Service Manual
Contents
1. 10 4T FIONECONIOLFaNiek es 10 4 21 Nomai DISDIay oc ecd idt a Waal ot SE a 10 4 3 BUNOM OPORNA Lu 10 44 ELI Metering DISDIay bs OE A 12 45 ColMroLRauelLIGRIS ni p ok Ra 12 4 0 Audible Alarm aan O SD 12 5 Communication Inter 688 ORO 13 5 02 53 232 POLL anui me ai O NOO AR GA 14 5 2 AS 400 amp Relay Contact Port Ue eet ere O d Vie d i ei isa ede 14 59 DD GOL o dacia 16 5 4 Bmergency Power Off la Ded ne m 16 5 5 Emergency Lighting Notification seii te dere rto iore Dee ae que to Ea 17 6 Optional SNe see HE O O R O OI 18 6 1 Simple Network Management Protocol SNMP 18 6 2 Monitoring and Optional Control Software sse 18 M4006 Aurora 10 15Kw Service Manual V3 0 2012 06 14 6 3 Normally OILPUDGIO OKNA to ee 18 gt OPERATION GOA AO A O 19 E ik 19 es SNUIJ WWErOCEJUIE costos ota ii O Pd LA 19 PTESUPIO2. M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 SINGLE PHASE 30 MINUTES BACKUP CONFIGURATIONS Standard Battery Systems for 30 Minute Runtime System Capacity Rating 10kW 15kW ELI Dimensions W x D x H in 42 x 27 x 67 42 x 27 x 67 ELI Dimensions W x D x H mm 1 067 x 686 x 1 702 1 067 x 686 x 1 702 BBU Dimensions W x D x H in 32 x 34 x 76 32 x 34 x 76 BBU Dimensions W x D x H mm 815 x 865 x 1 930 815 x 865 x 1 930 Configuration C C Maximum System Weight Ib 2 700 1 228 3 100 1 410 kg i SINGLE PHASE 60 MINUTES BACKUP CONFIGURATIONS Standard Battery Systems for 60 Minute Runtime System Capacity Rating uli AM 42 x 27 x 67 42 x 27 x 67 ELI Dimensions W x D x H in ELI Dimensions W x D x H mm 1 067 x 686 x 1 702 1 067 x 686 x 1 702 BBU Dimensions W x D x H in 32 x 84 x 76 32 x 34 x 76 BBU Dimensions W x Dx H mm 815 x 865 x 1 930 815 x 865 x 1 930 Configuration C C Maximum System Weight Ib 3 250 1 478 3 800 1 728 kg SINGLE PHASE 90 MINUTES BACKUP CONFIGURATIONS Standard Battery Systems for 90 Minute Runtime System Capacity Rating 42 x 27 x 67 42 x 27 x 67 1 ELI Dimensions W x D x H in ELI Dimensions W x D x H mm 1067 x 686 x 1702 10
3. 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 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 M4006 Aurora 10 15Kw Service Manual V3 0 2012 06 14 THIS SAFETY NOTICE IS ADDRESSED TO THE ALWAYS 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 i
4. Pin Assignment DB 25pin male connector e Input signal pin assignment Remote emergency power off Pin 24 25 o Remote shut down Pin 22 23 o If 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 Pin 4 5 6 Battery Low Pin 7 8 On Bypass Pin 9 10 On Inverter Pin 11 12 Dry Contact Capacity o Total maximum power rating is 30W o Maximum voltage rating is 250VAC o Maximum current rating is 3A Optional Features o Instrumentation Terminal Strip Allows for easy connection of wires if 25pin connector not available State 1 2 Pin2 3 Pin4 5 5 6 Pin7 8 Pin 9 10 11 12 Normal Open Closed Open Closed Open Open Closed Fault Closed Open 1 1 1 Closed Open On Battery Open Closed Closed Open 1 Open Closed Battery Open Closed Closed Open Closed Open Closed Low On Bypass 1 1 1 1 1 Closed_ Open On Inverter Open Closed 1 Closed 1 Inactive State may be open or closed condition Table 5 2 Output Truth Table for the AS 400 pins 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 15 5 3 5 4 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 notif
5. min Shows Estimated Backup time in minutes BAT CHARG Shows approximate of battery capacity TEMPERATURE C Shows approximate ambient temperature BAT PACK NUM Shows External Battery Packs Number RATING VA Shows ELI Rating CPU VERSION Shows CPU Version 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 e 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 Backup Mode The ELI will beep once every five 5 seconds and the BACKUP LED will illuminate beep beep beep Slow beep e 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 M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 12 5 COMMUNICATION INTERFACES There are thr
6. 14 2 2 ELI Subsystems Input Transformer A transformer is factory installed in the ELI Cabinet and connected to the AC input power supply 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 Input EMI RFI Filter This filter attenuates any electrical noise in the input AC power supply Input surge protector Provides protection to the ELI and equipment from power surges and transients such as lightning and phase to phase faults 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 Rectifier 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 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 Charger
