contact outputs are provided through the RS 232 port located at the front of the ELI Each output contact provides status information of the ELI operation These contacts enable the ELI to notify a computer or automation device being supported by the ELI of a power anomaly The connected device may then be programmed to recognize these signals and initiate a shutdown sequence The ELI reads the input signal through a photo coupled diode transistor pair so your control equipment remains electrically isolated The photo coupled transistor is capable of a maximum conduction level of 40VDC at 40mA Figure 5 3 Photo coupled Transistor 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 9 4 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Emergency Power Off A customer supplied switch may be located remotely as an emergency stop button for the ELI The switch may be used to open the EPO jumper connection and force ELI output to switch off Since the EPO shuts down the equipment immediately the power management software is prevented from performing an orderly shutdown The ELI will have to be manually restarted with the EPO jumper cl
16. Ooh SMCUILBOALOS waski Aid O A AA te rote 25 9 2 3kWto 7 5 kW Unit Pictures External 26 9 3 3kWto 7 5 kW Unit Pictures Internal 28 10 COMACE MAU OM Om 36 M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 1 INTRODUCTION Congratulations on your choice of the Aurora On Line Emergency Lighting Inverter ELI This ELI features the latest top of the line microprocessor technology and IGBT transistors and provides clean highly regulated and pulse width modulated PWM true sine wave power 1 1 1 2 Overview This ELI is designed for installation between your AC power supply utility or generator and your lighting equipment It provides power to your equipment during major power events such as blackouts and brownouts over voltage and under voltage conditions The ELI provides a consistent supply of regulated AC power during these power events allowing you to ensure safety and lighting for the period required Features This ELI provides full time self diagnostics as well as two levels of audible alarms when the unit is operating in battery mode Along
17. R OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER e Top Left of Unit CPU BOARD s POWER 7 BOARD DC BUSS CAPACITORS Figure 9 8 3kW Top Left View e Bottom Left of Unit 2 AC FILTER w jl 27 j nm OUTPUT W TRANSFORMER l TRANSFORMER _ 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 29 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 9 3 2 Right Side of 3kW Unit a i TRANSFORMERS Figure 9 10 3kW Right Side M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 30 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER e op Right of Unit CHARGER Figure 9 11 3kW Top Right View RZE SWITCHIII 1 MATE a E CAV INPUT OUTPUT 4 m a besi gt 4 1 1 gt Figure 9 12 3kW Bottom Right View M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06
18. RANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 37 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Always On M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 38
19. REMOTE SHUTDOWN SIGNAL INVERTER BYPASS 5V OR 12V LL O 1min gt 3 3mA GUNI AS 400 DRY CONTACT BATTERY LOW BACK UP O COM O COM NO ONC NO NC FAULT O COM Figure 5 2 AS 400 Communication Interface M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 15 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Pin Assignment DB 25pin male connector e Input signal pin assignment o Remote emergency power off Pin 24 25 o Remote shut down Pin 22 23 o f Vpin22 gt Vpin23 5V 12V the ELI will power off after a 1 second delay e Output signal pin assignment o Fault Pin 1 2 3 On Battery 4 5 6 Battery Low Pin 7 8 Bypass 9 10 On Inverter Pin 11 12 e Dry Contact Capacity o Total maximum power rating is 30W o Maximum voltage rating is 250VAC o Maximum current rating is 3A e Optional Features o Instrumentation Terminal Strip Allows for easy connection of wires if 25pin connector not available KRK dM NN Faut ____ Closed 4 47 1 Closed Open O O O Low 1 Inactive State may be open or closed condition Table 5 2 Output Truth Table for the AS 400 pins M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 9 3 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMM
20. TE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 5 COMMUNICATION INTERFACES There are three types of communication interfaces available on the standard ELI RS 232 Dry Contact and AS 400 There is also an SNMP adaptor available as an option SNMP AS400 94 97 Figure 5 1 Communication Interfaces M4003_Aurora_3 7 5Kw_ Service Manual V3 0 2012 06 14 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 5 1 RS 232 Port A 9 pin female SUB D connector is located on the ELI front panel to provide a communications link between the ELI and a computer The optional software package and cable allows you to connect the ELI to a computer and monitor the operating status of the ELI system Pin Signal Name Direction Ref ELI Functions 2 Output TxD Output 3 ___ ___ RxD inverter Off Input 5 Common 6 15 QOupt ACfailure Output DCD Qut Low Battery Output 9 7 840 24VDC Power Table 5 1 RS 232 Pinout 5 2 AS 400 amp Relay Contact Port Located on the front panel of the ELI is a 25 Pin connector which provides status information through relay contacts and control by photo coupled inputs REMOTE EMERGENCY POWER OFF
