single and parallel UPS Systems User's and Installation Manual
Contents
1. G 2150 1220 Figure 2 Dimensions of the UPS Battery Cabinet BCPWS Battery Cabinet BCPWD Auxiliary Cabinet ACPW ra 1 E lo hp 82 o M 1595 20 Figure 3 Battery cabinets amp auxiliary cabinets for 160 250kVA UPS The main considerations in planning the UPS system are The UPS output power rating shall be specified according to the total power demand of the protected system Some margin should be allowed for potential expansion of the protected system and for possible ina2. MUU MWY dm ANN L MOL 7 7 mM hur du AU AI MWY IM x N t Cable entries UPS x Pal NL SS IUU LL AI gt Cable entries Battery Cabinet Battery Cabinet 1 Battery Cabinet 2 Figure 23 Interconnection of Battery cabinets 34 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A BCPWS 1x32 400 Battery Cabinet 32 Monoblocks 12V Dimensions Height 1900 mm Width 818 mm Depth 860 mm To assemble the battery cabinet N IMPORTANT Open the IB battery switch before connecting the cables Remove the screws that fix the trays Extract the trays of the battery cabinet Place eight battery blocks on the trays of the first second third and fourth level In
3. Figure 10 Ventilation and space requirements for 160 500 kVA UPS 1024754 160 kVA 500 kVA UPS 17 RevisionA User s and Installation Manual 5 2 Floor loading When planning the installation the floor loading must be taken into consideration because of the heavy weight of the UPS and battery cabinets The strength of the installation surface must be adequate for point and distributed loadings given in table 1 Distributed Description Rane EE RUE loading iens kg m 160 250 kVA UPS 6 Pulse 1130 1 8 1077 1220x860x1900 160 250 kVA UPS 12 Pulse 1820 14 1306 1620x860x1900 160 250 kVA UPS 12 Pulse amp THD Filter 1910 1 5 1370 1620x860x1900 400 500 kVA UPS 2880 1 2 1564 2150x860x1900 THD Filter for 400 500 kVA UPS 390 ABM 160 250 kVA UPS option 15 ABM 400 500 kVA UPS option 16 Top cable entry option for 160 250 VA UPS 35 BCPWS Battery cabinet 210 818x860x1900 BCPWD Battery cabinet 410 1596x860x1900 Table 1 The UPS floor loading of UPS modules and external options The weight is referred to the empty cabinet add the weight of the battery
4. F P M Ws L 1 an saz E 3 F TN 742 743 Gel el ele 2 Fy f y y 9 N 941 942 943 1 Ello e To o 5 1 e O wa B s o fB 18 GN 611 642 SEZ Figure 38 3 switches 56 160 500 UPS 1024754 User s and Installation M anual Revision A Bypass 3 Switches The power rating is referred to 400Vac External Maintenance Bypass Cabinet MB32 UPS Systeminput to UPS Module s Position 11 Bypass Input directly from bypass line mains supply UPS SystemOutput from UPS Module s MPC board Terminal TB4 Figure 39 External Maintenance Bypass Switch 3 position 1024754 160 kVA 500 kVA UPS 57 Revision A User s and Installation M anual 9 Parallel UPS System 9 1 Introduction Up to 8 UPS modules Hot Sync may be installed together in the parallel for Redundancy or Capacity system L1L2L3N PE L1L2L3N PE BYPASS TB4 5 6 p MPP X3 MPP X4 Figure 40 System wiring diagram of 1 8 parallel UPS modules 58 160 kVA 500 kVA UPS 1024754 User s and Installati
5. FRONT OUTPUT TERMINALS T RECTIFIER INPUT TERMINAL 28 elle Toll fe Ele flo o co D JAF o 3 Figure 18 Cable Entry Terminals for UPS 400 500kVA STD 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A
6. gt Y ET Lil A 55 zt A F Lj cPooooobDodoo00000000000000 a vg or Y pooo p o o te m olo uo Bz bolg lt gt om gt I o 2 0 x olz jj HIIS 05 zt n eg amp LS c Pg ch E O 2 o p 102 RESI To ien lt x il Er en 5 i gt m T 5z 02 L T o E eee Li On Y a Oz LJ z ul 16 o fel fel Vor O 9 T NS ON VA 5 5 WJ M Ex Q9000000000000000000000 4 o 4 o J N J J f 7 7 Figure 12 UPS 160 250 6 Pulse full features Location of electrical components 1024754 RevisionA THD Filters Figure 13 UPS 160 250kVA 12 Pulse amp THD optional Filters Intelligent THDI reduction and PF improveme
7. O o o o o o o o o o o c D o o o o User s and Installation M anual RECTIFT INPUT TERMINALS Eur Oe ee gt M IS o 9 7 FRONT DISPLAY Figure 11 UPS 160 250kVA std 6 Pulse location of electrical components 20 XSLUTs NALS 21 BATTERY TERMI ENTRY BAR CABLE FIXING CABLE TOP BAR EARTH 160 kVA 500 kVA UPS User s and Installation Manual
8. Alarm Custom 1 8 Alarms Alarms Configuration Total of 191 alarms service Contrast 0 100 Date amp Time DAY DT MONTH YEAR HOUR MINUTE SAVE Serial Ports SLOT 1 4 300 RS232 1200 2400 4800 9600 19200 Modem None Generic XCP Enabled Disabled UPS code r4 Enabled Disabled Control Commands Enabled Disabled 1024754 160 kVA 500 kVA UPS 49 RevisionA User s and Installation Manual 7 3 Manual System Control The System Controls screen appears when the pushbutton is pressed The transfer to bypass and back to normal mode are controlled from this screen by pressing the Bypass and Normal pushbuttons As a safety feature the UPS can be locked to bypass mode via software and an alarm will be given To return to normal operation press Reset and UPS will transfer to normal operation These operations are controlled by the UPS firmware and allowed if the conditions for transfer are acceptable ia System Controls O Maintenance Bypass OFF A Bypass OFF o A RESET BYPASS NORMAL Pushbuttons i This button is for accessing the language selection menu future gt This button is used to access the manual system control menu RESET BYPASS NORMAL This button is used to acknowledge the alarms and silence the horn 7 4 Using the maintenance bypass switch The UPS unit is provided with an internal maintenance bypass switch This
9. USER INTERFACE XSLOTs SUPPLY B ARD T 3 N na ee ae I sy 8 B 9 2 fou V E E o aN o da o e m EI BY tec V ME E E TE ABM 2E j CONTACTOR BACKFEED 1 CONTACTOR IUG 5 g x I B EREE ert rel 8 IRP o o o 5 o d EEL I L 1 12 1 13 E E md Figure 15 UPS 400 500kVA full features location of electrical components 24 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 5 4 Information about power terminals Fastening torques for terminals depend on type of cable shoes and materials If using aluminium shoes please use anti oxydizing paste in the connections The UPS has bolts for the power connections Please check the local safety rules for the installation when designing the cables Bottom Cable Entry Terminal for 160 250kVA UPS Rectifier input Flat copper bar 40 5mm Bolt M12 Bypass input UPS Output Flat copper bar 30 8mm Bolt M12 Neutral Bolt M12 Ground Flat copper bar 40 5mm Bolt M12 Battery Input Flat copper bar 40 8mm Bolt M12 Top Cable Entry Terminal for 160 250kVA UPS Rectifier input Flat copper bar 80x40 5mm Bolt M12 Bypass input UPS Ou
10. RELAY 4 O QN E SLOT 3 12 COMMON RELAY3 5 NO 3 NC SLOT 4 19 COMMON RELAY 2 20 NO NC 19 COMMON RELAY 1 20 NO 30 NC BUILDING ALARM 1 BUILDING ALARM 2 BUILDING ALARM 3 Buiting ALARM 4 Figure 33 The user interface area Note All connections mentioned in chapter 6 must not be galvanically connected to any mains connected circuits Reinforced insulation to the mains is required The routing of the cables shall be done separate from any power cables 1024754 160 kVA 500 kVA UPS 41 Revision A User s and Installation Manual 6 1 Connecting the UPS to a computer The UPS is delivered as a complete solution package with accompanying Software Suite To connect the UPS to the computer use the communication cable provided with the package Note If using other cable verify the pin configuration from Table 5 Check from the software documentation that the platform running on your computer is supported Follow the instructions of the Software Suite to choose and complete the required software installation For other operating systems SNMP and more advanced power protection solution combinations please contact your local dealer RS232 serial data interfaces The RS232 interface J18 uses 9 pin female D sub connector The information includes data about the utility load and the UPS itself The connector J18 is
11. 29 500kVA full features 160 kVA 500 kVA UPS S AR RA oe dE EA CSSSSSS a gt Y S a Z E ul o E ETETITIITITEITITIERTIIDR YIN 99 7 j A es A e Y e 8 0 M ul LT o o a amp az e e e o wd 9 gt ollleIe 55 o P Ile gt aS eg 2 ee Se a E cu 5 Ed n Ijo T s 7 d N B5 ES OTT 7 User s and Installation Manual Figure 19 Cable EntryTerminals for UPS 400 7 S AN f amp y KEN i 05 as LS aS ae E amp Sf S d 35 BE a gi 1024754 Revision A 5 5 Mains and load connections The proper connection order is as follows 1 Switch off the supply to the distribution point to which the UPS unit is to be connected 2 For extra safety also remove the fuses from the selected lines Make absolutely sure with measurement that there is no power 3 A readily accessible disconnect devic
12. To calculate point loading kg cm add the weight of the cabinet to the weight of the batteries and divide by 640 for BCPWS and 1280 for BCPWD To calculate distributed loading kg m add the weight of the cabinet to the weight of the batteries and divide by 0 7 for BCPWS and 1 4 for BCPWD 18 160 kVA 500 kVA UPS User s and Installation Manual 1024754 Revision A 5 3 Power connections The electrical planning and the UPS installation must be done by qualified personnel only All power connections shall be done with cable lugs WARNING The UPS contains high voltage and current which can injure or kill personnel and damage equipment The customer has to supply the wiring to connect the UPS to power lines The installation inspection and initial start up of the UPS and extra battery cabinet must be carried out by a service engineer from the manufacturer or from an agent authorised by the manufacturer The UPS unit has the following power connections 3 phase and PE connection for rectifier input 3 phase and N and connection for bypass input 3 phase and N and connection for load output and PE connection for batteries Note PE connection is provided on a copper ground bar All input and output wiring of the UPS connects to the terminals located behind the cover plates behind the doors The UPS is provided with a single phase L N power outlet protected with a 10A fuse 1024754 160 kVA