7. 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 Battery Breaker This breaker is used to connect and disconnect the batteries to and from the ELI system 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 frequency magnetic components The inverter uses PWM to generate and regulate the pure sine wave AC output with a very small tolerance 2 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 2 3 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 si
8. O Contains the main microprocessor that provides monitoring and control of the main functions of the ELI system Provides data display and user interface to LCD panel Provides communications to the DB9 connector via the RS232 TX and RX Provides open collector dry contact status Generates synchronizing and control signals for the inverter section of the ELI O Sends status information to the AS400 PCB Main Power Board Provides interface between various monitoring points within the ELI and the CPU POB Converts low level inverter drive signals from the control interface to high level signals suitable for driving the inverter 1 G B T S Contains auxiliary DC switching power supply for the inverter section of the ELI e Charger Board Designed for 240 battery system O Capable of providing over 1200Watts of output power O Provides float voltage of approximately 274 0 0 10 0 M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 9 2 10 kW to 15 kW Unit Pictures Layout Figure 9 1 Front View of 10 15 kW ELI Figure 9 2 Rear View of 10 15 kW ELI Figure 9 3 Front View Door Open Figure 9 4 Door Open Panels Removed 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 24 Figure 9 5 10 15 kW Left Side View Figure 9 6 10 15 kW Right Side View OMMUNICATIONS RFA CE Figure 9 7 10 15 kW Sliding Shelf Retracted M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 25 OUTPUT INP
9. OFF efficiency optimizer mode Force Manual Bypass Manual Permanently force ELI to ON OFF OFF Bypass bypass For service only Do Battery Test Battery Test Detect battery is within normal parameters Silence Function Silence Set Enable or disable silence ON OFF OFF function Number of External Bat Cabinet setting is needed for 30 Battery Packs Set ELI s to predict expected 60 back up time 90 Site Wiring Alarm Site Fault Set You can enable or Enable Disable Disable disable the site wiring alarm Select Language Language Select display language English German English French Spanish Italian Set Generator Mode Generator Set unit in generator ON OFF OFF mode Set RS 232 RS 232 Set RS 232 Enable Disable Enable Communication Control communications on or off Table 4 1 ELI Configuration 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 4 4 ELI Metering Display Various measurements are available through the ELI meters display pressing the STATUS button will scroll through the following meters LCD Message Description O P VOLT V Shows Output AC voltage O P FREQ Hz Shows Output Frequency VP VOLT V Shows Input AC Voltage FREQ Hz Shows Input Frequency BAT VOLT V Shows Battery Voltage O P Load Shows of Maximum Rated Load W W Shows Output Watts O P VA VA Shows Output VA O P Curr A Shows Output Current BACKUP TIME
10. 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 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 M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 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 display by pressing the STATUS or FUNC buttons 4 3 Button Operation There are three operating buttons on the front panel e ON OFF button Push the ON OFF button for at least 3 seconds to turn on the ELI When ELI is running push the ON OFF button for at least 3 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 button for at least 2 seconds to choose the
11. used through out this manual Warning Information N This symbol alerts you to important information Electrical Hazard AN This symbol indicates an electrical hazard may be present Electrical Symbols U 2 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 A terminal to from which a direct current or voltage may be applied supplied This symbol indicates the word phase M4006 Aurora 10 15Kw Service Manual V3 0 2012 06 14 ZA Safety Instructions READ AND FOLLOW ALL SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during installation and maintenance of the 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 GE equipment being installed 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 at
