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Powerware 2500 Power Supply User Manual

1. of the UPS CONTROL E a PANEL I d c lO Old ce 2 e O Ode E20 5 o e O o q ez 9 loLO Ojo Ez MONITOR o Sd o SH H o QD 4 e O 0 d Ez a fe DELLELIIICENPE MT gt L000 l dDec edp k VPE rr n M y d d j ei sosi i I FIY teree 9 dr f 1 Id za S d 4 I zm Uu 6 FF e i m Jan E ee a O 5 o O Times le Td ice Li le o n iR mim j Le TA e p e Jr ais eee 4 E EE LIES sU L INC ael NN s CRUE U o 9 oo gt aad o Q ai XE i i XL dd pes Figure 22 Location of the Monitor Panel and the Control Panel T
2. 9 UPS CABINET Cutaway View of Communication Panel shown on sheet 1 NOTE Connections shown are external connections to the UPS system Connections between the DRAWING NO UPS cabinet and Environmental cabinet are ENVIRONMENTAL CABINET EXTERNAL WIRING DESCRIPTION CB2 Power Switch S1 Cold Start Switch S2 LOCATION OF UPS POWER TERMINALS 164201261 4 SHEET 10f2 REVISION p DATE 011001 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 DC Input to UPS E4 E5 Connect cables 205 and 206 Port 1 DB 9 RS 232 485 J3 Communication Panel Port 2 DB 25 RS 232 J4 Optional sh
3. TOP VIEW I CABLE ENTRY pe n z h UNINTERRUPTIBLE o POWER SYSTEM f o Q0 a A Sao cect fol el Ee Fae U FRONT VIEW E e h i L es o o p o 9 dE dh BOT d Figure 4 UPS and Environmental Cabinets Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 13 164201261 Rev F 111503 WARNING Installation should be performed by qualified personnel Note the following important information while installing the UPS Dimensions in this manual are provided in millimeters and inches Do not tilt the UPS or other cabinets more than x 10 during installation Cooling exhaust airflow is approximately 614 0 L S 1300 CFM The conduit landing plate is to be removed to add conduit landing holes as required Plate material is 16 gauge steel 0 06 in thick Terminals E9 through E15 and E19 E35 are UL and CSA rated at 90 C A hex key tool is required to attach wires to the terminals Details about control wiring are provided in each procedure for connecting options and features Table L in Appendix A identifies the control wiring terminations Installing the UPS Cabinet Sections Move the UPS and Environmental cabinet
4. EXHAUST AIR OUTLET s CABLE ENTRY Q FRONT VIEW UNINTERRUPTIBLE POWER SYSTEM 800 32 DOOR SWING TYP BOTTOM VIEW DESCRIPTION UPS CABINET DRAWING NO Dimensions are in millimeters inches 164201261 5 SHEET 1of1 REVISION A DATE 053099 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Knockout pattern typ 5 sides O UNINTERRUPT BLE POW EMERG OFF 9 ER SYSTEM EMERGENCY OFF TO UPS TO OTHER Dimensions are in millimeters inches EQUIPMENT DESCRIPTION 95 3 3 75 SQUARE REMOTE EMERGENCY POWER OFF DRAWING NO 164201261 6 SHEET 1 of 1 REVISION DATE 953099 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503
5. GS CONDUIT AND WIRING SUPPLIED BY 4 WIRES MUST CUSTOMER MAX DISTANCE BETWEEN BE TWISTED REMOTE MONITOR AND UPS NOT TO 14 18 gauge iz ep Loy Es cote ed Vis 2a Lob le Thy ee ee TO ul 5 9 IP ee es ek ie Sek ae Ty See KNOCKOUTS PROVIDED ON FIVE SURFACES MAX WIRE SIZE NO 14 AWG MIN WIRE SIZE NO 18 AWG FLUSH MOUNT gt SURFACE MOUNT FOR HANGING mo NE EXCEED 500 FEET Dimensions are in millimeters inches DESCRIPTION REMOTE MONITOR PANEL DRAWING NO 164201261 7 SHEET 1 of 1 REVISION A DATE 053099 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 FLUSH MOUNT SURFACE MOUNT FOR HANGING tyr dd gf O EXISTING INTERNAL WIRING SUPPLIED BY CUSTOMER Maximum distance between RIM and UPS not to exceed 500 feet Wires must be twisted MAX WIRE SIZE NO 14 AWG MIN WIRE SIZE NO 18 AWG Dimensions a
6. BYPASS INPUT MAINTENANCE MAINTENANCE RECTIFIER BREAKER BIB BYPASS ISOLATION INPUT BREAKER BREAKER MBP SWITCH MIS CB BATTERY BREAKER CB2 T CONTROL ls lel PANEL g 4 e O Ola E8 8 o o jae E20 g 2 o O Ola Eza o m e O O g Ex 2 9 MONITOR 4 ANEL A peog L POWER SWITCH S1 COLD START SWITCH S2 Hh P Dod eo o Us ea o o Eg 9 XL XL XEM XE Figure 33 Location of the Operating Controls Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 63 164201261 Rev F 111503 Using the Operating Controls Although the operating controls appear easy to use you should read these instructions and thoroughly understand how the controls work before attempting to use them Refer to oneline drawing 164201261 3 in Appendix A to clarify control functions Refer to Chapter 9 Using the Monitor Panel for instructions on using the monitor panel CAUTION Incorrect use of the power controls can cause a loss of power to your critical load The following paragraphs describe the switches on the Control Panel see Figure 34 The MODE switch is a two position rotary switch that controls the manual transfer of the UPS to and from Bypass mode The MODE switch is used to Place the critical load in Bypass mode when the UPS is operating in Normal mode and the bypass source is within acceptable limits If the transfer does not occur wi
7. Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Table B OUTPUT Ratings amp External Wiring Requirements for Powerware BPIII HE 50 75 kVA 208 and 480 Volt Rags f Unis Rating 60 Hz 0 8 lagging PF load KW 40 50 60 FE e m m i m o gt AC Output to Critical Load Full Load Current3 Amps Nom 139 175 75 208 0 1 Neutral 1 gnd Minimum conductor size AWG or 3 0 4 350 2 350 1 number per kcmil ea 1 1 1 1 1 1 7 The output of the UPS is a separately derived source Output neutral is bonded to equipment ground through the main bonding jumper Refer to NEC Article 250 and local codes for proper grounding practices 4AcvHCO o External overcurrent protection is not provided by this product but is required by codes Refer to Table A through C for wiring requirements If external overcurrent protection or an output lockable disconnect is required it is to be supplied by designated personnel Non linear loads can create neutral currents that are greater than 100 This product can accommodate double sized neutral terminations if needed DESCRIPTION NOTE Callout letter O O 9 ana INS TABEATION NOTES map to drawing 164201261 3 DRAWING NO 164201261 1 SHEET 2 of 11 REVISION c DATE 111503 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 Tab
8. STATIC L SWITCH A BYPASS CONTACTOR 250AF 250AT wee CRITICAL LOAD 4 WIRE A B C ROTATION BYPASS AUTO TRANSF ORMER REMOTE EPO COMMUNICATION PANEL Q ec MONITORING INVERTER FAIL RECTIFIER OK RECTIFIER FAIL ON INVERTER ON BYPASS GENERATOR INTERFACE INVERTER OK AC BYPASS INPUT 4 WIRE A B C ROTATION LEGEND RECTIFIER CHARGER INPUT BREAKER BATTERY BREAKER BYPASS INPUT BREAKER MAINTENANCE ISOLATION BREAKER MAINTENANCE BYPASS BREAKER UPS SYSTEM WITH 480 208 VOLT INPUT OUTPUT DESCRIPTION ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO 164201261 3 SHEET 2 of 4 REVISION 053099 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 RECTIFIER INVERTER OUTPUT CONTACTOR ENVIROMENTAL CABINET AC INPUT RECTIF IER 5 1 f Ls INPUT ISOLATION fYYYMC INPUT FILTER TRANSFORMER E E33 34 35 3 WIRE A B C ROTATION DC DC CONVERTER IC OUTPUT FILTER ooa PUT E25 26 27 e BATTERY INPUT OUTPUT AC OUTPUT STATIC L A SWITCH BYPASS CONTACTOR 250AF 250AT wee CRITICAL LOAD 4 WIRE A B C ROTATION TRANSF ORMER REMOTE EPO
9. INVERTER DC DC CONVERTER IC OUTPUT zl CONTACTOR Goa OUTPUT FILTER E25 26 27 S BATTERY INPUT OUTPUT AC OUTPUT X STATIC L A SWITCH BYPASS CONTACTOR 1SOAF 150AT wee CRITICAL LOAD 4 WIRE A B C ROTATION COMMUNICATION PANEL REMOTE EPO LR MONITORING ON INVERTER ON BYPASS GENERATOR INTERFACE INVERTER FAIL INVERTER OK RECTIFIER FAIL RECTIFIER OK AC BYPASS INPUT 4 WIRE A B C ROTATION LEGEND RECTIFIER CHARGER INPUT BREAKER BATTERY BREAKER BYPASS NPUT BREAKER MAINTENANCE ISOLATION BREAKER MAINTENANCE BYPASS BREAKER UPS SYSTEM WITH 480 480 OR 400 400 VOLT INPUT OUTPUT DESCRIPTION ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO 164201261 3 SHEET 1 of 4 REVISION DATE 953099 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 RECTIFIER INVERTER OUTPUT CONTACTOR ENVIROMENTAL CABINET E33334 39 AC INPUT RECTIF IER INPUT ISOLATION INPUT FILTER TRANSFORMER CB2 FUN 3 WIRE A B C ROTATION DC DC CONVERTER iC OUTPUT FILTER ooa Oo O 800AF 800AT E25 96 27 BATTERY INPUT OUTPUT AC OUTPUT