13. 500 UPS 19 RevisionA User s and Installation Manual TER TERMINALS INTERFACE BOARD XSLOT POWER SUPLLY A FIXING BAR 1024754 Revision ABLE oc USE B BATTERY MPC i an TERMINALS BYPASS LINE INPUT o SN ut pu coo BAR o L1 B OO OO0O0000000200000900002000 5 OUTPUT TERMINALS pi B Ol an SEPT Exam 0 27 O EARTH R E c o o 160 kVA 500 kVA UPS a Ol JJ
14. User s and Installation M anual e o 1 Cl 5 OUTPUT INPUT Gop l i E Bi sn faci aLa fan 8 1 i N 2 i 2 1 3 2 C C i RECTIFIER INPUT OUTPUT BYPASS LINE BA ERY TERMINALS TERMINALS TERMINALS TERMINALS J gt EARTH BAR _CABLE FIXING BA FROM THE FRONT FROM 100mm 1 240mm mf PS rey 9 o Corl e tel 6 lor 8 LI 2 1 uU lt e o o o g foul 30 60 165 142 110 160 210 L 270 320 370 L 420 Figure 16 Bottom Cable EntryTerminal for UPS 160 250kVA 26 160 500 UPS 1024754 RevisionA RECTIFIER BATTERY INPUT BYPASS LINE OUTPUT TERMINALS TERMINALS TERMINALS TERMINALS B B 1L2 103 4 N 4 13 4 12 4 11 5 543 5 12 5 11 e G 2 o O 6 o G GROUND REAR VIEW VIEW 1175 1050 587 n n D D 14 RAGE RABE YI m 5 e
15. figure 11 Open the left door of the UPS section Check that On Off switch 51 is in OFF position Check that the Maintenance Bypass Switch IBY is open Turn the switches IRP and IRE to ON position Start the UPS by turning the switch 1 to ON position The UPS will now check it s internal functions The UPS starts after 10 15 s 52 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A Check that inverter is running and then close the external battery circuit breaker Close IUG switch Close the left door of UPS Note Do not close the Battery Circut Breaker until the inverter is running Note The UPS start up without mains is possible only if ABM option is installed according to the following procedure Open the left door of the UPS section Check that On Off switch 51 is in OFF position Check that IRP is open Check that the maintenance bypass switch IBY is open Close the battery circut breaker Start the UPS by turning ON the 1 switch The UPS will precharge the inverter input capacitors and the inverter will start in 1 2 minutes Check that inverter is running Close IRP and IRE if present Close IUG switch Close the UPS door 7 6 Shutting down the UPS The UPS unit does not have to be shut down at the end of each day The unit is designed to cope with a continuous load from the day it is installed until a change is needed in the backup battery bank Shuttin
16. SSS ial PEPERIT PT H 1 M 1 7 N Sexe 44 B 1 I H B NN I H dd d 4g 8 1 1 2 I 1 NN gt fara l 1 A mom 8 2 Figure 27 BCPWD 400 amp BCPWD 630 6V bottom amp top cable entry battery layout 1024754 160 kVA 500 kVA UPS 37 RevisionA User s and Installation Manual WARNING after assembly there is a voltage of 48V on each level of left and right tiers Insert the trays into the battery cabinet and fix them with the screws Connect the battery blocks of the various levels to IB and connect IB to the relevant UPS terminals as shown in fig 28 N Ensure appropriate ventilation of the battery room according to the standard 62040 1 1 to prevent the risk of an explosion 8 MONOBL
17. block 1 negative pole gt block 2 positive pole according to the diagram on next page N WARNING The nominal voltage of the monoblocks must be 12V in fact 32x12 384V nominal voltage BCPWD 12V Bottom Cable Entry BCPWD 2V Top Cable Entry 1 1 H 4 NN 772 BH dag 1 1 E ANN 722 IN HE E N Sf H X V te NS 4 NZ N y v H M gt H N 4D Figure 30 BCPWD 400 amp BCPWD 630 2X32 12V bottom amp top cable entry battery layout 1024754 RevisionA 160 kVA 500 kVA UPS User s and Installation Manual 39 N Warning after assembly there is a voltage of 96V on each level of the left and right tiers Insert the trays into the battery cabinet and fix them with the screws Connect the battery blocks of the various levels to the IB battery switch and the IB to the terminals as shown in fig 31 N Ensure appropriate ve
18. gL fuses should be used to protect cables Note Cable size is for indication only The cross section including the PE cable will depend on insulation temperature rating cable lenght and local regulations Please note that the battery cables delivered with the external battery cabinets are to install the external battery cabinet to the right size of the UPS 32 160 500 UPS User s and Installation M anual 1024754 Revision A 5 6 Installation of Additional Optional cabinet L1 L2 L3 t N PE e 2 RIS ACPW A Vea Y 1 1 IRP IRE 2 IBY BCPW C1 5 ABM 1 3 IB C3 XA 1 C4 XA 3 i jo e N L1 L2 i L3 i N Note 1 Optional 2 HRE is an on load isolator or backfeed contactor as an option 3 Built in inverter transformer 4 The rating of the isolation transformer is limited to 100 of the UPS size Figure 22 Interc of UPS with bypass input transformer for input output isolation Power Fuse 1 Fuse 2 Cable A Cable
19. is important to all personnel involved 3 1 Storage and transportation Because of the heavy weight of the cabinets and the high energy battery bank the equipment must be handled with care The UPS must always be kept in the position marked on the package and must not be dropped 3 2 Installation Do not operate the equipment in the presence of flammable gases or fumes Operation of any electrical equipment in such an environment constitutes a safety hazard Do not place the UPS in an airtight room The UPS system must be installed according to the instructions in this manual Installation may be performed by qualified personnel only Failure to recognise the electrical hazards could prove fatal 14 160 kVA 500 KVA UPS 1024754 User s and Installation M anual Revision A N WARNING Do not open the UPS or battery cabinet Some components inside the cabinets carry high voltages To touch them may prove fatal All operations inside the cabinets must be carried out only by a service engineer from the manufacturer or from an agent authorised by the manufacturer 3 3 User operations The only user operations permitted are Starting up and shutting down the UPS unit not the initial start up Operating the user interface Connecting data interface cables Monitoring the UPS with the software provided These operations must be performed according to the instructions in this manual During any of these operations the user mu
20. is in bypass mode Bypass LED lit Close the maintenance bypass switch IBY see Shutting Down procedure for more information Note When the UPS is a module of parallel system the internal maintenance bypass must not be used If it is necessary to bypass the system an external maintenance system bypass must be used see Installation of an External Maintenance Bypass chapter Going to the UPS mode Before opening the Maintenance Bypass Switch IBY verify that the bypass LED is lit O Verify that the UPS returns to Normal mode It may be necessary to transfer the UPS to normal mode by pressing the Normal pushbutton in System Control menu If the rectifier input voltage is not present out of limits the UPS will stay on bypass mode as long as the bypass input voltage is within limits If the bypass goes out of limits or the rectifier input voltage returns within limits the unit will transfer to normal mode see Starting up the UPS procedure for more information 1024754 160 kVA 500 kVA UPS 51 Revision A User s and Installation M anual 7 5 Starting up the UPS Make sure that UPS installation has been carried out correctly and battery line neutral and protective earth inputs have been connected Figure 11 shows the location of the switches The UPS is also provided with a battery start up feature when the ABM option is provided In this case the UPS can be started if the input power line is not available or accep
21. one serial communication port Modbus Jbus Module connects to an industrial automation system AS400 Relay Module provides additional relay outputs SNMP Web Module has a flexible SNMP Web communication port Modem Module provides modem functions for remote monitoring 44 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 7 User s guide to operations This chapter contains the necessary information on how to use the UPS The control panel provided to the user UPS status measurements alarms and history log It is also used to control and configure the UPS with the function buttons underneath the display During commissioning the manufacturer representative will train the users to operate the UPS system 7 1 Graphical Control panel The monitor panel shows the status of UPS operation with five LED indicators and with aLCD screen The display also generates audible alarm if the user should be alerted Figure 35 Control panel with the main screen LED indicators This green LED is lit when there is voltage at the output terminals and when the UPS is in normal or static bypass mode This yellow LED is lit when the UPS is operating in battery mode This yellow LED is lit when UPS is on and is operating in bypass mode This yellow LED is lit when there is an active notice that does not require immediate action rb OG This red LED is lit when there is an active alarm that requires immed