12. 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 ALA TEST OUTPUT AKER 4 r BREAKER SURGE amp RECTIFIER BREAKER _ 4 X EMI RFI PFC CIRCUIT INVERTER oureur AC OUTPUT E T mw i FILTER static BORD TRANSFORMER BYPASS TRANSFORMER BATTERY INTERNAL 2 REAKER CHARGER BATTERY pre Figure 2 1 ELI Block Diagram M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06
13. 14 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 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 M4006_Aurora_10 15Kw Service Manual V3 0 2012 06 14 iii Symbols The following symbols are
14. 67 x 686 x 1702 BBU Dimensions W x D x H in 32 x 34 x 76 1 2 32 x 34 x 76 BBU Dimensions W x Dx H 815 x 865 x 1 930 2 815x865 x mm 1 930 Configuration C D Maximum System Weight Ib 3 800 1 728 4 750 2 160 kg Includes two battery cabinets Longer runtimes available Consult factory Specifications are subject to change without prior notice to reflect upgrades and technology advances 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 30 Configuration 76 NN QOD NNNNNNNNNNNNNNNNNNNNNNNNNNNNN NN maga 0000000 DDD UPS BATTERY CABINET 42 X27 X67 32 X34 X76 woe NNNNNNNNNNNNNNNNNNNNNNNNNNNNNN NNNNNNNN NNNNNNN Wd UPS CABINET BATTERY CABINET BATTERY CABINET 42 X27 X67 32 X34 X76 32 X34 X76 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 31 11 CONTACT INFORMATION Warranty Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 7S8 Phone 250 491 9777 Ext 209 Fax 250 491 9775 Email qaQalwayson com Website www alwayson com Software Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 7S8 Phone 250 491 9777 Ext 204 Fax 250 491 9775 Email webmaste
15. Always On UPS Systems c Aurora Series Single Phase ELI System 10 KW 15 KW Service Manual M4006 Aurora 10 15Kw Service Manual V3 0 2012 06 14 M4006_Aurora_10 15Kw Service Manual V3 0 2012 06 14 The instructions contained in this manual 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 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 this installation manual carefully as it contains the necessary information required to install the ELI properly Thank you for choosing Always On M4006 Aurora 10 15Kw Service Manual V3 0 2012 06
16. CEJUIE zadac a pata eR E oPh 20 7 4 Maintenance Bypass Procedure ee suseu susa aaa aaa aaa aaa aaa aaa ae aaa nennen 20 5 Manual Battery e gutem 21 B TROUBLESHOOTING w dta E AA 22 9 Layout Details EE 23 9 1 7 Circuit Board Sennan pretio 23 9 2 10kWto 15 kW Unit Pictures 0 4 22 24 1 0 24 10 Technical Specifications tsere cc cito ehe O a 28 iis WA O CRK actu peste EU 22 M4006 Aurora 10 15Kw Service Manual V3 0 2012 06 14 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 o
17. DY ON The unit will automatically perform a self test and then go to line mode Shutdown Procedure e Shut down 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 shut down fully Open the OUTPUT BREAKER on the front of the ELI Open the INPUT BREAKER on the front of the ELI and wait 10 seconds e Open the BATTERY BREAKER on front of ELI Open all the BATTERY BREAKERS on battery cabinet ELI is completely shutdown Remove input power from ELI 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 19 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 Turn the 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 Turn the INPUT TEST BREAKER back to the position 7 4 Maintenance Bypass Procedure Maintenance Mode is used to bypass the inverter portion of the ELI without 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 ut
18. UT LCD TERMINAL TERMINAL CONTROL BLOCK BLOCK PANEL Figure 9 9 10 15 kW LCD Control Panel M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 26 Figure 9 10 10 15 kW Communications Interface M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 27 10 TECHNICAL SPECIFICATIONS Model 10kW Capacity 12 5 10 kW 18 75 15 kW Phase Frequency 1 0 2 Wire GND 50 60 Hz Rated Voltage 208 240 277 347 VAC Input Voltage Range 25 to 15 208 100 A 208 150 A 240 80 A 240 125 Input Current 277 70A 277 125 347 60 A 347 90 A Voltage Phase 120 240 277 347 VAC 2 Wire G Voltage Regulation 2 120 83 3 A 120 125 A 208 48 A 208 72 1 A Total Current 240 41 6 A 240 62 5 A 277 36 1 A 277 54 1 A 347 28 8 A 347 43 2 A Frequenc 50Hz 60Hz 0 5 THD lt 3 Linear Load lt 5 Rectified Load Output Load Power Factor 0 7 Slew Rate 1 Hz Second Transient Response t 4 100 Load Change 110 125 for 1 min then switch to bypass Overload Capacity 125 150 for 10 sec then switch to AE Crest Factor 3 1 Efficiency gt 85 Transfer Time 0ms Outlets Hard Wired DC System DC System Voltage 240 VDC Protection Interface Environment Safety Approval Physical Data Output Short Yes Abnormal Voltage Yes I O Noise Protection 1 Spike 8 Transient Protect