10. AUPS alarm or notice occurs that is programmed to cause a Call Out The UPS takes the modem off the hook and sends a command to the modem to call the notification groups phone numbers required The command sent to the modem for group one is ATDTSO and ATDTS1 for group two This allows the user to program the phone numbers into the modem Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 105 164201261 Rev F 111503 The UPS logs a successful notify to the event log when the remote computer or modem answers and leaves an event message with the following format nnn space mmm LF CR where nnn The telephone number of the UPS 20 characters maximum space ASCII space character 0x20 mmm Event message for notice or alarm 40 characters maximum lt LF gt ASCII line feed character 0x0A lt CR gt ASCII carriage return character Ox0D If calling a pager service and the service answers the UPS delays momentarily and then dials the pager number Refer to the Configuring the Modem to Call a Numeric Pager section of this chapter for more information on configuring a modem to dial a pager NOTE Because the pager service is not a modem the UPS does not know if its message got through therefore the UPS continues to call the pager service for a programmed number of times or until a call in reset is performed An unsuccessful notify event is logged into the UPS eve
11. COMMUNICATION PANEL Q ON INVERTER ON BYPASS MONITORING GENERATOR INTERFACE INVERTER OK INVERTER FAIL RECTIFIER OK RECTIFIER FAIL AC BYPASS INPUT 4 WIRE A B C ROTATION LEGEND RECTIFIER CHARGER INPUT BREAKER BATTERY BREAKER BYPASS INPUT BREAKER MAINTENANCE ISOLATION BREAKER MAINTENANCE BYPASS BREAKER UPS SYSTEM WITH 208 208 VOLT INPUT OUTPUT DESCRIPTION ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO 164201261 3 SHEET 3of4 REVISION DATE 953099 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 ENVIROMENTAL CABINET d 3 WIRE A B C ROTATION Lerta INPUT ISOLATION TRANSFORMER cl P E33 34 al AC INPUT RECTIFIER fYYYMC INPUT FILTER RECTIFIER 24 BATTERY INPUT OUTPUT DC DC INVERTER CONVERTER IC OUTPUT FILTER OUTPUT CONTACTOR GAIT OUTPUT E295 26 27 NE AC OUTPUT CRITICAL LOAD 4 WIRE A B C ROTATION SWITCH T CONTACTOR 3 1 EAS BYPASS AUTO TRANSF ORMER 250AF A STATIC BYPASS 250AT weP 1 AC BYPASS INPUT l 4 WIRE A B C ROTATION COMMUNICATION PANEL Q Qo Qo ON INVERTER REMOTE EPO ON BYPASS MONITORING LEGEND GENERATO
12. Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 vii Figure 25 System Meters Screen Typical for Powerware BPIII HE 75 480 480V Unit 55 Figure 26 Load Amps Meters Screen 00 0c eee eee eee 56 Figure 27 Event History Log Screen 06 ee eee eee eee 57 Figure 28 Active System Events Screen 0 cece eee eee 58 Figure 29 Unit Statistics Screen cee eee 59 Figure 30 Mimic Screen iiio no it ek avi ee eet eee beeen es 60 Figure 31 Time Setup Screen sese 61 Figure 32 Port Setup Screen sess Eu ER eser epus dea 62 Figure 33 Location of the Operating Controls sse 63 Figure 34 UPS Control Panel 0 eee eee eee ee eee 64 Figure 35 External Connections for Building Alarm Monitoring 71 Figure 36 Summary Alarm Contacts 000 c cece eee eee 72 Figure 37 Remote Monitor Panel 0 c eee eee eee eee 73 Figure 38 Relay Interface Module 2 c cece eee eee ees 74 Figure 39 Supervisory Contact Module 0 ce ee eee ee 76 Figure 40 Location of Communications Ports on the Powerware BPIII HE UPS shown without the Environmental Cabinet 86 Figure 41 Port 1 Pin Assignments 0002 c cece eee eee 87 Figure 42 Port 2 Pin Assignments 000 c ce eee eee ee 88 Figure 43 Setup Serial Port 1 Screen 2 0
13. 1 Connect the modem to the PC through the serial port as described in the modem manufacturer s manual 2 Key in A T then press ENTER 3 Confirm that the modem responds with OK or 0 zero NOTE In steps 4 and 5 the xxxxxxx is the phone number of a remote computer The phone number should include all local line and long distance access numbers needed to dial out This number is limited to 32 characters Placing a T at the beginning of the number informs the modem to use tone dialing For example use 9 if needed for an outside line 1 for long distance Area Code Number or whatever access codes are needed to dial the call directly Add a in the number anywhere that a delay is needed This will cause a one second delay More than one delay may be added to the number for example enter AT amp ZO 1 9 1 Area Code Phone Number 4 To program a group one number key in A T amp Z 0 zero T xxxxxxx then press ENTER 5 To program a group two number key in A T amp Z 1 T L beoooxxx then press ENTER Confirm that the modem responds with OK or 0 zero Key in A T amp W 0 zero then press ENTER Confirm that the modem responds with OK or 0 zero oO N Oo Connect a telephone line to the modem and test the modem by keying in A T D S 0 ze
14. UPS AVAILABLE pins 1 and 12 Contacts are closed when the UPS is offline UPS OFF LINE pins 3 and 13 Contacts are closed when the UPS is operating in Normal mode e UTILITY FAILURE pins 6 and 15 Contacts are closed when Utility Failure is detected BATTERY WEAK pins 5 and 14 Contacts are closed when approximately 2 minutes of battery time is remaining before the critical load is lost Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 75 164201261 Rev F 111503 Supervisory Contact Module An optional Supervisory Contact Module SCM establishes an interface between the UPS manufacturer s equipment and the customer s monitor This interface allows the customer to monitor operational status of the UPS equipment A maximum of two monitoring accessories RMPs RIMs or SCMs can be installed See Table 1 for the number of accessories permitted Figure 39 shows the SCM input connections on TB1 and output connections on TB2 BUNR 24VDC RDX RDX x RETURN O Ok O O O O mwi 4 ljO O EES o o O O o O O O 5O O TB1 1 TB1 2 TB1 3 TB1 6 TB1 7 NINNI N Lo Figure 39 Supervisory Contact Module The SCM provides signals for the following indications SYSTEM NORMAL TB2 1 through TB2
15. Locate the four 7 in jacking bolts and install them in the threaded holes in the front and rear supports Place a floor protector underneath each jacking bolt and screw the bolts down against them The floor protectors will save the floor from being marred by the jacking bolts 3 Loosen but do not remove the hardware holding the foam cushions to the front and rear supports labeled 1 in Figure 3 4 Turn each jacking bolt consecutively two full turns until the foam cushions clear the floor by approximately 3 mm 1 8 in 5 After the foam cushions clear the floor remove the hardware loosened in step 3 Pull the foam cushions out from under the cabinet and discard or recycle them in a responsible manner Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 11 164201261 Rev F 111503 DOOR FOAM SIDE CUSHION FRONT SUPPORT SUPPORT FLOOR PROTECTOR 2 JACKING BOLT 1 Figure 3 Removing Front and Rear Supports WARNING Cabinet may fall Do not loosen hardware attaching the side or front supports to cabinet base Also do not loosen supports from each other The cabinet must be lowered using jacking bolts before supports can be removed 6 Carefully and evenly lower the cabinet by turning each jacking bolt consecutively two full turns maximum until the supports contact the floor and the cabinet is no longer supported by the jacking bolts T
16. COMMUNICATIONS PANEL EE Cc o O z uuuud prese PORT 1 DB 9F RS 232 485 Connection a TE i 5 PORT 2 DB 25F RS 232 Connection Optional Uoo 6 B b Figure 40 Location of Communications Ports on the Powerware BPIII HE UPS shown without the Environmental Cabinet 86 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Connecting Equipment to a Serial Port You can connect a wide variety of terminals printers and computers to each port and configure the UPS as the Data Communication Equipment DCE Set up the remote equipment using the appropriate parameters for the mode you select The following section provides more information about configuration The cables you use for connection depend on the equipment you are connecting to the UPS Cables should be no longer than 16m 50 ft The connectors for Port 1 and Port 2 on the Communications Panel in the UPS are female so the cables should be male Figure 41 shows the pin assignments for Port 1 and Table 2 describes them Figure 42 shows the pin assignments for Port 2 and Table 3 describes them PORT 1 DB 9 um 0 6 NOT USED RS232 TXD 2 7 485 RS232 RXD 3 485 NOT USED o RETURN RETURN 8 Figure 41