22. publisher and may not be reproduced even extracts unless permission granted Every care has been taken to ensure the accuracy of the information contained in this manual but no liability can be accepted for any errors or omission The right to make design modifications is reserved 1 Safety Instruction IN The unit must be used as intended Follow the instructions given in the Operating Manual The UPS must be installed and serviced by manufacturer technicians or authorized personnel only If necessary only original spare parts are allowed N See installation instructions before connecting to the supply AN Dangerous voltages are present inside the unit N Installation and use of this equipment must comply with all national and local regulations and procedures IN To prevent overheating do not obstruct for ventilation grills of the unit IN The components inside the unit are not repairable by the user The user must not open the UPS cabinet or auxiliary cabinets or remove any protective covers from inside the UPS cabinet N To completely isolate the equipment the switches IRP IRE IBY and IUG must be open the input supply and the battery supply must be isolated from the UPS and the output isolated from other modules if the unit is part of a multi module system N Capacitors inside require 5 minutes to discharge to a safe level after all power is removed See service manual for instructions N High leakage current c
23. switch is used to bypass the UPS during maintenance or servicing Maintenance bypass switch is located behind the left door The maintenance bypass switch has the following positions OPEN UPS normal position inverter static switch is supplying power to the load CLOSED BYPASS the UPS is mechanically bypassed and the load is supplied from the bypass input power line This position allows testing of the UPS without disturbing the load When the UPS is turned off andthe maintenance bypass switch is closed and IRP IRE IUG are opened the UPS is isolated from the input and output power lines Open the switch in the battery cabinets to isolate the UPS from the battery 50 160 500 UPS 1024754 User s and Installation M anual Revision A N WARNING Dangerous voltages are still present on the switch terminals during the bypass operation Note Maintenance bypass switch is used only on rare occasions If the bypass input frequency or voltage is not correct and the UPS is not synchronized to mains or static switch is not gated turning the switch to bypass or UPS position may cause short break to output voltage If the load is connected to maintenance bypass the UPS is no longer protecting the critical load Going to the maintenance bypass mode Before going to maintenance bypass transfer the unit to static bypass mode by pressing the Bypass pushbutton in System Control menu on LCD screen After this verify that UPS
24. the load when servicing the UPS To allow transfer of the load to the bypass line without interruption a single Make Before Break MBB switch is used When the external maintenance bypass is installed a normally open voltage free contact is available This contact must be connected to the connector TB4 of MPC board Pin5 and Pin 6 There are 6 types of Maintenance Bypass Cabinet MB3 2 switches 250kVA 500kVA 800kVA MB3 3 switches 250kVA 500kVA 800kVA 2 Switch Maintenance Bypass The two switch Maintenance Bypass consists of two internally interconnected 4 pole switches which provide a make before break changeover from to the UPS output and the external bypass supply by manually switching a single key interlocked switch An interlock is provided to prevent erroneous switching of the maintenance bypass if the inverter supply is still connected to the UPS system output The three positions are labelled I for normal II for bypassed and I II when both switches are closed When switching to the maintenance bypass the switch must be switched all the way to position II P Fx SEZ B B L M R A 5 da A j 5 ole It F Tn Td 7
25. the shipping cartons and packing materials should be stored for further investigation If the damage is visible a claim for shipping damage must be filed immediately Note Check the shock tilt indicator To file a claim for shipping damage The carrier must be informed within 7 days of receipt of the equipment Remove the equipment from the pallet according to figure 9 The equipment must be checked against the packing list to verify that the shipment is complete UPS 160 250kVA UPS 400 500kVA 2 L y PA Figure 9 Removing the UPS from a pallet Note The 400 500 kVA UPS should be be forked from the rear side where the unit is heavier it can be also forked from the right side if a long fork is used The UPS is thoroughly inspected at the factory If there is no damage or discrepancies the installation may proceed 4 2 Moving The UPS units can be moved with fork lift or pallet jack Because the UPS is heavy it should be verified that surfaces on which it is moved are strong enough 16 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 5 Installation The UPS unit i
26. 12 7 D EN tlle Jo al 1 H wa al Ti 00 Sts 2 B E 1 y oJ SEZ Bypass 2 interruttori The power rating is referred to 400Vac 1024754 160 kVA 500 kVA UPS 55 Revision A User s and Installation M anual External Maintenance Bypass Cabinet 1 Position 11 Input ypass Inp directly from bypass L2 line mains supply Z L3 m To Load UPS SystemOutput from UPS Module s MPC board terminal TB4 Figure 37 External Maintenance Bypass Switch 2 position 3 Switches Maintenance Bypass The three switches of the Maintenance Bypass consist of three internally interconnected 4 pole switches which provide a make before break changeover from to the UPS output and the external bypass supply with a single manual operation of the key interlocked switch In the third position 1 the UPS is isolated from the mains supply An interlock is provided to prevent erroneous switching of the maintenance bypass if the inverter supply is still connected to the UPS system output The three positions are labelled I for normal II for isolated and I II when both switched are closed To isolate the UPS system the switch must be switched all the way to position II SEZ B B
27. 160 500 kVA single and parallel UPS Systems User s and Installation Manual 160kVA 500kVA UPS User s and Installation Manual DE 5 2 7 2 1 System description ERE 7 2 2 7 2 3 UPS COMM dllfls 10 extu wlliuribpie 14 3 1 Storage and transportation 14 Sra M rry 14 3 3 User OD SR ALONG m 15 Shipping and 15 4 1 Unpacking and incoming 1 lt 16 42 MOVIN 16 SNL m Y 17 51 rune m 17 5 2 Flo r ELLEN 18 5 3 Power 5 19 5 4 Information about power terminals 25 5 9 Mains COMICON OIG E 30 5 6 Installation of Additional Optional 33 5 7 External Battery Cabinet Installation enn 34 6 Computer and alarm 41 6 1 Connecting the UPS to a 42 6 2 Potential free relay outputs 85 42 6 3 Emergen
28. 5 1945 9522 i GB 4 5 L8 GROUND ELD 96 0 Y N N NN x EN b n EN XN A P SCALE 12 d S x p NA SZ ERMINAL BOARD REAR VIEW BN E n NN n A Ne NN OW N N DF THE SABINETN Distence from the top cabinet to ra Se if E auxiliary terminal amp top bar 290 mm a d N N Z lt N lt M j B 3 o 8 15 50 15 Bolt M12 for cable fixing N 922 BW So F ar T SR x 9 2 is 25 30 7 es d A ac p Figure 17 Top Cable Entry Terminal for UPS 160 250kVA 1024754 160 kVA 500 kVA UPS 27 Revision A User s and Installation M anual BYPASS LINE TERMINALS 80 _140_80 FRONT VIEW
29. 50 25 0 L1 L2 L3 46 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A Setup Fimware Revision MCU Comm Server Rectifier Display Inverter UPS Identity TypeString PartNo SerialNo This unit number Parallel Information Units communicative Units On Line Parameters Nominal output voltages 220 V 230 V 240 V default factory setting 1024754 RevisionA 4 20 10 Bypass overvoltage limit Bypass undervoltage limit 4 20 15 UPS frequencies In Out 50 50 Hz In Out 60 60 Hz In Out 50 60 Hz In Out 60 50 Hz Bypass Frequency Limits 0 5 2 3 Hz 2Hz Overload operations Transfer to bypass Immediately Transfer to bypass After delay Battery low alarm level 376 V 326 V 353V Battery test Enabled Disabled ABM functions All ABM functions enabled ABM charging cycles disabled ABM failure alarms disabled No ABM alarms or charging cycles ABM contactor K3 not installed Parallel unit number Single UPS 160 kVA 500 kVA UPS Unit 1 8 User s and Installation Manual 47 Disable input filter Filter d
30. B Cable N Cable C Cable D 160 kVA 400A 310A 3x2x95 3x2x95 mm 1 2 95 3x2x95 mm 2 2 120 mm 200 kVA 400A 310A 3 2 120 mm 3x2x120 mm 1x2x120 mm 3 2 120 2 2 185 mm 250 kVA 630A 400A 3x2x150 mm 150 mm 1x2x185 mm 3 2 150 mm 2 2 120 mm 400 kVA 800A 3x2x300 mm 3x2x240 mm 1x3x240 mm 3x2x240 mm 2x3x240 mm 500 kVA 1000A 3x3x240 mm 3 3 185 mm 1x4x185 mm 3 3 185 mm 2 3 300 mm Tab 4 Fuse and cable dimensions for installations of UPS units from 160 to 500 kVA 1024754 Revision A 160 kVA 500 kVA UPS User s and Installation M anual 33 5 7 External Battery Cabinet Installation The batteries should preferably be installed next to the UPS The right side is recommended due to the power cable fastening an opening is provided on the right panel of the UPS and on the left panel of the battery cabinet for cabling UPS Battery Cabinet 1 Battery Cabinet 2
31. J j Y Um mm c rd D A u ia Q N my O 1 e 4 bl ee 3 p Ls UEM E f i 857 3 D E 11 160 kVA 500 kVA UPS User s and Installation Manual Figure 5 Base Plant for 160 250kVA UPS 6 Pulse amp 12 Pulse 1024754 Revision A OO OO 860 WT 1 Front door 2 Top panel 3 Rear panel 1024754 160 500 UPS User s and Installation M anual Revision A UT U ARK AKI AN Figure 6 Dimensions of 12 Pulse Extention Cabinet for 160 250kVA UPS 12 13 160 kVA 500 kVA UPS User s and Installation Manual Er gt 98 se f 1