19. d Do not use this equipment for other than intended use M4006_Aurora_10 15Kw Service Manual V3 0 2012 06 14 vi INSTALLATION This ELI 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 not exceed 40 C 104 F Optimal battery life is obtained if the ambient temperature does not exceed 25 C 77 F HIGH GROUND LEAKAGE CURRENT ground connection completed before connecting the AC voltage wires on the input Switching 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 Store the ELI in a dry location free of contaminants Storage temperature must be within 25 C 13 F to 55 C 131 F 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 IS APPARENTLY NOT OPERATING
20. ee types of communication interfaces available the standard ELI RS 232 Dry Contact and AS 400 There is also an SNMP adaptor available as an option ALARM PANEL INPUTOUTPUT POWER SNMP AS400 Figure 5 1 Communication Interfaces M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 13 5 1 5 232 9 pin female SUB D connector is located on the ELI front panel to provide 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 TxD Output TxD Output 3 RxD Input RxD Inverter Off Input 5 Common Common 6 CTS Output Failure Output 8 DCD Output Low Battery Output 9 RI Output 8 to 24VDC Power Table 5 1 RS 232 Pinout 5 2 AS 400 8 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 REMOTE SHUTDOWN SIGNAL INVERTER BYPASS 5V OR 12V im NE BATTERY LOW 1min gt 3 3mA AS 400 DRY CONTACT COM NO ONC FAULT NO NC Figure 5 2 AS 400 Communication Interface M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 14
21. f audible alarms when the unit is operating in battery mode Along 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 currents and alarm status is available to the monitoring system Other communications options include An SNMP adapter to remotely control and monitor the unit via a network or the Internet An AS 400 interface to allow for relay communications in PLC or dry contact environments M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 1 3 Definitions 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 portion of the ELI system that contains one or more of the rectifier DFC charger inverter static bypass switch maintenance bypass switch contr
22. f 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 electrolytic 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 M4006_Aurora_10 15Kw Service Manual V3 0 2012 06 14 viii TABLE CONTENTS 15 Lao dt ie 1 dcl UAM Saw d tii Ud REN 1 1 2 cec 1 tC A e M 2 2 Theory Od O AG a 3 A EEG SII icm PER 3 2 2 ELI SUDSVSIOITIS Sob und ta ead nda P ly wes UE oa 4 2432 WOES Ol ODGraliODo st eoe ede el oa E e 5 9 Ubphysical ODO OY edt O E c LL 7 Sos Us ace bea bati Uds ra tU 7 3 2 Battery and cote 9 Ay erian oo RR ARGE
23. function that you want O Move between items by pressing the button once See table 7 2 O Each function can be displayed by pressing the button once and there are fourteen different settings to choose from Push the ENTER button to choose the selected setting Push the function button to select desired parameter Push the ENTER button to save your setting Push the ENTER button to confirm and enable the selected setting If nothing has been pressed for 10 seconds the display will return to original status O OO O O M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 10 Settings LCD Display Explanation Selection Default Free Run Mode O P Wire Set O P Voltage Select nominal output 120 208 240 277 347 Setting voltage Wire Set I P Voltage Select nominal input 120 208 240 277 347 Setting voltage Input Frequency I P Frequency Select input frequency 2 5 Setting range when ELI goes into 5 free run mode 7 Input Bypass Voltage I P Bypass Select input voltage 10 10 to Set range when bypass is 10 to 15 15 available 15 to 20 Free Run Mode Free Run Set Select if ELI can run in ON OFF ON unsynchronized Bypass Bypass If enable is chosen the Enable Disable Disable Enable Disable at Disable ELI can go to bypass Free Run Mode when unsynchronized HE Mode Setting HE Mode Set Select if ELI runs in ON OFF