17. Powerware a B p I Harsh Environment UPS 50 75 kVA INSTALLATION amp OPERATION MANUAL www powerware com POW ERWARE IMPORTANT SAFETY INSTRUCTIONS Instructions Importantes Concernant La S curit SAVE THESE INSTRUCTIONS Conserver Ces Instructions This manual contains important instructions for your Uninterruptible Power Supply UPS system You should follow these instructions during the installation and maintenance of the UPS options accessories and batteries Cette notice contient des instructions importantes concernant la s curit This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense ii Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Table of Contents Introduction so oco S oda estan ea ban Loeb rete b aba Sese LE a 1 Using This Manual 2 40 223 m LR Re De
18. After the cabinet is resting on the floor remove the jacking bolts and discard or recycle them in a responsible manner 8 Remove the hardware labeled 2 in Figure 3 holding the front rear and side supports to the cabinet base Discard or recycle the hardware and support brackets in a responsible manner 9 Replace the door that was removed in step 1 The cabinet is now ready to be rolled to its final location 10 Repeat steps 1 through 9 for the Environmental cabinet Wiring Requirements For external wiring requirements including the minimum AWGi size of external wiring see Tables A and E of Appendix A The power wiring for this equipment is rated at 90 C 12 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Installing the Harsh Environment UPS System After the UPS system is unpacked and moved to the final installation location the UPS and Environmental Cabinets are ready to be joined Once the cabinets are joined internal and external wiring is installed Figure 4 shows the UPS and Environmental cabinets assembled The top view shows the cable entry plate in the Environmental cabinet
19. The following message appears on the screen Notice OK to Close CB2 Converter In Startup Close battery breaker CB2 When the DC reaches 250 VDC the converter starts The DC walks up to 540 VDC The inverter starts K3 closes All fans and blowers are functional 68 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 12 System is now on line Inverter input supported by battery and will continue until the battery is depleted or commercial input power returns The following messages appear on the screen Status System Normal On Battery Alarm On Battery more than 30 Seconds Notice Bypass AC Under Voltage Bypass is Not Available Input AC Under Voltage 13 Place Power Switch S1 located in the environmental cabinet to the OFF position 14 To return the UPS to NORMAL MODE of operation when commercial power returns close the feeder breaker The UPS can be transferred to bypass and shut down normally To Shut Down the UPS from Cold Start 1 Place Power Switch S1 located in the environmental cabinet to the ON position Place the BATTERY switch in the OFF position Place the MODE switch in the BYPASS position Place Power Switch S1 located in the environmental cabinet to the OFF position Open battery breaker CB2 BON Oo Cc Open input breaker CB1 To Reset the DC to DC Converter 1 Turn BATTERY switch to OFF 2 Wait at least f
20. options Remote Monitor Panel An optional Remote Monitor Panel RMP contains backlit status indicators and a local horn allowing you to monitor the operational status and alarm condition of the UPS from virtually any location within your facility You can install multiple RMPs at remote locations to increase your monitoring capabilities This option is described further in Chapter 11 Using Features and Options Relay Interface Module An optional Relay Interface Module RIM uses relay contact closures to indicate the operating status and alarm condition of the UPS system The module uses a serial interface line and may support up to eight critical loads This option is described further in Chapter 11 Using Features and Options Supervisory Contact Module An optional Supervisory Contact Module SCM establishes an interface between the UPS manufacturer s equipment and the customer s monitor This interface allows the customer to monitor operational status of the UPS equipment This option is described further in Chapter 11 Using Features and Options Modem An optional modem is available for use with the UPS Remote Notification feature described in Chapter 14 Optional Remote Notification Refer to the manual supplied with the modem for modem operating instructions Customer Convenience Outlet An uninterruptible 120 VAC 0 2 amp fuse protected convenience outlet is provided with the optional modem It is located adjacent to
21. Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Data Stop The data size and stop bits of the equipment connected to this port These settings determine the number of bits transmitted per ASCII character The data size and stop bits you specify depend on the configuration of your equipment For Port 1 the data size must be set to 8 with 1 or 2 stop bits Settings of 7 data bits 1 stop bit and 7 data bits 2 stop bits are available for Port 2 NOTE When connecting a computer running a terminal emulation program you should set your equipment to NO PARITY Handshaking This setting controls handshaking You can select XON XOFF or Disabled for this setting Disabled No Handshaking If handshaking is disabled the UPS will transmit and receive data via the serial port ignoring all inputs from handshaking lines XON XOFF If handshaking is enabled the UPS uses special characters XON and XOFF to handshake with the host terminal The XON character is defined to be ASCII value 11 hex and the XOFF character is defined to be ASCII value 13 hex Upon reception of an XOFF command the UPS halts transmission until an XON command is received In the same way if the terminal receives an XOFF command the UPS expects the terminal to halt transmission until the UPS sends an XON command Save Set to YES to save any changes to configuration settings upon exit from the Setup screen Set to NO if you do not want
22. Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 25 164201261 Rev F 111503 DB 9 CONNECTOR ON COMMUNICATIONS PANEL OF THE UPS TB1 TB2 Figure 9 Wiring an RMP to the UPS 4 Connect RMP wiring to the terminal block using terminations shown in Table D Table D RMP Wire Terminations From RMP A Remarks TB1 4 TB1 5 TWISTED WIRES 4 1 2 TURNS PER TB1 6 3 INCHES TB1 7 From RMP B if used Remarks TB1 4 TB1 5 TWISTED WIRES 4 1 2 TURNS PER e 3 INCHES TB1 7 26 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 5 To check the operation of the RMP ensure that the UPS is supplying the load via inverter or bypass If the indicators on the RMP show the appropriate status then it is operating correctly If the communications link between the UPS and the RMP is not present the RMP will self test all indicators flash and the horn beeps at one second intervals If this occurs check all harness connectors and the fuse for proper seating If all connections are secure but the RMP continues to self test replace the fuse with the spare included in the hardware kit If this does not correct the problem contact your local field service office for verification that the RMP is working correctl
23. UPS status A maximum of two monitoring accessories RMPs RIMs or SCMs can be installed Refer to Chapter 4 Table C for the number of accessories permitted See Drawing 164201261 9 in Appendix A for enclosure dimensions side views and knockout patterns SURFACE MOUNT FOR HANGING WIRES MUST BE TWISTED Figure 13 Supervisory Contact Module Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 33 164201261 Rev F 111503 Before installing an RMP be sure you have prepared the UPS according to the instructions in Chapter 2 To install a Supervisory Contact Module 1 Securely mount the SCM 2 Install wiring from the SCM using z in conduit through the 7 8 in knockout in either the top or bottom of the UPS cabinet The top entry connection requires installation of 1 in flexible conduit within the UPS Bottom entry connection requires no additional routing of conduit within the UPS 3 If not already installed locate the RMP adapter cable assembly see Figure 14 in the spare parts kit Mate the DB 9 connector on the back of the terminal block into the DB 9 connector on the Communications Panel of the UPS see Figure 15 Use two screws from the spare parts kit to secure the terminal block bracket to the Communications Panel Connect to Port