21. Wait 10 seconds Apply utility power to ELI Turn ON the INPUT BREAKER on front of ELI ELI will enter stand by mode Push ON OFF button on front panel hold button for seconds or until ELI beeps and displays READY ON The unit will automatically perform a self test and then go to line mode Use the front panel FUNC button to place the unit into bypass mode Bypass LED will light On the rear panel turn the MAINTENANCE SWITCH to the NORMAL INVERTER position Use the FUNC button to turn off the manual bypass mode ELI will start inverter and enter inverter mode Bypass LED will go out Line LED will become lit The ELI is now in Normal Operating Mode 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 23 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 8 TROUBLESHOOTING Displayed on LCD Audible Alarm Alarm Description What You Should Do Output Overload Two beeps per second Over Charge Constant beep Batteries are overcharged Low Battery Once every 5 seconds The unit is operating on Battery Power Charger Fail Over Temperature Two beeps every 5 seconds Constant beep Constant beep The ELI is overloaded in line mode Your equipment needs more power than the ELI can provide The ELI operates in by
22. Y AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 9 2 3 kW to 7 5 kW Unit Pictures External Layout e Front View Figure 9 1 Front View of Both Units e Rear view Figure 9 2 Rear View of 3kW Unit Figure 9 3 Rear View of 5 7 5kW Unit 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 26 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Inside front door Figure 9 4 Front View Door Open Figure 9 5 Rear View Back Plate Removed Terminal block detail Figure 9 6 Terminal Block Detail 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 47 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 9 3 3 kW to 7 5 kW Unit Pictures Internal Layout 9 3 1 Left Side of 3kW Unit 5 41 ulli TRITT TRANSFORMERS Figure 9 7 3kW Left SideView M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 28 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP O
23. been removed and the screws holding the battery slide out shelves in place should have been unscrewed allowing for ease of battery replacement CAUTION Only qualified service personnel should attempt battery bank maintenance Removal of the side access panels exposes personnel to potential dangerous voltages and shock hazards that may cause damage injury or death If screws have not been properly removed prior to BBU installation completely shut down ELI wait for 30 minutes until capacitors have fully discharged and disconnect ELI from BBU prior to servicing TO PULL OUT A DRAWER REMOVE THESE TWO SCREWS s US BEFORE CABINET IS PLACED IN FINAL LOCATION REMOVE SIDE PANELS FROM BOTH SIDES OF CABINET TAKE OUT THESE TWO SCREWS FOR EACH DRAWER REPLACE SIDE PANELS Figure 3 4 Slide out BBU shelves M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 10 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 4 USER INTERFACE 4 1 Front Control Panel ON ON LINE ON BAT BYPASS FAULT ESCAPE ENTER FUNC STATUS ON OFF Figure 4 1 Front Control Panel of ELI 4 2 Normal Display The LCD displays the operating status of the ELI From here you have a choice to go to ELI meters display and the settings
24. ctable when input frequency is outside of 3Hz or when no input utility is present Of course high efficiency is standard and the default operation is in on line mode The bypass can be activated in the LCD panel though on line can be run permanently if preferred Free Run Mode The ELI operates in free run mode when input frequency is outside of the selected input frequency setting Free run mode is when output frequency does not match input frequency When starting the ELI the frequency regulation detected is 50 or 60 Hz 0 25Hz Diagnostic tests When you start the ELI a diagnostic test is automatically executed that checks the electronics and battery and reports any problems on the LCD display An advanced battery management system continuously monitors the conditions of the batteries sending a warning if replacement is needed A battery discharge test is performed every 30 days of normal operation and if a problem arises it will be reported on the LCD display Other than during the initial 24 hours after start up or while the ELI is in charging mode diagnostic tests can be performed manually from the front panel at any time 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 3 PHYSICAL TOPOLOGY 3 1 Front view