24. gnals 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 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 Output Isolation Transformer An output isolation transformer factory installed in 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 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 wavefor
25. ility 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 front access panel e MAINTENANCE SWITCH to BYPASS position 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 shut down 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 front 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 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 20 7 4 2 Restoring normal operation 7 5 Turn ON all BATTERY BREAKERS on battery cabinet Turn ON BATTERY BREAKER on front of ELI 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 3 seconds or until ELI beeps and displays READY The unit will automatically perform a self test and then go to line mode Use the front panel button to place the unit into bypa
26. ion Communication Common amp Normal Mode Noise Suppression RS 232 Dry Contact Optional SNMP or AS400 Displa Audible Alarms Operating Temp Led Indicator Status Panel On Battery Low Battery Overload Fault 0 40 C Humidity 096 9596 Non Condensing Audible Noise Safety 55 dBA At 1 Meter from Unit UL1778 CSA C22 2 EMI RFI FCC Part 15 Class A Surge Transient WxDxH in mm Gross Net Weight in kg IEEE C62 41 Cat A 1120 x 865 x 1880 900 825 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 28 Model Size 10kW 15kW Output Power Factor 0 8 208 120 208 120 240 208 277 208 347 240 120 240 120 240 240 277 Input Output Voltage Combinations Available Single Phase za 277 120 240 277 Il 277 277 347 347 120 347 120 240 347 277 347 347 208 100 208 150A AC Input Voltage Input Service Amps gt z e 347 60A 347 90 120 83 3A 120 125A 208 48A 208 72 1A Output Voltage and Maximum Output Current in Amperes at 100 load 240 41 6A 240 62 5A 277 36 1A 277 54 1A 347 28 8A 347 43 2A Standard Charger Size amps 10 DC System Voltage 240 VDC 240 VDC Consult factory for other voltage ratings Circuit Breakers cabling and other electrical components should be sized according to your national and local electrical codes
27. m 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 M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 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 different 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 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 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 regulatio
28. n 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 M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 3 PHYSICAL TOPOLOGY 3 1 Front view Figure 3 1 Front view of the ELI M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 Figure 3 2 Front Doors Open Removal of the rear access cover exposes personnel to dangerous voltages and shock hazards that may cause damage injury or death M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 3 2 Battery Cabinets Some battery cabinets feature slide out shelves Prior to installation of the BBU the side panels should have 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
29. ols monitoring and indicators 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 Charger Contained in the ELI module Responsible for recharging the batteries 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 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 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 Battery The battery system provides DC power to the inverter input when the normal AC input power to the ELI fails IGBT Isolated Gate Bipolar Transistor PWM Pulse Width Modulation ELI Emergency Lighting Inverter BBU Battery Backup Unit PFC Power Factor Correction EPO Emergency Power Off 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 2 THEORY OPERATION ELI uses a variety of technologies
30. r alwayson com Website www alwayson com Additional Purchases or Upgrades Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 7S8 Phone 250 491 9777 Ext 451 Fax 250 491 9775 Email sales alwayson com Website www alwayson com M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 32 Always On M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 33
31. rter failure due to Output short circuit Inverter fuse open Over temperature condition Inverter overload condition Inverter stop activation Inverter output outside or parameters Bypass activated h Inverter shutdown 3 Battery low Inverter shutdown condition 4 No output voltage present onoooo M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 17 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 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 i