24. an alarm sounds Close MIS circuit breaker Caution Failure to close the MIS circuit breaker will result in loss of power to the critical load Open MBP circuit breaker The critical load is now on UPS bypass To transfer the critical load to normal mode follow the procedure To Place the UPS in Normal Mode at the beginning of this section Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 67 164201261 Rev F 111503 To Cold Start the UPS from Battery No AC Input Power To start the UPS system when commercial power is not available perform the following procedure 1 Qu Im ee du 10 11 Ensure the feeder breaker is open no input or bypass power available Place the BATTERY switch in the NORMAL position Place the MODE switch in the NORMAL position Ensure the Emergency Power Off PUSH TO RESET pushbutton is pressed in Close input breaker CB1 Place Power Switch S1 located in the environmental cabinet to the ON position Logic power comes on for all PCBs and Horn sounds every 2 seconds The following UPS messages are displayed on the Monitor Panel LCD screen Status Load Off Alarm Converter Offline Notice Bypass AC Under Voltage Output AC Under Voltage Converter in Shutdown Monitor the LCD meter screen for battery voltage Press and hold Cold Start switch S2 The converter K1 contactor closes after 5 seconds LCD meter screen should indicate 120 to 130 VDC
25. building alarms they display as Building Alarm 1 Building Alarm 2 Building Alarm 3 etc on the LCD screen of the Monitor Panel You should use twisted pair wires for each alarm input and common Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 71 164201261 Rev F 111503 Summary Alarm Contacts Two summary alarm contacts are provided as a standard feature on the UPS The alarm contacts one notice and one alarm are located inside the UPS on the customer interface panel see Figure 36 p 2 23 ALARMNO 10 ALARMNG 11 COMMON 120 NOTICENO 130 NoTIcENC 140 COMMON 150 Me Eos ath eet EE xs Figure 36 Summary Alarm Contacts You can specify that each contact be either normally closed NC or normally open NO Ifthe state of the contact changes from the state you specify as normal an alarm is issued You can connect these contacts to equipment at your facility such as a light or an alarm bell to let you know when an alarm is active on the UPS This feature is useful if the UPS is located in a remote area where the UPS alarm horn may not be heard immediately CAUTION Contacts should not be operated in excess of 30 VAC or 42 4V peak AC or DC 1A maximum Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Remote Monitor Panel As an option you can install Remote Monitor Panels RMPs to moni
26. can hear them opening The breaker CB1 trips and the Emergency Power Off PUSH TO RESET pushbutton on the UPS Control Panel pops out The UPS system shuts down Resetting UPS System after Emergency Power Off CAUTION Do not attempt to restart the system until the cause of the emergency has been identified and cleared The Emergency Power Off PUSH TO RESET pushbutton is a small white button on the UPS Control Panel The PUSH TO RESET pushbutton pops out and the CB1 switch trips when the EMERGENCY POWER OFF pushbutton on the Monitor Panel is activated To reset the UPS system 1 Press the Emergency Power Off PUSH TO RESET pushbutton until it clicks in and remains recessed 2 Move the CB1 switch from the TRIPPED center position to OFF The switch should be difficult to move from the TRIPPED position 3 The UPS system is now reset To restart the UPS system follow the procedure at the beginning of this chapter 70 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 EN EN a BEBE Features and Options Features and Options The many standard features of your UPS provide consistent economical and dependable power protection In addition you can add available options and accessories to enhance the performance of your UPS system This chapter provides detailed descriptions of some of the features and options introduced earlier in this manual Building Alarm Mon
27. defect is within the terms of this warranty the Unit will be repaired or replaced at the option of Powerware with no charge for replacement parts Labor required to make upgrades repairs or replacement installation is not included under the terms of this Limited Warranty except for labor and travel costs required during the first 90 days of this warranty USA only provided that startup of the unit onsite has been performed by Powerware in USA or its agent outside of USA Equipment sold but not manufactured by Powerware and only the manufacturer of such equipment shall warrant this equipment and is not included as part of this warranty agreement Equipment repaired or replaced pursuant to this warranty will be warranted for the remaining portion of the original warranty subject to all the terms thereof This warranty is not valid unless an authorized Powerware Service Engineer in USA or Agent outside USA performs startup and commissioning This warranty does not apply to any Unit that has been subject to neglect accident abuse misuse misapplication incorrect installation or that has been subject to repair or alteration not authorized in writing by Powerware personnel or performed by an authorized Powerware Service Engineer or Agent Purchaser shall be invoiced for and shall pay for all services not expressly provided for by the terms hereof including without limitation site calls involving an inspection that determines no correctiv
28. dial out as well as the pause necessary between dialing the pager service and sending the pager the numeric message This number is limited to 32 characters Placing a T at the beginning of the number informs the modem to use tone dialing For example use 9 if needed for an outside line 1 for long distance Area Code Number or whatever access codes are needed to dial the call directly Add a in the number anywhere that a delay is needed This causes a one second delay More than one delay may be added to the number for example enter AT amp ZO T 9 1 Area Code Phone Number Pauses Numeric Message For areas with pulse dialing the T should be inserted before the numeric message to switch to tone dialing The numeric message can only be delivered using tone dialing Keying in the pound character at the end of the numeric message is very important It prevents the pager service from picking up on the modem hang up commands and sending additional characters To program a group one number key in A T amp Z 0 zero T L xxxxxxx L L Iyyyyyyy then press ENTER To program a group two number key in A T amp Z 1 T L peeooox LJ b1 LI yyyyyyy then press ENTER Confirm that the modem responds with OK or 0 zero Key in A T amp W 0 zero then press ENTER Confirm that the
29. display a listing of all system events that are currently active The most recent system event is listed first As events clear they are removed from the Active System Events listing Figure 28 shows the Active System Events screen Uninterruptible Power System 04 MAY 1998 14 25 50 Alarm On Battery Shutdown Imminent Notice None Battery Active System Events eR NOTICE Input power unavailable NOTICE Bypass Not Available ALARM Shutdown Imminent History Meters Statistics Graphics Setup ny Figure 28 Active System Events Screen 58 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Select Unit from the Statistics menu to display a listing of statistics about UPS operation Figure 29 shows the Unit Statistics screen Uninterruptible Power System UPS System Normal 04 MAY 1998 14 23 50 Alarm None Notice None Battery Start Date 04 MAY 1998 Percent 100 Number of Incidents Month Total Time On DAYS On Battery lt 1 Min On Battery 1 4 Min On Battery gt 4 Min Full Batt Discharge Building Alarm 1 Statistics Building Alarm Building Alarm Building Alarm Building Alarm Building Alarm 0 UPS 0035 Bypass 0000 Battery 0000 Generator 0000 Logic 0035 eo Availability UPS Bypass WWNHWNHNOOF Oo wo00U 10 On oo Meters Events DAZA Graphics Figure 29 Unit Statistics Screen The