32. Note UPS modules should be transferred to static bypass from the LCD control panel before operating the system bypass switch MB3 This procedure ensures UPS modules to check for the internal bypass condition and inverter synchronization A safe transfer is not guaranteed if the system bypass switch MB3 is operated without first transferring UPS modules to static bypass mode Remember to check from the LCD control panel that UPS modules return to online mode in the UPS position of system bypass switch MB3 1024754 160 kVA 500 kVA UPS 65 Revision A User s and Installation Manual 10 Maintenance All operations inside the unit must be carried out only by a service engineer from the manufacturer or from an agent authorized by a manufacturer Battery maintenance The condition of the batteries is crucial to correct operation of the UPS The UPS units are provided with the automatic battery test which continuously monitors the condition of the battery bank When the capacity of the battery bank has decreased remarkably the UPS will indicate this by audible and visual alarms In addition to the automatic battery test it is recommended that a battery discharge test is done once or twice per year This test is recommended to be done together with the preventive maintenance by service engineer from the manufacturer of by an agent authorised by the manufacturer 11 Recycling the used UPS or batteries Before scrapping UPS or its battery
33. OCC 8 MONOBLOCKS 1 PIANO 1 TER IB f s II PIANC 3D 4 8 1 TIER 3 ees P p 3 3 30 2 E BOBINA D 25 oo SGANCIO 24Vec TM PIANO EE id TIER 5 III TIER gt TRIP 2 Vdc 4 4D XC 4 yE IV PIANO V TIER V TIER 9 oc 8 MONOBLOCCHI g E E I TIER XC 45 0 Ee x 85 um um aS ES XC Qe MEX M dd 1L PIANO 1 PIANO join D Il TIER 3s TIER 5 xf x 35 3 g PIANO TIER 1i TIER a es 2 ven aC 8 E g IV paa V PIANO IV TIER V TIER Figure 29 BCPWD 400 amp BCPWD 630 6V bottom cable entry elect connections 38 160 500 UPS 1024754 User s and Installation M anual Revision A BCPWD 2x32 400 amp BCPWD 2x32 630 Battery Cabinet 64 Monobloks 2x32 12V Dimensions Height 1900 mm Width 1596 mm Depth 860 mm To assemble the battery cabinet N IMPORTANT Open the IB battery switch before connecting the cables Remove the screws that fix the trays Extract the trays of the battery cabinet Place eight battery blocks on the left and right trays of the first second third and fourth level Interconnect the blocks in series
34. S 111 voltage and frequency independent operation 1 4 Efficiency 9396 at nominal load 1 5 Standards Performance EN62040 3 IEC62040 3 Safety IEC62040 1 1 IEC60950 EMC EN50091 2 62040 2 1 6 Conformity CE ISO 9001 2 Mechanical construction 2 1 Dimensions WxDxH UPS 160 250 kVA 6P 1220x860x1900 mm UPS 160 250 kVA 12P 1620x860x1900 mm UPS 400 500 kVA 2150x860x1900 mm 2 2 Weight 1130 kg 160 250 kVA 6P UPS model 1820 kg 160 250 kVA 12 UPS model 1910 kg 160 250 kVA 12 UPS with THD Filter 2880 kg 400 500 kVA UPS 2 4 Enclosure IP20 2 3 Color RAL 7035 2 5 Cabling direction Bottom Top is optional for 160 250 kVA UPS Bottom amp Top for 400 500 kVA UPS 1024754 160 kVA 500 kVA UPS 67 RevisionA User s and Installation Manual 3 Eletrical Characteristics Input 3 1 Nominal voltage 3 2 Input voltage range 3 3 Rated input Current 3 4 Input Power factor 220 380 230 400 240 415 V 50 60 Hz 342 to 456 V 45 to 65 Hz 160 kVA x 265A 3x 216A with THD filter 200 kVA 3 x 331 A 3x 280 Awith THD filter 250 kVA 3 x 413A 3x 350A with THD filter 400 kVA x 640 A 3x 565 A with THD filter 500 kVA 3 x 790A 3x 700A with THD filter 0 8 lagging 0 95 at rated current with filter 4 Electrical Characteristics Output 4 1 Nominal power at PF 0 8 160 kVA 128 kW 4 2 Nominal voltage 4 3 Crest factor 4 4 Linear loads 4 5 Voltage regulation 4 6 Current 4 7 Short circuit capability
35. S 500 kVA 30 kW UPS 160 250 kVA 3000 m h 833 l s UPS 400 kVA 4800 m h 1333 l s UPS 500 kVA 5100 m h 1416 1 5 70 dB A max ISO 7779 Valve Regulated Lead Acid or vented lead acid Advanced Battery Management or traditional float charging UPS 160 250kVA 384 VDC 192 cells UPS 400 500kVA 480 VDC 240 cells 160 kVA 500 kVA UPS 69 User s and Installation M anual 6 4 DC bus ref in float mode 2 25 VPC without ABM Temperature compensation 3mV cell C when monitoring probe is installed 6 5 Battery cut off voltage 1 7 VPC volt per cell 6 6 Battery charging current according to the batt data UPS 160 250 kVA from 10 to 250A UPS 400 500 KVA from 20 to 250A 6 7 Max Battery discharging current 1 7VPC 320VDC UPS 160 kVA 420A UPS 200 kVA 525A UPS 250 kVA 650A UPS 400 kVA 840A UPS 500 kVA 1050A 70 160 kVA 500 UPS 1024754 User s and Installation M anual Revision A
36. The control and monitoring circuits measure monitor and control the operation of the UPS system It gives the user the status of the system operation by visual and audible indicators The UPS sends information about the system operation via potential free relay outputs and RS232 serial data interface This information includes data about the utility the load and the UPS itself The information can be used in a computer to ensure total protection of software and data Bypass Input REI Filter Rectifier Load Input Static Bypass Maintenance Rectifier 8 Inverter Transformer i Switch Bypass Switch Filter Monitoring User Panel Batt CONTROL amp MONITORING ABM Computer Figure 1 Block diagram of the UPS 8 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A Advanced Battery Management ABM ABM monitors the status of the battery and charges it only when the battery needs charging This feature is very valuable since most of the time the battery does not need charging Hence the function of ABM is to prolong the battery life by up to 50 on average It also ensure that the load never looses power because of bad or defective battery The key to long battery life is low corrosion inside the battery The main cause of corrosion is current flowing through the battery The more current flowing through the battery the shorter the battery life Current flows through the battery whe
37. als 5 and 6 The external bypass switch auxiliary contact wires are connected on terminals 5 and 6 see figure 33 For normal UPS operation the connection shall be open as default If an external bypass switch will be used contact your dealer first Environment Alarm Input TB4 7 8 The environment alarm input is used for connecting the UPS to your building alarms such as overtemperature or smoke detector alarms The environment alarm input contact wires are connected on terminals 7 and 8 see figure 33 When this alarm is activated it will be indicated to the user through RS232 ports When connection on terminals 7 8 is open the alarm is inactive as default Note The programmable auxiliary inputs Generator ON External Bypass Switch Remote Output On Off Environment Alarm must not be galvanically connected to any mains connected circuits Reinforced insulation to the mains is required for equipments and cables connected to these connections Note The programmable auxiliary inputs are NOT galvanically isolated from each other Use dry contacts WARNING If the contacts must be connected to more than one input of the same board or to input of more than one unit it s mandatory to respect the polarity 6 5 X Slot Modules Optional X Slot modules allow the UPS to communicate in a variety of networking environments and with different types of devices The UPS is compatible with any X slot module including RS232 Module has
38. an explosion 8 MONOBLOCKS gt 8 MONOBLOCKS 8 MONOBLOCKS 8 MONOBLOC S XC T _ Hl a 3 urn 6 11 D c i 8 BOBINA DI SGANCIO e4Vcc y xE 3 RIP CUI 2 Figure 26 BCPWS 1 32 400 12V top cable entry electrical connections 36 160 500 UPS 1024754 User s and Installation M anual Revision A BCPWD 400 amp BCPWD 630 Battery Cabinet 64 Monoblocks 6V Dimensions Height 1900 mm Width 1596 mm Depth 860 mm To assemble the battery cabinet N IMPORTANT Open the IB battery switch before connecting the cables Remove the screws that fix the trays Extract the trays of the battery cabinet Place eight battery blocks on the left and right trays of the first second third and fourth level Interconnect the blocks in series block 1 negative pole gt block 2 positive pole according to the diagram on next page WARNING The nominal voltage of the monoblocks must be 6V in fact 64x6 384V nominal voltage BCPWD 6V Bottom Cable Entry BCPWD 6V Top Cable Entry i manne H 1 1 NN 77 I lt i
39. ass mode after overload or load transient situation System communication with a CANBUS interface A 10 meter CANBUS interconnection cable with termination resistors 2 120 ohm are supplied for parallel UPS modules The CANBUS cable must be connected between the TB3 terminals of two successive UPS modules as shown in the earlier wiring diagram of parallel UPS system A shielded twisted pair cable with maximum length of 40 meters must be used The CANBUS is a linear communication interface It must not form a loop configuration Intermediate termination resistors are removed in parallel systems of more than 2 UPS modules Only the first and last UPS modules in the CANBUS chain must have a termination resistor fitted in cable end connected to TB3 terminals pin 1 CANH and pin 2 CANL Refer to board assembly drawing for pin numbering 3 COMMON Resistor 2 CANL 120 ohm p TB3 123 S Figure 41 TB3 communication terminals of UPS modules and CAN cable with resistors 1024754 160 kVA 500 kVA UPS 59 Revision A User s and Installation Manual Note Pay attention to the signal polarity because pins 1 CANF and pin 2 must not be interchanged between UPS modules The shield is connected to pin 3 COMMON on the TB4 terminal from both ends Hot Sync communication with a 6 pin parallel interface In addition to the CANBUS cable a 6 pin parallel intercommunication cable 10 m