25. ctrolytic capacitors When system is in bypass mode and all fuses have been opened dangerous voltages may exist within the ELI system Use extreme caution when exchanging boards and working inside the unit READ AND FOLLOW ALL SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 vil WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER TABLE OF CONTENTS 1 eo 1 50 al gt LL OO M MA IM CM M EM WA OE 1 Uo eene RR 2 2 Theoy ol Operaio 3 21 215159818 22 00 3 22 EI OUDSVSICIMS NW W Meu MER E MEE ME 4 20 Of COC FANON ___ 5 9 IPRYSICAIL T ME ones _8_ T 92 TL 8 3 3 Rear View Cover 9 Banery Gabel a e debated oa M Ie 10 eU EP 14 4 14 GOMUO tute E 11 42 WMornal DISDIdi zasada AEO EA AE bait AP AO YOU Al A de Pla 11 43 OMe AUOM
26. e ELI system that contains one or more of the rectifier DFC charger inverter static bypass switch maintenance bypass switch controls monitoring and indicators e Rectifier DFC Contained in the ELI module Responsible for converting the normal AC input power to DC power and supplying the inverter with DC power e Charger Contained in the ELI module Responsible for recharging the batteries e Inverter Contained in the ELI module Responsible for converting DC power supplied by the rectifier to regulated and filtered AC power that is then supplied to the critical loads e Static Bypass Switch Contained in the ELI module Responsible for automatically transferring the attached load without interruption from the inverter AC output to the bypass AC power source in the event of an overload or degradation of the inverter s performance e Maintenance Bypass Switch Contained in the ELI module Used to transferring the attached load without interruption from the inverter AC output to the bypass AC power source while electrically isolating the static bypass switch rectifier DFC charger and inverter Used for maintenance purposes e Battery The battery system provides DC power to the inverter input when the normal AC input power to the ELI fails e IGBT lsolated Gate Bipolar Transistor PWM Pulse Width Modulation e ELI Emergency Lighting Inverter e BBU Battery Backup Unit PFC Power Factor Correction e EPO
27. e configured to schedule battery tests The software can also shutdown the system in a safe fashion before the batteries run out in the case of an extended blackout e Install the software package according to the instructions included with CD Connect the ELI to the computer using the RS 232 cable included Start the software Normally Off Function All Normally Off loads shall not exceed 50 of the ELI rating per phase 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 20 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 OPERATION Not following the start up and shutdown procedures correctly can damage the system or cause injury 7 1 7 2 Start up Procedure Remove cover on rear of ELI e Confirm MAINTENANCE SWITCH is in NORMAL INVERTER position e Confirm BATTERY BREAKER is in OFF position e Open front door of ELI e Confirm INPUT BREAKER is in OFF position e Remove cover plates on battery cabinet e ON all BATTERY BREAKERS on battery cabinet ON BATTERY BREAKER on rear of ELI e 10 seconds Apply utility power to Turn ON the INPUT BREAKER on front of ELI ELI will enter stand by mode e urn ON the OUTPUT BREAKER on front of ELI e Push ON OFF button on front panel hold button for 3
28. er PFC circuit ensures that the waveform of the input current used by the ELI Inverter is close to ideal This type of conversion and state of the art technology maintains two key objectives the utility power is used as efficiently as possible and the amount of distortion reflected back to the utility is minimized therefore providing cleaner power to other devices in the building not being protected by the ELI e PFC Control Note By utilizing control circuits the current drawn from the utility power is in phase with the input voltage The control circuit also allows the ELI to have a broader input voltage range 25 e Charger During normal operation the charger converts AC voltage drawn from utility power into regulated DC voltage which charges the batteries and maintains the batteries at the desired level by a float charge Batteries The batteries provide power to the critical load when the input power is interrupted Battery sizes vary between series and series parallel configurations All batteries are sealed lead acid valve regulated gel cells e Battery Breaker This breaker is used to connect and disconnect the batteries to and from the ELI system e Inverter The inverter s solid state electronics convert DC provided by the rectifier DFC or batteries to AC power The inverter will produce 50 or 60Hz auto selected using IGBT technology that switches at 18kHz This is above the audible frequency range and does not generate low