30. eee eee eee 89 Figure 44 Event History Log 00c cue eee eee eee 93 Figure 45 System Meters aaneen 94 Figure 46 Battery Test Log 2 6 5 c eee eee ene 95 viii Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Introduction Powerware BPIII online power protection can be utilized to prevent loss of valuable electronic information minimize equipment downtime and or minimize the adverse effect on equipment production due to unexpected power problems The Powerware BPIII Harsh Environment HE Uninterruptible Power Supply UPS system continually monitors incoming electrical power and removes the surges spikes sags and other irregularities that are inherent in commercial utility power Working with the electrical system the UPS supplies clean consistent power that sensitive electronic equipment requires for reliable operation During brownouts blackouts and other power interruptions one or more optional battery cabinets can provide emergency power to safeguard your operation The UPS will function automatically and requires very little attention during normal operation However read and understand the procedures described in this manual to ensure trouble free operation This manual describes how to install and operate the Powerware BPIII HE Uninterruptible Power Supply UPS system It contains instructions for installing and operating both the UPS and Env
31. efficiently for many trouble free years Important Safety Instructions Remember that your UPS is designed to supply power EVEN WHEN DISCONNECTED FROM THE UTILITY POWER The UPS interior is unsafe until the DC power source is disconnected and the electrolytic capacitors are discharged After disconnecting the utility power and the DC power authorized service personnel should wait at least 5 minutes before attempting internal access to the UPS system WARNING LETHAL VOLTAGE PRESENT This unit should not be operated with the cabinet doors open or protective panels removed Do not make any assumptions about the electrical state of any cabinet in the UPS system WARNING Battery maintenance or battery replacement should be performed by authorized service personnel only Keep unauthorized personnel away from battery room Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 117 164201261 Rev F 111503 Performing Preventive Maintenance The UPS requires very little preventive maintenance However the UPS should be inspected periodically to verify that the unit is operating normally Perform the following checks DAILY e Check the area surrounding the UPS and environmental cabinet Ensure the area is not cluttered allowing free access to the unit Ensure the air intakes filters on right side of Environmental Cabinet and exhaust openings on top of the UPS cabinet are not block
32. into the event log When the modem link is confirmed the UPS communications resume normal operation and Call Out is enabled 106 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Hardware Requirements The following hardware components are required to connect the Remote Notification function Modem Basic external PC modem supporting the following AT commands EO Do not echo characters in command state MO Turn speaker off NO Handshake only at speed specified by S37 QO Return result codes in both originate and answer mode VO Display result codes as numbers XO Provide basic result codes CONNECT NO CARRIER and RING amp AO Connect as answering modem when auto answering amp DO Ignore status of DTR signal amp KO Disable local flow control amp Q5 Communicate in error control mode NOTE Consult the modem manufacturer s manual to confirm that the above commands are supported by your modem e Standard serial cable with a male DB25 connector on both ends e DB25 null modem adapter All the above items can be acquired at your local computer products supply store An alternative to purchasing a cable is to build your own serial cable using the following pin out description Male DB25 Male DB25 pin 7 pin 7 pin 2 pin 2 pin 3 pin 2 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 107
33. mode The critical load is supported by the bypass source The Normal indicator is not lit when the system is in Bypass mode This yellow indicator is lit when the system needs attention The LCD screen shows all active notices Some notices may be accompanied by an audible horn To silence the horn press the and I pushbuttons simultaneously The Notice indicator may be lit along with other indicators This red indicator is lit when a situation requires immediate attention The LCD screen shows the highest priority active alarms All alarms are accompanied by an audible horn To silence the horn press the 8 and pushbuttons simultaneously The Alarm indicator may be lit along with other indicators This yellow indicator is lit when electricity is present in the PPU of the UPS and the Normal indicator is not lit During normal startup this indicator illuminates until the UPS transfers to Normal mode at which point the Normal indicator is lit During normal shutdown the Standby indicator is lit until all energy in the UPS is dissipated and shutdown is complete For more information about audible horns refer to the System Event Horns section of Chapter 12 To test the LED lamp status indicators press the and I pushbuttons simultaneously for 3 seconds All the indicators should light while you hold down these pushbuttons If any indicator does not light its LED may need to be replaced Contact Customer Service if you have
34. modem responds with OK or 0 zero Connect a telephone line to the modem and test the modem by keying in A T D S 0 zero then pressing ENTER 10 The modem dials the telephone number stored in step 4 or step 5 The number is displayed on the terminal screen as it is dialed Confirm that the pager receives the message Repeat steps 4 or 5 through 9 as required to modify the telephone number and message NOTE To set up a group one or group two number to call a computer refer to Configuring the Modem to Call a Remote Computer section of this chapter 110 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Configuring the Modem to Answer Incoming Calls To configure the modem to answer incoming calls perform the following procedure NOTE Calling into the UPS does not present any type of security risk There are no commands that can be executed via the call in feature except those available to the Terminal mode 1 Connect the modem to the PC through the serial port as described in the modem manufacturer s manual NOTE The brackets in the following steps indicate characters that require keying in prior to pressing ENTER Key in A T then press ENTER Confirm that the modem responds with OK or 0 zero Key in A T S 0 zero 2 then press ENTER Confirm that the modem responds wit
35. n AVAILABLE 27 1 390 eee 15 16 UPS MEN F we BN o BYPASS PEE 22 IMMINENT Note Supervisory contacts are rated at 2 0 amps at 28 Vdc or 120 Vac and 0 15 amp at 115 Vac Supervisory contacts require external power supply Internal 24 Vdc is not capable of supplying contact current Figure 16 Supervisory Contact Module TB2 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Section II Operation Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 37 This Page Intentionally Left Blank 38 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 BV Understanding UPS Operation Your UPS functions automatically to supply AC electrical power to your critical load The UPS always operates in one of four modes n Normal mode the critical load is supplied by the inverter which derives its power from rectified utility AC power In this mode the rectifier also provides charging current for the battery n Battery mode the battery cabinet provides DC power which maintains inverter operation The battery supports the critical load n Bypass mode the critical load is directly supported by the utility through an isolation transformer n Maintenance Bypass mode the critical load is directly supported by the utility through a Maintenance Bypass