40. cabinet the batteries must be removed Due to high energy and high voltage removal of batteries is allowed only for authorised service personnel Do not discard waste electrical or electronic equipment or batteries in the trash For proper disposal contact your local collecting recycling reuse or hazardous waste center and follow the local legislation These symbols indicate on a product Use proper local collecting centers meeting local legislation when handling waste of electrical and electronic equipment ANwaRNING HAZARDOUS MATERIALS Batteries may contain HIGH VOLTAGES and CAUSTIC TOXIC and FLAMMABLE substances Batteries injure or kill people and damage equipment if used improperly DO NOT DISCARD unwanted batteries or battery material in the public waste disposal system Follow ALL applicable local regulations for storage handling and disposal of batteries and battery materials 66 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 12 Warranty The product is warranted against defects in material and workmanship for a period of 12 months from its original date of purchase 13 Technical specifications 1 General charasteristics 1 1 UPS models 160 kVA 9370 160 200 kVA 9370 200 250 kVA 9370 250 400 kVA 9370 400 500 kVA 9370 500 1 2 Technology Double conversion online UPS topology with automatic bypass switch and maintenance bypass switch 1 3 Performance Class VFI S
41. ccuracy in calculating or measuring the actual power requirement The battery shall be sized according to the desired backup time Note that the backup time is longer if the load is less than the nominal power rating of the UPS 10 160 kVA 500 kVA UPS 1024754 User s and Installation Manual Revision A o g SES E cu Apa ow RT V 66 o S 911 2 7 2 8 _ rr 2 c zy i Fd Susa 0 D Soft E p ES z Li bd d WW Fg 006 N m s Lj F1 E E En AT pg bd 2 HE P EN Dy ee E a A D g bao 1 DO 5 bg po 5 E J H 1 N Wn EE bg AG D Eg N i 1 RON 5 d ET S d l 00 1 CN e Qu lees Fd 00 e a qe P a a 1 D N Uu i E X c i 9 CN in 1 c 3 A QJ o 3
42. cy Power Input EPO TBS 43 MIG TBA e 43 6 5 KS OE MOQUIGS icit mi 44 7 USER S guide to operations diua kd risque ELM 44 7 1 Graphical Control panel erronee 45 T2 MENU SUCCES Mer 46 7 3 Manual System Control M 50 7 4 Using the maintenance bypass SWIECh isnt 50 7 5 Starting up the UP cC 52 TO Shutting down E E 53 8 Installation of an External Maintenance Bypass 55 9 Parallel UPS System e dace cis coxa uS S Ear 58 9 1 emm 58 9 2 Selecting redundancy or capacity 59 9 3 Installation 59 E Mee quU o 64 9 5 OW icio e 65 10 TIE TREE 66 11 Recycling the used atttem nna utu om taria an 66 12 rupi 67 13 Technical specifications ucro tar trenta danane nau nu secun 67 Copyright 2004 2005 The contents of this manual are the copyright of the
43. d circuits Reinforced insulation to the mains is required 42 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 6 3 Emergency Power Off Input EPO TB9 This input is used to shut down the UPS from a distance This feature can be used for emergency power down or for shutting down the load and the UPS by thermal relay for instance in the event of room overtemperature Remote shut down wires are connected to terminal block TB9 pins 1 and 2 see figure 33 The EPO terminals have been connected together at the factory When this connection is open the logic hard wire circuitry will immediately shut down the UPS thus preventing the UPS from supplying the load In order to have the UPS running again the EPO pins have to be connected and the UPS restarts The pins must be shorted in order to keep the UPS running Maximum resistance is 10 ohm The EPO must not be galvanically connected to any mains connected circuits Reinforced insulation to the mains is required N The EPO condition is reset if the contact is closed after having opened for this reason use a contact that latches in the open position and that can be reset only intentionally 6 4 Inputs TB4 The UPS communication device includes four inputs terminal block 4 1 2 3 4 5 6 7 8 for building alarms These inputs can be used for example on Generator signal shutting down and starting up inverter remotely or switching to bypass mode remotely These
44. e limits given in table 3 of EN50091 2 Installation instructions must be issued in order to ensure proper shield ing of the power cables in the field in order to comply with all the EMC requirements and in particular with the radiated emission limits in accordance to EN50091 2 all power cables must be installed with adequate earthed shield The UPS unit is now connected to the mains and to the load but there is no power Make sure that the connections are properly made 30 160 500 UPS 1024754 User s and Installation M anual Revision A 1 ABM Optional 2 IRE is an on load isolator or backfeed contactor as an option Figure 20 Interconnection of 6 Pulse UPS 160 250 kVA Power Fuse 1 Fuse 2 CableA Cable B Cable N Cable Cable D 160kVA 400A 400 A 3x2x95 mm 3x2x95 mm 1 2 95 mm 3x2x95 mm 2 2 120 mm 200 400A 400 A 3 2 120 mm 3 2 120 1 2 120 mm 3 2 120 mm 2 2 185 mm 250kVA 630A 630A 3 2 150 mm 3 2 150 mm 1x2x185 mm 3x2x150 2 2 120 mm Table 2 Fuse and cable dimensions for installations of UPS units from 160 to 250 kVA Note that the fuse numbers and the cable letters refer to the numbers letters figure 20 Slow gG gL fuses should be used to protect cables Note Cable size is for indicati
45. e must be incorporated in all fixed input wiring The disconnect device shall have a contact separation of at least 3 mm 4 Check that electrical connections to the installation site have been properly executed Also check fuse or circuit breaker ratings and cable dimensions against tables 2or 3for 160 500 kVA systems 5 The UPS should be connected in accordance with figures 20 and 21 6 If singlefeed installation is required the interconnection cables between the 2 inputs must be provided by the customer 7 Connect input cables and output cables to the UPS Neutral is requested on the bypass input 8 sure that the UPS unit output cable is connected to the load 9 Connect the battery to the UPS power cables to terminals B B Connect C1 C2 n o auxiliary contact to terminals XA5 XA4 and C3 C4 shunt trip to XA1 XA3 If multiple battery cabinets are used connect the power cables in parallel to B B all shunt trip coils in parallel to XA1 XA3 and connect in parallel the auxiliary contacts 10 Also connect any computer and alarm connections according to chapter 6 These connections are in the user interface area behind the right hand door 11 If an external bypass switch will be used contact your dealer first Note If the battery breaker is not equipped with an auxiliary contact monitoring of the switch status can be disabled via Service Software With shielded power cables the 9370 500 complies with th
46. eters is supplied with parallel UPS modules The cable forms a redundant communication interface between successive MPP communication boards of UPS modules The MPP communication boards have parallel terminals X3 and X4 The 6 pin parallel cable must be connected between these two terminals of UPS modules It s recommended that the cabling form a loop configuration to increase redundancy level of pararallel communication Shield connection to PE shall be performed on the X4 side of the connection This way there should be only one shield connection in each unit X3 4 loooooo OO LI OOQ Figure 42 X3 and X4 communication terminals in the MPP communication board See picture 1 for UPS 160 250kVa signal cable fixing see pictures 2 3 4 for UPS 400 500kVA signal cables fixing Picture 1 UPS 160 250kVA Signal cables fixing 60 160 500 UPS 1024754 User s and Installation M anual Revision A Picture 2 UPS 400 500 kVA Signal cables fixing 1024754 160 kVA 500 UPS 61 RevisionA User s and Installation Manual Picture 3 UPS 400 500 kVA TB3 Signal cable fixing 62 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A E 3 X 4 TB3 Picture 4 UPS 400 500 kVA 4 Signal cables fixing 1024754 160 kVA 500 kVA UPS RevisionA User s and Installation Manual 63 If an external system bypass switch MB3 is used an auxiliary contact m
47. g down to Maintenance Bypass Go to System Control menu in LCD display and press Bypass pushbutton to transfer to static bypass mode Verify that the Bypass LED is O lit If the Bypass LED is not lit check the active events to verify the reason and correct the anomalous condition Open the left door of the UPS Close the Maintenance Bypass switch IBY Turn the on off switch 1 to OFF position Turn the switch IUG to OFF position Turn the switches IRP and IRE to OFF position Open the Battery Circuit Breaker in the battery cabinets The UPS stops supplying power The load is supplied through mechanical bypass 1024754 160 kVA 500 kVA UPS 53 RevisionA User s and Installation Manual Shutting down and disconnecting load Open the left door of the UPS Turn the on off switch S1 to OFF position Turn the switch IUG to OFF position Turn the switches IRP and IRE to OFF position Open the Battery Circuit Breaker in the battery cabinets The UPS stops supplying power Note Units equipped with ABM automatically open the ABM contactor to isolate the battery Battery Circuit Breaker must be disconnected to ensure safe operation of the UPS battery terminals 54 160 kVA 500 UPS User s and Installation M anual 1024754 Revision A 8 Installation of an External Maintenance Bypass An External Maintenance Bypass is used to provide a separate bypass line external to the UPS cabinet to supply