29. ferent methods Automatic In the unlikely event of an internal failure or an inverter overload the unit will perform an automatic transfer of the load from the inverter to the bypass source M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Manual Should the unit need to be taken out of service for maintenance or repair manual activation of the bypass will cause an immediate transfer of the load from the inverter to the bypass source The input rectifier inverter and battery charging operations will be interrupted until the user transfers the ELI back to normal operation e Efficiency Optimizer function The efficiency optimizer function adds cost effectiveness minimizes power loss and reduces power consumption The function alternates between bypass and on line modes and is achieved automatically in accordance with the conditions of the utility AC power On line mode may be used by the function during times of intermittent power and bypass mode when the utility is within selectable parameters in order to obtain greatest efficiency Irregularities can be detected in less than a millisecond and on line mode reactivated immediately Switching back to on line mode occurs when input voltage is outside 10 of nominal 15 sele
30. fety Instructions READ AND FOLLOW ALL SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during installation and maintenance of the ELI system and optional packages Before the installation process begins we recommend that the installer read through the safety precautions operators manual and the option installation instructions taking all necessary safety precautions to protect themselves and the equipment being installed GE NERAL Move the ELI in an upright position in its original packaging to its final destination To lift the cabinets use a forklift or lifting belts with spreader bars Check for sufficient floor and elevator loading capacity Check the integrity of the ELI equipment carefully If visible damage is evident do not attempt to install or start the ELI Contact the transport delivery company immediately file a claim with the transport company and inform Always On directly Do not use outdoors The use of accessory equipment not recommended by Always On may cause an unsafe condition WARNING RISK OF ELECTRICAL SHOCK use extreme caution when removing covers All maintenance and service work should be performed by qualified and trained service personnel The ELI may contain its own energy source batteries which can be dangerous to the untrained person This ELI contains potentially hazardous voltages The field wiring terminals may be electr
31. ically live even when the ELI is not connected to the utility Use caution when servicing batteries A battery can present a risk of electrical shock burn from high short current Battery acid can cause burns to skin and eyes If acid is spilled on skin or in eyes flush with fresh water and contact physician immediately When replacing batteries use the same number and type sealed cell lead acid Proper disposal of batteries is required Refer to your local codes for disposal requirements Dangerous voltages may be present during battery operation The batteries must be disconnected during maintenance or service work Open battery breaker or fuses Be aware that the inverter can restart automatically after the utility voltage is restored Do not use this equipment for other than intended use M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER INSTALLATION This is intended for use in a controlled indoor environment free of conductive contaminants and protected against any type of intrusion Do not install the ELI in an excessively humid environment or near water Avoid spilling liquids and or dropping any foreign object s onto the ELI The unit must be placed in a sufficiently ventilated area the ambient temperature should
32. isplay pressing the STATUS button will scroll through the following meters LCD Message Description O O ____ O P Load 7 of Maximum Rated Load BAT CHARG approximate 96 of battery capacit Table 4 2 ELI Meters 4 5 Control Panel Lights Operation of the ELI is indicated on the monitor panel with five LED indicators e ON LINE When the ELI is in normal or static bypass modes there is voltage at the output terminals and this LED will light up in green ON BAT This LED is lit while the unit is operating in battery mode e BYPASS While the unit is operating in bypass mode this LED will light up in yellow e FAULT If an internal error occurs in the ELI this LED will light up in red 4 6 Audible Alarm Pressing any button on the front of the ELI will silence the audible alarm The audible alarm will sound when the ELI enters one of the following states e Backup Mode The ELI will beep once every five 5 seconds and the BACKUP LED will illuminate beep beep beep Slow beep Low Battery The ELI will beep once every second when the batteries are almost depleted beep beep beep Fast beep e Fault The ELI will sound a continuous beep and the FAULT LIGHT indicator will illuminate beeeeep Continuous beep 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERA
33. ng voltage I P Wire Set I P Voltage Select nominal input 120 208 240 277 347 Setting voltage Input Frequency I P Frequency Select input frequency 5 range when ELI goes free run mode Select input voltage 10 to 1010 15 HI 5 range when bypass is ae to 15 available 1 15 to 20 to 20 Free Run Mode Free Run Set Select if ELI can run ON OFF Free Run Mode unsynchronized bwe E on ope Enable Disable at Disable ELI can go to bypass Free Run Mode when unsynchronized efficiency optimizer mode Bypass bypass For service onl mee normal parameters function Number of External Cabinet setting is needed for B Battery Packs Set ELI s to predict expected back up time Site Wiring Alarm Site Fault Set You can enable or Enable Disable Disable disable the site wiring alarm French Spanish Italian Generator Mode Set unit in generator RS 232 RS 232 Set RS 232 S Communication Control communications on or off Table 4 1 ELI Configuration 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 4 4 ELI Metering Display Various measurements are available through the EL meters d
34. osed again in order to reconnect power to the load The ELI comes with a simple jumper in place of the push button so that it runs without a switch REMO TE EMERGENCY SIOP BUTION i 12 VDC 10mA ET EPO PORT n Figure 5 4 EPO Switch Configuration 4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 18 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 5 5 Emergency Lighting Notification FIELD SUPPLIED RS232 OS TO FIRE ALARM PANEL ANNUNCIATOR U CONTACT RATING 3A 120Vac 30 WATTS NORMALLY OPEN FACTORY Lcd SUPPLIED Figure 5 5 Emergency Lighting Notification The fire alarm panel connections are provided to allow the fire alarm panel recognition of the following fault conditions using normally open contacts of the ELI Bypass Status 1 Output overload condition 2 Inverter failure due to Output short circuit Inverter fuse open Over temperature condition Inverter overload condition Inverter stop activation Inverter output outside of parameters Bypass activated h Inverter shutdown 3 Battery low Inverter shutdown condition 4 No output voltage present Oo 0oococop M4003 Aurora 3 7 5 Kw Service Manual V3 0 2012 06 14 19 WARN
35. pass The ELI is doing a battery test The unit is operating on Battery Power and will shut down soon due to very low battery voltage Charger has failed High ambient temperature Shut off the least important equipment connected to the ELI If this solves the overload problem the ELI will switch from bypass back to normal operation No action needed The ELI will return to normal operation when it successfully completes the battery test Turn off protected loads Turn off the ELI and call your local dealer The unit will restart Automatically when acceptable power returns Save your data and perform a controlled shutdown Call the local dealer Make sure the unit s fans and vent holes are not blocked Make sure the ambient surrounding temperature is not above 40 C If these conditions did not solve the problem call your service representative Output Short Constant beep Output short circuit Call the local dealer Low Output Voltage Constant beep Low output voltage Call the local dealer Bus Fault Two beeps per second High internal DC bus voltage Turn off protected loads Turn off the ELI and call your local dealer High Output Voltage Constant beep High output voltage Call the local dealer Line Abnormal One beep per second Wrong AC Line backed up during auto restart M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 24 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL
36. seconds or until ELI beeps and displays READY ON The unit will automatically perform a self test and then go to line mode Shutdown Procedure e Shutdown and turn off all the attached loads e Push the ON OFF button on the front panel for five seconds The alarm will sound and the ELI will shutdown The LCD will display UPS OFF for a few seconds and then shutdown fully e Open the OUTPUT BREAKER on the front of the e Open the INPUT BREAKER on the front of the ELI and wait 10 seconds e Open the BATTERY BREAKER on rear of ELI e Open all the BATTERY BREAKERS on battery cabinet ELI is complete shutdown M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 21 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 3 Test Procedure The ELI input test breaker is used to test the ELI for backup operation with only one simple operation 7 3 1 Starting the Test e INPUT TEST BREAKER to the OFF TEST position This puts the ELI in backup mode while loaded The load will not see a power fluctuation if the ELI is functioning correctly LCD will display status of ELI during test 7 3 2 Stopping the Test e urn the INPUT TEST BREAKER back to the ON position 7 4 Maintenance Bypass Procedure Maintenance Mode is used to bypass the inverter portion of the ELI wi