36. power wiring cables 600 to Neutral terminal E12 Refer to Appendix A of this manual for terminal locations and tightening torques Route wiring harness with connectors P20 P22 and P23 from the Environmental cabinet through the cutout in cabinet sides Connect connectors P20 P22 and P23 to connectors J20 J22 and J23 respectively Reinstall UPS Cabinet sheetmetal shield 16 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Installing UPS External Wiring t 3 Install rectifier bypass and battery input power wiring to terminals in the Environmental cabinet Refer to Drawings 164201261 1 and 164201261 4 in Appendix A of this manual for wiring and termination requirements and terminal locations Install the critical load output power wiring to terminals in the Environmental cabinet Refer to Drawings 164201261 1 and 164201261 4 in Appendix A of this manual for wiring and termination requirements and terminal locations Reinstall cabinet doors Preparing the UPS for Installing Optional Accessories If you are installing optional accessories such as a Remot EPO or an RMP you must prepare the UPS cabinet for the installation of these options To prepare the UPS for wiring to an RMP RIM SCM or Remote EPO 1 2 3 Be sure the UPS is turned off and all power sources are removed See the operator s manual for instructions Open the door
37. rectifier The rectifier supplies DC power to the inverter which then supplies the critical load with AC power The rectifier also provides charging power to the battery through a DC to DC voltage converter The battery charge condition is monitored by the UPS and reported by a status indicator on the Monitor Panel The message System Normal appears in the status area of the LCD screen Figure 18 shows the path of electrical power through the UPS system when the UPS is operating in Normal mode Bypass Input BIB closed BYPASS MBP open OUTPUT TRANSFORMER RECTIFIER INVERTER gt IO Output MIS j closed Rectifier Input Input Isolation Transformer closed CB2 4 closed i BATTERY Figure 18 Path of Current Through the UPS in Normal Mode Path of electrical power If the utility AC power is interrupted or is out of specification the UPS automatically switches to Battery mode to support the critical load with no interruption When utility power returns the UPS returns to Normal mode If the UPS system becomes overloaded the UPS switches to Bypass mode The UPS automatically returns to Normal mode when the error condition is cleared and system operation is restored within specified limits If the UPS suffers an internal failure it switches automatically to Bypass mode and remains in that mode until the failure is corrected and the UPS is back in service Powerwa
38. remove filters 1 Loosen captive screw at left side of filter grill 2 Open grill 3 Remove and replace filter 4 Close filter grill and secure with captive screw 118 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Maintenance Training A basic training course available from Powerware gives you a competent working knowledge of UPS operation and teaches you how to perform first level corrective maintenance For more information about training and other services contact the Powerware Training Coordinator in Raleigh North Carolina or call Powerware field service at 1 800 843 9433 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 119 This Page Intentionally Left Blank 120 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 By F Product Product Specifications cations The following sections detail the input output and environmental specifications for the UPS system System Models Notes Powerware BPIII HE 50 50 kVA 40kW 50 Hz 60 Hz models Powerware BPIII HE 62 5 62 5 kVA 50kW 50 Hz 60 Hz models Powerware BPIII HE 75 75 kVA 60kW 60 Hz models System Input Operating Input 208 VAC for operation from 177 VAC to 229 VAC 60 Hz only Voltage 400 VAC for operation from 340 VAC to 440 VAC 50 Hz only 480 VAC for operation from 408 VAC to 528 VAC 60 Hz o
39. the Communications Panel 48 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Safety Considerations The UPS enclosures are designed for industrial or computer room applications and contain safety shields behind the doors However the UPS is a sophisticated power system and should be handled with appropriate care following these guidelines Keep surroundings clean and free from excess moisture Do not operate the UPS close to gas or electric heat sources The system is not intended for outdoor use The UPS operating environment should be maintained within the parameters stated in this manual Keep the UPS doors closed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit The UPS contains its own power source Lethal voltages are present even when the UPS is disconnected from utility power WARNING Only AUTHORIZED SERVICE PERSONNEL should perform service or maintenance on the UPS or battery If service or routine UPS maintenance is required Ensure all power is disconnected before performing installation or service Ensure the area around the UPS system is clean and uncluttered Battery cabinet maintenance or battery replacement should be performed only by authorized service personnel Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment Always conform to the m
40. the unit This factory warranty will not be in effect if the End User does not properly store the equipment including the trickle charge of batteries no later than the date indicated on the packaging before installation and does not cover shipping damages if FOB Factory Cost for replacement equipment installation material freight charges travel expenses and labor of Powerware representatives will be borne by the Purchaser user Any advice furnished the Purchaser before or after delivery in regard to use or application of Powerware equipment is furnished without charge and on the basis that it represents Powerware s best judgment under the circumstances The use of any such advice by the Purchaser is solely and entirely at its own risk Any other agreements such as Service contracts or Sales Concessions are not means to annul this Factory Warranty For comment or questions about this Limited Factory Warranty write to the Customer Quality Representative 3301 Spring Forest Road Raleigh NC 27601 or call 919 872 3020 Powerware BPIII Harsh Environment UPS 50 75 kVA W 1 Installation and Operation 164201261 Rev F 111503 This Page Intentionally Left Blank Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 164201261 Rev F
41. this manual the power required by your equipment is called the critical load The UPS supplies the critical load with conditioned power that is synchronized with your utility power Figure 17 shows the main elements of the UPS DC INPUT AC INPUT TO AC OUTPUT AC INPUT RECTIFIER TO CRITICAL TO BYPASS CHARGER LOAD ISOLATION i TRANSFORMER TRANSFORMER MAINTENANCE ISOLATION SWITCH MIS OUTPUT CONTACTOR RECTIFIER CHARGER MAINTENANCE BYPASS DIGITAL BREAKER MBP METERING STATIC SWITCH BYPASS INPUT BIB BYPASS CONTACTOR UPS CABINET Figure 17 Main Elements of the UPS System If utility power is interrupted or falls outside the parameters specified in the Product Specifications section of Chapter 16 the UPS uses a backup supply to sustain power to the critical load for a specified period of time or until the utility power returns For extended power outages the backup supply allows you to either transfer to an alternative power system such as a generator or shut down your critical load in an orderly manner The operation of the UPS system is described in greater detail in the following paragraphs The Product Specifications section of Chapter 16 outlines the storage and operating specifications for the UPS Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Normal Mode In Normal mode utility AC power is supplied to the
42. to the DC input terminal E5 Refer to Appendix A of this manual for terminal locations and tightening torque Route AC Input Bypass Transformer cables cables 227 228 and 229 from the Environmental cabinet through the cutout in cabinet sides to the Bypass Transformer Input terminals in the UPS cabinet Connect phase A B and C power wiring cables 227 228 and 229 to Bypass Transformer Input terminals E13 E14 and E15 respectively Refer to Appendix A of this manual for terminal locations and tightening torques Route AC Input to UPS Rectifier cables cables 250 251 and 252 from the Environmental cabinet through the cutout in cabinet sides to the UPS Rectifier Input terminals in the UPS cabinet Connect phase A B and C power wiring cables 250 251 and 252 to AC Input to UPS Rectifier Input terminals E1 E2 and E3 respectively Refer to Appendix A of this manual for terminal locations and tightening torques Route AC Output cables cables 237 238 and 239 from the Environmental cabinet through the cutout in cabinet sides to the AC Output terminals in the UPS cabinet Connect phase A B and C power wiring cables 237 238 and 239 to AC Output terminals E9 E10 and E11 respectively Refer to Appendix A of this manual for terminal locations and tightening torques Route two Neutral cables cable 600 from the Environmental cabinet through the cutout in cabinet sides to the Neutral terminal in the UPS cabinet Connect two Neutral