48. iD Doo X ze o 9 T N 5 Orn ou 9 9 s A gt z n 594 855 d F m stain O 0 feat 5j 9 x g e e WY U Q he MQ UGG 59 069 1 u NEA WA YE c WG A WW 3 Sem ae ees 1 gt Ve WAC c sg WG Wg Kg x LZ P a 1 i N i g Lon 08 02v 3 2 n 008 Lu Figure 8 Base Plant for 400 500kVA UPS 1024754 Revision A Options The options are used to tailor the solution to the site and load requirements of the installation The following options are available External battery cabinets External bypass isolation transformers 12 Pulse Rectifier without galvanic isolation standard for 400 500kVA UPS 12 Pulse rectifier and XI amp XIII harmonic THD filter External Maintenance Bypass 2 switches External Maintenance Bypass 3 switches External Battery Breakers Remote and multilingual ViewUPS display panel RS 232 communication adapter xslot SNMP Web communication adapter ConnectUPS AS 400 relay adapter xslot Modem board xslot Modbus Jbus communication adapter xslot Top cable entry standard for 400 500kVA UPS Backfeed protection ABM 3 Safety information Since the UPS system operates on line power and contains a bank of high current backup batteries the information in this chapter
49. iate action There are five pushbuttons underneath the LCD display that are used to access the menu structure 1024754 160 kVA 500 kVA UPS 45 RevisionA User s and Installation Manual 7 2 Menu structure The UPS main menu allows you to display data in the information area to help you monitor and control UPS operation The following menus and options are available Events Meters Setup Displays the list of Active Events and a historical log of system events Displays performance meters for the system or critical load Allows one to view contrast date amp time firmware versions system identity and parallel information Configuration of the UPS requires a password The password for changing defaults is USER Returns to Main Menu and displays a real time graphic representation of the power flow through the internal UPS components You can access the above mentioned menus by pressing the function button underneath the respective menu To scroll through the menu selections use or 4 pushbuttons from the display menu Events Active Events History Meters Input U12 U23 U31 Freq Output L N UL1 UL2 UL3 kVA kW PF 11 12 13 Freq L L U12 U23 U31 kVA kW PF 11 12 IL3 Freq Bypass U12 U23 U31 Freq UL1 UL2 UL3 Battery Backup time lt ABM status gt Output load 125 100 75
50. inputs can be activated by connecting the two pins together of the particular terminal These inputs have the following values Generator On Input TB4 1 2 The Generator On input is used for inhibiting the transfer to static bypass line when the UPS is supplied by an unstable ac source The generator auxiliary contact wires are connected on terminal block 4 1 2 see figure 33 In normal operations the terminals 1 and 2 are not connected together When these pins are connected together by floating contacts of the generator control device the logic circuitry in the UPS will prevent the transfer to an unstable power source When the unit is delivered the connection on terminals 1 and 2 will be open Remote Output On Off Input TB4 3 4 The Remote Output On Off input is used to turn off the output of the UPS froma distance Remote Output On Off wires are connected on terminals 3 and 4 see figure 33 The terminals 3 and 4 are not connected together in normal operation When the pins are connected together by floating contact the inverter will be turned off and also the static bypass line will be turned off In order to turn on the inverter and the static bypass line the connection between these pins has to be opened External Bypass Switch Input TB4 5 6 1024754 160 kVA 500 kVA UPS 43 RevisionA User s and Installation Manual If the UPS system is equipped with an external bypass switch its status can be monitored by the UPS via termin
51. isabled not installed Reset all parameters Filter disabled on sig in 1 Filter disabled on sig in 2 Filter disabled on sig in 3 Filter disabled on sig in 4 Filter disabled on sig in 12 Filter disabled on sig in 23 Filter disabled on sig in 34 Filter disabled on sig in 1 3 Filter disabled on sig in 1 4 Filter disabled on sig in 2 4 Filter disabled on sig in 234 Filter disabled on sig in 1 34 Filter disabled on sig in 12 4 Filter disabled on sig in 123 Filter disabled on sig in 1234 Filter Enabled Batteries Show cabinet info Install new cabinet I Remove cabinet Battery capacity 48 Signal Inputs TBA 1 2 Generator On Signal TB4 3 4 Remote Shutdown Signal TB4 5 6 External Bypass Switch Signal TB4 7 8 Environment Alarm 1 8 160 kVA 500 kVA UPS User s and Installation M anual 1024754 Revision A Relays On board 8 System on battery On board TB7 Battery low UPS On Ok UPS on bypass SLOT1 4 Relay K 1 4
52. max 300 ms duration 68 200 kVA 160 kW 250 kVA 200 kW 400 kVA 320 kW 500 kVA 400 kW 220 380 230 400 240 415 50 60 Hz 3 1 computer and server loads 0 6 to 0 95 lagging leading 1 static 5 dynamic 160 kVA 231 200 kVA 289 250 kVA 3 x 361 400 kVA 3 x 578A 500 kVA 3 x 722A Amp phase to neutral inverter 160 kVA 1083 A 200 kVA 1083 A 250 kVA 1083 A 400 kVA 1734A 500 kVA 2166 A Amp phase to phase inverter or limited by the bypass line impedance and fusing 160kVA 626 A 200kVA 626 A 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 4 8 Voltage distortion VHD 4 9 Syncron bypass input 5 Environmental Ambient temperature Altitude Humidity Heat dissipation Cooling air Audible noise 6 DC circuit 6 1 Battery type 6 2 Battery charging 6 3 Nominal battery voltage 1024754 RevisionA 250kVA 626 A 400kVA 1000 5OOKVA 1250A 1 with linear loads 5 with non linear loads 0 5 to 3 Hz with slew rate of changes lt 0 5 Hz per second 0 05 Hz free running 0 to 40 C in normal UPS condition 25 C 60 C in storage condition 15 C to 25 C recommended for batteries Max 1000 min normal UPS condition 5 to 95 RH non condensing UPS 6P 160 kVA 8 96 kW UPS 6P 200 kVA 11 2 kW UPS 6P 250 kVA 14kW UPS 12P 160 kVA 10 24 kW UPS 12P 200 kVA 12 8 kW UPS 12P 250 kVA 16 kW UPS 400 kVA 24 kw UP
53. mputer systems and other intelligent devices such as measurement instruments and industrial automation applications It conditions the raw mains and supplies continuous clean three phase power to the critical systems While feeding the load the UPS also keeps the battery constantly charged If utility power fails the UPS will continue to supply clean power without any interruption at the UPS output If the power failure outlasts the backup time the UPS will shut down in order to prevent a total discharge of the battery When the line voltage is restored the UPS will start up again automatically providing power to the critical load and charging the battery bank 1024754 160 kVA 500 kVA UPS 7 Revision A User s and Installation M anual UPS block diagram An UPS module consists of several blocks each having its own functions Transients in the input and load are reduced by filters AC power is rectified and regulated in the rectifier which provides the power to the inverter and charges the batteries The rectifier keeps the battery fully charged The battery provides power to the load during a mains failure The inverter converts the DC power back to AC power which is delivered to the load The static bypass switch transfers automaticly the load to the bypass line when the inverter is overloaded or the inverter is not able to feed the load Maintenance bypass switch is used to bypass the single UPS during service
54. n it is discharged or charged There is very little that can be done for discharging because it depends on the number of power outages in the utility line However charging can be controlled and initiated on the following occasions When turning the unit on using the on off switch After 18 days without charging If the open cell voltage decreases below predetermined voltage level Traditional UPS charge batteries continuously This means that there is current flowing through batteries all the time and this causes corrosion a traditional on line UPS the inverter also causes ripple current to be fed to the batteries causing corrosion Hot Sync for parallel UPS systems A parallel UPS system means the linking together of two or more UPS units in parallel so that in the unlikely event one fails the others can automatically take up the load Traditionally a parallel redundant configuration uses a common paralleling logic circuit in the system This logic circuit provides individual commands to all the different units Unfortunately this can lead to a single point of failure for the whole system because if the logic system fails the whole UPS system will malfunction That is why Hot Sync technology was developed An industry leading paralleling technology in its own right the patented Hot Sync enables you to set up a parallel redundant system giving you 100 conditioned power at all times Its unique digital design eliminates the s
55. ndancy mode it is possible to shut down a single UPS module for service In the capacity mode the external system bypass switch MB3 must be first used to transfer the system load to external bypass power The redundant UPS module of the parallel UPS system can be switched off in the following manner if no critical UPS alarms are present 1 Check that all UPS modules in the operational condition and open front door of the selected UPS module Main switch S1 switches IRP and IRE and the battery breaker in the battery cubicle are in ON position 2 Check from control panel that the parallel UPS system is in the N 1 redundancy mode Note The external system bypass switch MB3 must be used for transfer operation if the system has capacity mode and load exceeds N 1 redundancy level Hence the load must be disconnected if the parallel UPS system does not contain the system bypass switch 3 Turn the S1 switch to OFF position Turn the main input switches IRP amp IRE and the battery circuit breaker to OFF position The selected UPS module has now stopped to supply output power 5 Turnthe appropriate output breaker IUG to OFF position This prevents high voltage to be present inside the disconnected UPS module AN WARNING Even though the input and output switches are open there is still a dangerous voltage inside the unit on all the parts upstream the input switches and downstream the output switches