37. the ELI cabinet and connected to the ELI output It provides galvanic isolation between the ELI and the critical load e Output breaker Allows the ELI output to be shutdown without operating the inverter controls 2 3 Modes of Operation The ELI is designed to operate continuously as an on line dual conversion system in the following modes e Normal Mode The rectifier converts the utility or AC source input to DC and then supplies the DC current to the inverter unit The inverter unit continuously supplies the attached load with regulated AC power The output voltage Is precisely regulated at all times regardless of the input voltage e Back Up Mode When the AC input power is interrupted the inverter is supplied with power from the storage batteries without interruption There are no interruptions to the output voltage or waveform during transfer to battery power e Recharge When AC input power is restored the rectifier DFC will automatically restart and continue to supply power to the inverter The charger re charges the battery e Automatic Restart During an extended input power outage that leads to a complete battery discharge the unit will automatically shutdown When input power is restored the unit will automatically restart and resume supplying power to the load and battery charger e Static Bypass The bypass provides an alternate path other than the regulated path for power to reach the load The bypass can be activated by two dif
38. this installation manual carefully as it contains the necessary information required to install the ELI properly Thank you for choosing Always On M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Preface Congratulations on your choice of our emergency lighting inverter ELI This equipment has been manufactured and tested using methods and procedures equivalent to UL 924 This manual describes the recommended procedures for installing the ELI While every effort has been made to ensure the completeness and accuracy of this manual Always On assumes no responsibility or liability for any losses or damages resulting from the use of the information contained in this document WARNING This manual is intended to provide installation instructions only The information contained in this manual is to be used as a guideline and recommendation only Only qualified personnel should perform installation and maintenance Factory authorized personnel shall inspect installation prior to start up and commissioning to validate warranty Failure to follow this directive will void the warranty We recommend that this manual be kept with the ELI for future reference If any problems are encountered with the procedures contained in this
39. thout disrupting the load When the INPUT BREAKER is closed the ELI tracks the phase of the input waveform and the transition from inverter mode to maintenance mode is seamless provided that the utility is functioning satisfactorily 7 4 1 Entering Maintenance Bypass Mode e Use the front panel FUNC button to place the unit into bypass mode Bypass LED will light e Remove rear access panel e Turn MAINTENANCE SWITCH to BYPASS position Push the ON OFF button on the front panel for five seconds The alarm will sound and the ELI will shutdown e The LCD will display UPS OFF for a few seconds and then shutdown fully ELI will power down LCD will go out e Open the INPUT BREAKER on the front of the ELI and wait 10 seconds WARNING DO NOT OPEN OUTPUT BREAKER THIS WILL SHUTDOWN LOADS IMMEDIATELY e Open the BATTERY BREAKER on rear of ELI e Open all the BATTERY BREAKERS on battery cabinet WARNING Make sure AC Input and Battery Circuit Breakers are in the Open position before working on the ELI inverter in Maintenance Mode M4003 Aurora 3 7 5Kw Service Manual V3 0 2012 06 14 22 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER 7 4 2 Restoring normal operation Turn ON all BATTERY BREAKERS on battery cabinet Turn ON BATTERY BREAKER on rear of ELI
40. with the current mode of operation the LCD screen displays critical system information including Percent Load Watt VA Remaining battery capacity battery voltage Input voltage Output voltage Input frequency Output frequency and Internal ELI temperature A manual test switch has been incorporated into the input test breaker that makes testing a simple procedure The internal bypass switch allows maintenance on the ELI to be performed without interruption of power to the load The communications port in conjunction with multi platform monitoring and control software enables the unit to be connected to a local or networked computer system Detailed operating information including voltages currents and alarm status is available to the monitoring system Other communications options include An SNMP adapter to remotely control and monitor the unit a network or the Internet a An AS 400 interface to allow for relay communications in PLC or dry contact environments M4003_Aurora_3 7 5Kw_Service_Manual V3 0 2012 06 14 1 3 WARNING ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION START UP OR OPERATE THE INVERTER SYSTEM ELI WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER Definitions e Critical Load These are loads that require clean regulated and continuous AC power and which are connected to the output of the ELI module ELI Module The portion of th

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