43. used to indicate On Inverter status of UPS 6 ovevWs 7 Contacts used to indicate On Bypass status of UPS BATTERY CONTACTOR CLOSED Contacts used to indicate UPS Battery Contactor is General purpose NO and NC relay contacts General purpose NO and NC relay contacts DESCRIPTION INSTALLATION NOTES DRAWING NO 164201 261 1 SHEET 9 of 1 1 REVISION A DATE 053099 A 10 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Terminal Description Terminal Block 28 Use Class 1 wiring methods as defined by the NEC for control wiring Install the control wiring in separate ferrous conduit from the power wiring The wire should be rated at 24 volts 1 amp minimum Control wiring and conduit to be supplied by designated personnel 29 Refer to Tables L M and N and to applicable chapters for information about installing control wiring for options and accessories Table L Control Wiring Terminations Terminal Function Not available to customer Terminal Block Remote EPO On Inverter Monitoring On Bypass Monitoring Summary Alarm amp Notice Contacts Table M Summary Alarm Relay Contacts CONTACT RATING Maximum Switched Voltage Maximum Carrying Current DESCRIPTION INSTALLATION NOTES PRAMING NO 164201261 1 SHEET 40 of 11 REVISION A DATE 0530
44. 1 DB 9 on Communications Panel Q 2 TERMINAL L BLOCK A TB3 A Q Figure 14 Terminal Block Bracket 34 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 DB 9 CONNECTOR ON COMMUNICATIONS PANEL OF THE UPS TB1 TB2 e pele U E Figure 15 Wiring an SCM to the UPS 4 Connect the SCM wiring to the terminal block using the terminations shown in Table F 5 Contact your local field service office for verification and testing of the SCM and its connections prior to making connections to terminal strip shown in Figure 16 6 Repeat steps 1 through 5 for each SCM you are installing T f you are installing an RMP or RIM in addition to an SCM proceed to Chapter 4 or 5 respectively otherwise secure the UPS cabinet by reversing the steps contained in procedure To Prepare the UPS for Wiring to an RMP RIM SCM or Remote EPO of Chapter 2 Table F Supervisory Contact Module Wire Terminations TWISTED WIRES 4 1 2 TURNS PER 3 INCHES From SCM B if used To UPS TWISTED WIRES 4 1 2 TURNS PER 3 INCHES Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 35 164201261 Rev F 111503 NORMAL 3 EE DUNDANGY u A ON t 8 GENERATOR LIS 10 BYPASS NOT t
45. 115 95min PF 3 0 1 gnd Amps Max Minimum conductor size CA AWG or m i A a s m i number per kcmil ea AC Input to Bypass INPUT Full Load Current VOLTAGE 208 480 208 208 480 208 208 20 3 1 gnd number per O awe or m T 7 A a kcmil ea DC Input from Battery to UPS 1 positive 1 negative VDC 120 120 120 120 120 120 120 120 120 Float VDC 135 135 135 135 185 135 135 135 135 Amps 360 360 360 455 455 455 545 545 545 2 0V cell Minimum conductor size o AWG or e p o rx o P PN P number per pole kcmil ea Read and understand the following notes while planning your installation 1 Refer to national and local electrical codes for acceptable external wiring practices Material and labor for external wiring requirements are to be provided by designated personnel For external wiring requirements including the minimum AWG size of external wiring see the appropriate column in Tables A throuigh C The power wiring for this equipment is rated at 90 C Critical load power to be run in separate conduits busways or cabletrays and sufficiently separated from source power System to be grounded to single point local or utility ground A B C phase rotation required DESCRIPTION INSTALLATION NOTES NOTE Callout letter A O and map to drawing 164201261 3 DRAWING NO 164201261 1 SHEET 4 rat REVISION c DATE 111503
46. 135 VDC based on 60 cells Initialize Charge 150 VDC when inverter DC link set to 572 VAC Battery Charge Current Limited to 3596 of full plus 6 Kw regardless of actual load Limit on inverter Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 123 164201261 Rev F 111503 This Page Intentionally Left Blank 124 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Appendix A Customer Information The information in this appendix will help you plan for and install your UPS system This appendix contains the following drawings e 164201261 1 Installation Notes e 164201261 2 Typical UPS System e 164201261 3 Oneline Drawings of UPS System e 164201261 4 Location of UPS Power Terminals e 164201261 5 UPS Cabinet e 164201261 6 Remote Emergency Power Off e 164201261 7 Remote Monitor Panel e 164201261 8 Relay Interface Module e 164201261 9 Supervisory Contact Module Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 Table A INPUT Ratings amp External Wiring Requirements for Powerware BPIII HE 50 75 kVA 208 480 and 600 Volt Rems J Ums Peing6 Hz Basic unit rating at 20 a 5 d 0 8 lagging PF load INPUT SreEETE AC Input to UPS Rectifier Full Load Amps 180 60 220 90 70 260 110 80 Full Load Batt Chg max Nom 230 100 275 120 96 320 140
47. 1503 Installation Checklist _JAll packing materials and restraints have been removed from each cabinet JEach cabinet in the UPS system is placed in its installed location _JAll cabinets are bolted together _JA ground bond is installed between all cabinets that are bolted together _JAll switchboards conduits and cables are properly routed to the UPS Power cables are terminated on AC Input terminals UPS Cabinet E1 E3 Power cables are terminated on Bypass Transformer input terminals UPS Cabinet E13 E15 Power cables are terminated on AC Output terminals UPS Cabinet E9 E12 Power cables are terminated on DC Input terminals UPS Cabinet E4 E5 Power cables are terminated on bypass terminals E19 E21 Power cables are terminated on the CB1 input breaker E33 E35 Power cables are terminated on output terminals E25 E27 _JA ground conductor is properly installed If N is used no other N G bonds exist downstream from the UPS _ Battery cables and harness are terminated on the CB2 battery breaker E31 and E32 _ The area around the installed UPS system is clean and dust free It is recommended that the UPS be installed on a sealed concrete pad on a sealed concrete floor JAdequate workspace exists around the UPS and other cabinets JAdequate lighting is provided around all UPS equipment _JA 120V service outlet is located within 25 feet o
48. 164201261 Rev F 111503 Configuring the Modem The modem must be configured by the user before connecting to the UPS In addition the modem must be programmed with the Call Out telephone numbers in order to operate the Remote Notification option To configure the modem connect the serial port of a standard PC computer to the modem through the serial cable Run a terminal emulation program on the computer Test the connection to the modem by typing A T and ENTER The modem should respond with either OK or 0 zero If the modem does not respond consult the modem manufacturer s manual to confirm your setup If the modem still does not respond then seek technical assistance from your modem manufacturer After connection perform Basic Modem Configuration and the remaining sections of this chapter Basic Modem Configuration The modem should be a plug and play type All setup is configured by the UPS Only the initial phone number needs to be entered by the user 108 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Configuring the Modem to Call a Remote Computer To configure the modem to call a remote computer perform the following procedure NOTE Perform this procedure only after completing Basic Modem Configuration section of this chapter The brackets in the following steps indicate characters that require keying in prior to pressing ENTER