56. nt The load is continuosly monitored with filter disconnection if load is lt 25 and overcurrent protection 22 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A POWER SUPPLY IRE S1 MPC USER INTERFACE XSLUTs BOARD 4 11 4 12 4 13 o o o B E Si gi lag o o C o al o o o o o o o o o o o 2 1 o o o o Sp 5 11 5 12 5 13 o fo fo o o o o o o o o o ELI 13 Figure 14 UPS 400 500 std location of electrical components 1024754 RevisionA 160 kVA 500 kVA UPS User s and Installation Manual 23 POWER 51
57. ntilation of the battery room according to the standard 62040 1 1 to prevent the risk of an explosion PIANO TIER D s Cl Beg um N XC IB _ D Mingarria B B PIANI LAA E TIER 3D 77 nml 30 T 6 SGANCIO 24Vcc 362000 24 g X03 TRIP COIL PAV 4D XC FIG 31 BCPWD 400 amp BCPWD 630 2X32 12V bottom cable entry electrical connections PIANI PIAN eR 4S TIER 4 XC 45 Cal XC IB s_ B B PIAN I PIANO st Il 38 ee E 3 30 37 a d ma uu poet BOBINA DI PIANI SGANCIO 24Vcc 5 3 TRIP COIL 24Voc XC 4 FIG 32 BCPWD 400 amp BCPWD 630 2X32 12V top cable entry electrical connections 40 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 6 Computer and alarm connections An interface for direct communication with your computer system is supplied in the UPS unit The interface consists of RS232 serial data interface four optional X slots four potential free relays and four programmable inputs for building alarms These interfaces are located behind the right hand door MPC PCB RS232 18 TB9 SLOT 1 EPO TB8 SLOT2 COMMON NO NC
58. on M anual Revision A 9 2 Selecting redundancy or capacity mode A parallel system is parameter selectable between N 1 redundancy and capacity modes The parameters are displayed in the LCD control panel Factory default is the parallel system for N 1 redundancy where user gets an alarm if the 1 redundancy level is exceeded in the load 9 3 Installation requirements The system is designed with all vital parts accessible from front Power cable entries are from bottom or top optional Separately from the power cabling signal cable routing can be done from the top or bottom depending on installation Power cables Allinput cables bypass cables output cables and system bypass cables of the parallel UPS system must be dimensioned according to local regulations 1 The cable must be able to carry the nominal current Pay attention to proper dimensioning of neutral N according to the load type 2 The cable must be rated for at least 70 C maximum operating temperature and copper cables should be used to fit terminals 3 Thecable must fulfil the requirements of the short circuit and overcurrent protection level with the correct fuse size Note The total length of UPS bypass and output cables must be inside 10 tolerances and the same type Due to the same cabling impedance the equal cables mean equal load sharing for the static bypass mode Negligence of the instructions may cause the parallel UPS system to lock in the byp
59. on only The cross section including the PE cable will depend on insulation temperature rating cable lenght and local regulations Please note that the battery cables delivered with the external battery cabinets are to install the external battery cabinet to the right side of the UPS 1024754 RevisionA 160 kVA 500 kVA UPS 31 User s and Installation Manual L3 A N 117 0 n dg l bod o LL Ld a IBY il IRP 3Ph Transformer ERES mir Ad 1 ABM Optional 2 HRE is an on load isolator or backfeed contactor as an option Figure 21 Interconnection of 12 Pulse UPS Power Fuse 1 Fuse 2 Cable A Cable B Cable N Cable C Cable D 160kVA 400 400 3 2 95 mm 3 2 95 1 2 95 mm 3 2 95 2 2 120 200 400 400 3 2 120 mm 3 2 120 1 2 120 mm 3 2 120 mm 2x2x185 mm 250 630A 630A 3 2 150 mm 3x2x150 1x2x185 mm 3x2x150 mm 2x2x120 mm 400 kVA _ 800A 800A 3 2 300 mm 3 2 240 1x3x240 mm 3x2x240 mm 2x3x240 mm 500 kVA 1000 1000 3 3 240 mm 3 3 185 1 4 185 mm 3 3 185 mm 2x3x300 mm Table 3 Fuse and cable dimensions for five wire installations of UPS units from 160 to 500 kVA Note that the fuse numbers and the cable letters refer to the numbers letters in figure 21 Slow gG
60. onnect protective earth before power supply cables N Earth leakage protection this device has a high leakage current to protectition earth The maximum earth leakage current is 300 mA When setting the threshold of the earth leakage circuit breaker installed upstream from this equipment consider this amount of current and that due to the loads AN An earth fault protection device must be installed upstream the UPS in accordance to all applicable local regulation 1024754 160 kVA 500 kVA UPS 5 Revision A User s and Installation M anual N All primary power switches installed downstream of the UPS must be labelled as follows Isolate UPS Uninterruptible Power Supply before working on this circuit All primary power isolators installed remote from UPS require the fitting of a waring label Isolate UPS Uninterruptible Power Supply before working on this circuit if the automatic beckfeed isolator is not installed AN The unit is provided with an E P O Emergency Power Off function This function is activated by opening the contact at pins 1 2 of terminal TB9 This function provides UPS disconnection from the load and from the battery if a shunt trip is installed in all the battery cabinets connected to the UPS and they are connected to terminals XA1 XA3 of the UPS Dangerous voltages will still be present inside the unit unless a shunt trip for the input supply and external battery breakers is provided The EPO condi
61. r Main switch S1 input switches IRP amp IRE and the battery breaker are in OFF position 2 Checkthatthe system bypass switch MB3 is in the BYPASS position and the IUG switches of all the systems in the ON position Note Battery start of parallel UPS modules must be made in the UPS position of system bypass switch MB3 3 Startall UPS modules within 30 sec to prevent start of a single module with overload Turn on the input switches IRP amp IRE to ON position Start the UPS modules by turning switch S1 to the ON position Check that the yellow bypass LED is lit this verifies that auxiliary contact signal from the external system bypass switch MB3 is OK Check that the inverter is running Close the battery breaker in the battery cubicle Repeat for all the units 64 160 kVA 500 kVA UPS 1024754 User s and Installation M anual Revision A 4 Transfer the critical load to the parallel UPS system by turning the external system bypass switch to UPS position 5 Check from LCD display of UPS modules that the parallel system is running on inverter power instead of static bypass Hence the critical load should be now supplied by the parallel UPS system 9 5 System Shutdown The UPS system does not have to be shut down at the end of each day The system is designed to cope with a continuous load from the day it is installed until a change is needed in the backup battery bank In the N 1 redu
62. s designed with all vital parts accessible from front All cables and protective fuses must be dimensioned according to local regulations 5 1 Environment All the requirements concerning environment described in this chapter Installation or Technical specifications chapter must be met If they are neglected the manufacturer cannot guarantee the safety of personnel during installation or use or that the unit will function properly When locating the UPS system and the battery options the following points have to be remembered Avoid temperature and humidity extremes maximise the life time of the batteries an ambient temperature of 15 C to 25 C is recommended Provide shelter from the elements especially moisture The UPS can be mounted against the wall No space is required at rear or sides of the UPS Always leave 500 mm free space above the UPS Always leave enough space in front of the UPS minimum 1 meter for service and maintenance See figure 10 The batteries should preferably be installed next to the UPS The right side is recommended due to the power cable fastening an opening is provided on the right panel of the UPS and on the left panel of the battery cabinet for cabling see External Battery Cabinet Installation chapter
63. st take greatest care and perform only the prescribed operations Any deviation from the instructions could be dangerous to the operator 4 Shipping and handling The UPS equipment is shipped on specifically designed pallets so that it is easy to move with a forklift or pallet jack Do not stack the pallets Because of the sensitive electronics and high energy stored within batteries the UPS and the battery cabinet must be handled with care The UPS and battery cabinet must always be kept in an upright position and must not be dropped Because of the heavy weight of the UPS system proper provision must be made for transportation See technical specifications for dimensions and weights of the UPS If the UPS is not immediately installed the following must be remembered The UPS should be stored in the original packing and shipping carton The recommended storing temperature is between 15 C 25 C The equipment must always be protected from dust moisture and weather If the UPS is stored for a long period of time the batteries of the UPS should be charged for at least 8 hours every 6 months to maintain the battery condition 1024754 160 kVA 500 kVA UPS 15 RevisionA User s and Installation Manual 4 1 Unpacking and incoming inspection Unpack the equipment and remove all the packing materials and shipping cartons The equipment must be inspected for damage after shipment If damage has occurred during transit all