32. s 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 be 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 e Connect the ELI to the computer using the RS 232 cable included e Start the software Normally Off Function All Normally Off loads shall not exceed 50 of the ELI rating per phase 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 18 7 OPERATION damage the system or cause injury Not following the start up and shutdown procedures correctly can 7 1 7 2 Start up Procedure Open front door of ELI Remove breaker panel cover on front of ELI Confirm MAINTENANCE SWITCH is in NORMAL position Confirm BATTERY BREAKER is in OFF position Confirm INPUT BREAKER is in OFF position Open battery cabinet door Turn ON all BATTERY BREAKERS on battery cabinet S Turn ON BATTERY BREAKER on front of ELI Wait 10 seconds Apply utility power to ELI Turn ON the INPUT BREAKER on front of ELI ELI will enter stand by mode e Turn ON the OUTPUT BREAKER on front of ELI e Push ON OFF button on front panel hold button for 3 seconds or until ELI beeps and displays REA
33. ss mode Bypass LED will illuminate On the front panel turn the MAINTENANCE SWITCH to the NORMAL position Use the button to turn off the manual bypass mode ELI will start inverter and enter inverter mode Bypass LED will go out Line LED will illuminate The ELI is now in Normal Operating Mode Manual Battery Test To be performed by authorized service personnel only To initiate a manual battery test turn off the input breaker to disconnect all ungrounded conductors This process will simulate a failure of utility supply Battery status will be displayed via the front panel controls and LCD for the duration of the test 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 21 8 TROUBLESHOOTING Displayed LCD Audible Alarm Alarm Description What You Should Do Output Overload Two beeps per second The ELI is overloaded in Shut off the least line mode Your important equipment equipment needs more connected to the ELI If power than the ELI can this solves the overload provide The ELI problem the ELI will operates in bypass switch from bypass back to normal operation Battery Test No beeps The ELI is doing a No action needed The battery test ELI will return to normal operation when it successfully completes the battery test Over Charge Constant beep Batteries are Turn off protected loads overcharged Turn off the ELI and call your local dealer Low Battery Two beeps ever
34. tempt 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 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 field wiring terminals may be electrically 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 M4006 Aurora 10 15Kw Service Manual V3 0 2012 06 14 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 restore
35. y 5 The unit is operating on The unit will restart seconds Battery Power and will Automatically when shut down soon due to acceptable power very low battery voltage returns On Battery Once every 5 seconds The unit is operating on Save your data and Battery Power perform a controlled shutdown Charger Fail Constant beep Charger has failed Call the local dealer Over Temperature Constant beep High ambient Make sure the unit s temperature 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 High Output Voltage Constant beep High output voltage 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 Turn off protected loads voltage Turn off the ELI and call your local dealer Line Abnormal One beep per second Wrong AC Line backed up during auto restart M4006_Aurora_10 15Kw_Service_Manual V3 0 2012 06 14 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 Provides interface to control the function of the ELI by front panel ON OFF FUNC STATUS ENTER and ESCAPE buttons e CPU Board
36. y 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 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 closed 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 4006 Aurora 10 15 Service Manual V3 0 2012 06 14 5 5 Emergency Lighting Notification RS232 TO FIRE ALARM PANEL EMERGENCY ANNUNCIATOR POWER OFF CONTACT RATING 3A 120 VAG 30 WATTS JL NORMALLY OPEN CONTACTS 5400 ZZ 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 Inve
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