64. table In this case the UPS will be in battery mode supplying power from the batteries or in the static bypass mode if the bypass line voltage and frequency are acceptable During battery start up the UPS will not transfer to normal mode if the bypass is within limits The UPS will transfer to normal mode when the rectifier input voltage returns within limits or bypass voltage is no longer acceptable During battery start up UPS will charge the DC link capacitors from batteries and this causes longer start up time Starting up the UPS load energized bypass switch IBY is closed and voltage is present in the output terminals see figure 8a Open the left door of the UPS Check that On Off switch 51 is in OFF position Check that the Maintenance Bypass Switch IBY is closed Turn the switches IRP and IRE to ON position Start the UPS by turning the switch 54 to ON position The UPS will now check its internal functions The UPS starts after 10 15 s Check that the yellow bypass LED is lit Close IUG switch Check that there are active alarms that require immediate action Open Maintenance Bypass Switch IBY Check that inverter is running and close the external battery circuit breaker Close the left door of UPS Note Do not close the Battery Circut Breaker until the inverter is running Starting up the UPS load de energized Bypass Switch IBY is open and voltage is not present in the output terminals see
65. terconnect the blocks in series block 1 negative pole gt block 2 positive pole according to the diagram on next page BCPWS 12V Bottom Cable Entry BCPWS 12V Top Cable Entry M Y 1 N N 177 N TX if N N f AM i l LL 2 Figure 24 BCPWS 1 32 400 12V Battery layout bottom amp top cable entry 1024754 160 kVA 500 kVA UPS 35 RevisionA User s and Installation Manual N WARNING after assembly there is a voltage of 96V on each level Insert the trays and fix them with the screws Connect the battery blocks of the various levels to IB and connect IB to the relevant UPS terminals as shown in figure 25 Ensure appropriate ventilation of the battery room according to the standard 62040 1 1 to prevent the risk of
66. tion is reset if the contact is closed after having opened for this reason use a contact that latches in the open position and that can be reset only intentionally AN During electrolysis batteries release hydrogen gas There is a risk of an explosion if the amount of hydrogen in the battery room becomes too high Ensure appropriate ventilation of the battery room according to the standard 62040 1 1 to prevent the risk of an explosion N Install the UPS in a temperature and humidity controlled indoor environment Ambient temperature must not exceed 40 C and relative humidity 95 These UPSs are products for restricted sales distribution to informed partners Installation restrictions or additional measures may be needed to prevent disturbances 6 160 kVA 500 KVA UPS 1024754 User s and Installation M anual Revision A 2 Introduction This User s manual gives basic information about 160 500 kVA uninterruptible power supplies their basic function their features how to use them and what to do in case of trouble Instructions for shipping storing handling and installing the equipment are also given The planning guidelines of this manual describe only the specific demands of UPS units Local legislation and regulations for electrical installations must be followed in the UPS installation This manual is mainly intended for the chief operator system supervisor electrical consultants and installation electricians The UPS s
67. to be used with a computer connection or a modem connection See below the meaning of the pins The RS232 must not be galvanically connected to any mains connected circuits Reinforced insulation to the mains is required The baud rate can be configured for 1200 2400 9600 19200 bps from the LCD display For appropriate baud setting refer to software manuals The serial port has the following format e Data bits 8 e Parity None e Stop bits 1 e Handshake None Direction from the UPS Description Received data Transmitted data 5 GND Signal ground 9 sf Power source 8 to 12 volts DC Table 5 RS232 connection 18 for the computer 9 pin female D sub 6 2 Potential free relay outputs TB5 TB8 This relay interface consists of four potential free relays providing complete isolation between the UPS and the computer The Relay 1 and Relay 2 are not used at the moment The function for Relay 3 is System on battery The function for Relay 4 is UPS on ok In figure 34 the relay is shown as de energized 3 INC 2 1 Figure 34 Programable output relay configuration All potential free contacts Note The relay contacts are rated for maximum 8 A 240 Vac or 5A 30 Vdc resistive load All relay outputs are galvanically isolated from the other circuits of the UPS IEC 60950 EN 620401 1 The relay contacts must not be galvanically connected to any mains connecte
68. tput Flat copper bar 80x40 5mm Bolt M12 Neutral Bolt M12 Ground Flat copper bar 50 8mm Bolt M12 Battery Input Flat copper bar 50 8mm Bolt M12 Cable Entry Terminal for 400 500kVA UPS Rectifier input Flat copper bar 255x80 6mm Bolt M12 Bypass input Flat copper bar 255x80 6mm Bolt M12 Neutral Bolt M12 UPS Output Flat copper bar 400x80 6mm Bolt M12 Ground Flat copper bar 100x80 6mm Bolt M12 Battery Input Flat copper bar 40 8mm x2 Bolt M12 1024754 160 kVA 500 kVA UPS 25 Revision A User s and Installation M anual
69. ust be provided to each individual UPS module It s connected to the TB4 BUILDING ALARM 3 terminal and between pins 5 and 6 TB4 19 20 BUILDING ALARM 1 BUILDING ALARM 2 BUILDING ALARM 3 BUILDING ALARM 4 Figure 43 TB4 signal terminal of UPS modules Note Pay attention to the signal polarity because the signal must be the same for all UPS modules Negligence of the instructions may cause a high inrush currents to bypass line UPS output and cause a load dump Moreover it in under no circumstances allowed to operate the UPS internal mechanical bypass switch The handle must be removed if it is fitted to the UPS modules For proper transfer the auxiliary contact must close before the main power contacts when switching from UPS position to BYPASS position The auxiliary contact from the bypass switch should be with minimum of 10 ms leading operation The common system bypass signal initiates parallel UPS modules to gate static switch regardless of internal bypass condition or inverter synchronization 9 4 System Startup Check that the power and control wiring has been done correctly before starting up any UPS modules There should be voltage in both rectifier and internal bypass input Make sure that ground connections have been done The parallel UPS system 1 to N should be started in the orderly manner 1 Checkthatthe UPS modules are in the start up condition and open front doo
70. ystem level single point of failure inherent in traditional parallel UPS modules and exponentially increases the reliability of the overall system Hot Sync allows two or more UPS units to cover the same load in parallel and or redundant configuration by working in complete synchronization No common logic is needed in this patented design It provides automatic load sharing and module level redundancy with nothing other than the power connecting the Hot Sync UPS modules 1024754 160 kVA 500 kVA UPS 9 RevisionA User s and Installation Manual 2 3 UPS configurations The UPS system consists of the UPS device itself and the external backup battery In addition several options may be included in the system UPS 160 250kVA 6 pulse UPS 160 250kVA 12 Pulse UPS 400 500kVA
71. ystem must be installed according to the instructions in this manual Fixed installation may be performed by qualified personnel only Failure to recognise the electrical hazards could prove fatal 2 L System description A UPS Uninterruptible Power Supply protects different types of sensitive electrical equipment computers workstations sales terminals critical instrumentation telecommunications systems process control systems etc The UPS protects them from problems associated with utility power of poor quality or a complete loss of power Sensitive electrical equipment needs protection from electrical interference Interference from outside the facility such as lightning power company accidents and radio transmissions and interference from inside the facility from motors air conditioners vending machines and arc welders for example can create problems in the AC power line for the sensitive equipment The problems can be power outage low or high voltage slow voltage fluctuation frequency variations differential and common mode noise transients etc The UPS cleans the utility AC power maintains a constant voltage and if needed isolates the output to the critical load These actions help to keep power line problems from reaching the critical system where they can damage software and hardware and cause the equipment to operate erratically 2 2 UPS features This UPS is a double conversion on line UPS for protection of co
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