49. 3 NOREDUNDANCY TB2 4 through TB2 6 ON GENERATOR TB2 7 through TB2 9 BYPASS NOT AVAILABLE TB2 10 through TB2 12 ONBATTERY TB2 18 through TB2 15 UPS ALARM TB2 16 through TB2 18 ONBYPASS TB2 19 through TB2 21 SHUTDOWN IMMINENT TB2 22 through TB2 24 See Chapter 6 Installing a Supervisory Contact Module for TB2 contact configurations 76 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Responding to System Events When the UPS system is running in Normal mode it continually monitors itself and the incoming utility power In Battery or Bypass modes the UPS may issue alarms to let you know exactly what event caused the change from Normal mode System events can be indicated by horns lights on the UPS or both Select Active from the Events menu on the LCD screen to look at the Active System Events screen This screen shows any currently active alarms notices or commands System Event Horns The system event horn beeps according to the type of event it is signifying When the UPS detects an alarm that requires your attention the horn beeps at Ve second intervals When a notice occurs the horn beeps at 2 second intervals e Ifthe battery contactor is open and the Bypass mode is unavailable the horn beeps every 4 seconds System Event Lights The status indicators on the UPS Monitor Panel work in conjunction with the event horn
50. 75 kVA Installation and Operation 51 164201261 Rev F 111503 The Monitor Panel contains 1 A flat liquid crystal display LCD screen 2 A horizontal row of pushbuttons 3 A vertical column of backlit status indicators 4 A red EMERGENCY POWER OFF pushbutton A quick reference label describing how to use the Monitor Panel is located below the Monitor Panel The following sections describe the Monitor Panel in detail Using the LCD Screen The LCD screen at the top of the Monitor Panel provides an operator interface with the UPS Figure 24 identifies the display fields discussed in the following sections Uninterruptible Power System System Normal 04 MAY 1998 14 23 42 Alarm None Notice None Battery Input Output Percent 100 09 VAB VBC VCA FREQ VBC VCA FREQ 480 480 480 60 0 480 480 60 0 IA IB IC IB IC IN 88 88 88 90 90 000 KVA KW PF KVA KW PF 73 69 0 95 75 60 0 80 Meters Load Amps VBC VCA 480 480 Wasa Events Statistics Graphics Setup Figure 24 Parts of the LCD Screen Typical for Powerware BPIII HE 75 480 480V Unit A The UPS status area contains three lines that display the current state of the UPS The first line shows the present operational mode of the UPS The second line shows the highest level of the current active alarms and the third line shows any notices the UPS has posted For more information about alarms and notices refer to Chapter 12 Respondi
51. 99 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 30 The Remote EPO feature opens all breakers and contactors in the UPS cabinet and isolates power from your critical load Local electrical codes may also require tripping upstream protective devices to the UPS Table N Remote EPO REMOTE EPO SWITCH ji TWISTED WIRES 2 Remote EPO switch rating is 24 VDC 1 Amp minimum if supplied by user NOTE This switch must be a dedicated switch not tied into any other circuits DESCRIPTION INSTALLATION NOTES DRAWING NO 164201 261 1 SHEET 1 1 of 1 1 REVISION A DATE 053099 A 12 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 WALLA NSNSSSSSSNSSSS QQ NS WO NN SS S SS SS SS qq hhh SS SSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS SS SS SS LOTR QQ WONKA NN RLM e DESCRIPTION TYPICAL UPS SYSTEM DRAWING NO 164201261 2 SHEET 1 of 1 REVISION DATE 053099 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 ENVIROMENTAL CABINET AC INPUT RECTIF IER i 1 f ee INPUT ISOLATION RECTIFIER f YYYMC INPUT FILTER TRANSFORMER E E33 34 35 3 WIRE A B C ROTATION
52. A hex key tool is required to attach wires to terminals Table D Internal Power Cable Terminations Tightening Bolt or Torque Hex Size of Size Terminal Function Terminal Function Termination ji In AC Input to UPS Phase A 1 bolt mounting 1 4 bolt Rectifier from Phase B 1 bolt mounting 1 4 bolt Environmental Cabinet Phase C 1 bolt mounting 1 4 bolt AC Input to Bypass Phase A 444 500 kcmil i 3 8 Transformer from Phase B 4 500 kcmil 3 8 Environmental Cabinet Phase C 44 500 kcmil 3 8 AC Output to Phase A 446 350 kcmil 3 8 Environmental Phase B 6 350 kcmil 3 8 Cabinet Phase C 4 6 350 kcmil 3 8 Neutral 4 500 kcmil 3 8 Gnd DC Input from Battery 1 bolt mounting 3 8 bolt Environmental Cabinet Battery 1 bolt mounting 3 8 bolt DESCRIPTION INSTALLATION NOTES DRAWNGNO 16420126811 EEA REVISION B DATE 011500 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation A 5 164201261 Rev F 111503 Table E External Power Cable Terminations Tightening Size of Pressure Torque Terminal Function Voltage Terminal Function Termination N M Ib in AC Input to Phase A 2 3 0 250kcmil 42 4 375 UPS CB1 Phase B 2 3 0 250kcmil 42 4 375 Phase C 2 3 0 250kcm
53. ION NOTES DRAWINGNO 464201261 1 SHEET 7 of 11 REVISION p DATE 011500 A 8 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Communications Panel E BLDG ALARM 1 BLDG ALARM 1 RTN BLDG ALARM 2 BLDG ALARM 2 RTN BLDG ALARM 3 LDG ALARM 3 LDG ALARM 4 LDG ALARM 4 LDG ALARM 5 LDG ALARM 5 LDG ALARM 6 LAI LAI LAI LAI LAI LAI DG ALARM 6 TB2 AJOJN o NI oJ ao ila jo oO N Er o mi A EN a REMOTE EPO REMOTE EPO RTN ON INV ON INV RTN ON BYPASS ON BYPASS RTN BATTERY CONTACTOR CLOSED BATTERY CONT RTN A gt RELAY 1 NO RELAY 1 NC ALARM RTN RELAY 2 NO RELAY 2 NC NOTICE RTN RS232 Optional DESCRIPTION NOTE Not all building alarms are available for customer use For remote EPO use an isolated normally open contactor switch 24VDC 20ma minimum connected at TB2 1 and TB2 2 INSTALLATION NOTES DRAWING NO 164201261 1 REVISION c Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 Contacts used to activate remote EPO of UPS icf phe co nog m o0 TI Contacts
54. Module cece ence eee eee 48 Modem p 48 Customer Convenience Outlet sselusssluuessss 48 Safety Considerations 00 cece eee eee 49 Symbols Controls and Indicators 0 ccc cece eee ee 50 9 Using the Monitor Panel cccc eee eee eens 51 Using the LCD Screen ioo RE LER ERI UE E UE et 52 Using the Pushbuttons 4 n br LR ERR EE I Ye ex n 53 Adjusting the Contrast se ors ed eee oe e a ec ees 53 Reading the Status Indicators 0 00 cece eee 54 Using the Menu Options 000 c cee eee eee eee 55 iv Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 10 Operating the UPS eeeeeeeeeee Using the Operating Controls 00 00 ccc cece eens Operation och iot aos edna etae ep Sta ipso vie autas EA To Place the UPS in Normal Mode uuueuususss To Shut Down the UPS from Normal Mode To Start the UPS in Bypass Mode 0 cece eee eee To Transfer the Critical Load to Maintenance Bypass from UPS Bypass istas iE SC dett ds ee Dac dde des To Transfer the Critical Load to UPS Bypass from Maintenance Bypass 0 6 500 To Cold Start the UPS from Battery No AC Input Power To Shut Down the UPS from Cold Start 0 To Reset the DC to DC Converter 0 c eee eee eee Using the EMERGENCY POWER OFF Pushbutt
55. PS TB1 TB2 CTT g Figure 12 Wiring an RIM to the UPS Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 31 Connect RIM wiring to the terminal block using the terminations shown in Table E Contact your local field service office for verification and testing of the RIM and its connections prior to making connections with J1 4J4 You can order interface cables separately for connecting to the 15 Pin D Sub Connectors Repeat steps 1 through 5 for each RIM you are installing If you are installing an RMP or SCM in addition to an RIM proceed to Chapter 4 or 6 respectively otherwise secure the UPS cabinet by reversing the steps contained in procedure To Prepare the UPS for Wiring to an RMB RIM SCM or Remote EPO of Chapter 2 Table E RIM Wire Terminations From RIM A Remarks TB1 4 TB1 5 TWISTED WIRES 4 1 2 TURNS PER TB1 6 3 INCHES TB1 7 From RIM B if used Remarks TB1 4 TB1 5 TWISTED WIRES 4 n 1 2 TURNS PER TB1 6 3 INCHES TB1 7 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Installing a Supervisory Contact Module The optional Supervisory Contact Module SCM as shown in Figure 13 provides contacts for monitoring
56. Port 1 Pin Assignments Table 2 Pin Assignments for Port 1 DB 9 Pin Symbol Description Comments TXD Transmit Data Input to UPS RXD Receive Data Output from UPS RTN Return 485 RS485 Data 485 RS485 Data RTN Return Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 87 164201261 Rev F 111503 Optional PORT 2 DB 25 Ted NOT USED 2 15 NOT USED seems a NOTUSED RS232 CTS 17 NOT USED f 5 NOT USED RS232 DSR 6 ERN 5 NOT USED 20 RS232 DTR anes NOT me e3 12V a 2 3 NOT USED NOT USED D NOT USED 13 NOT USED Saruses 25 NOT USED Figure 42 Port 2 Pin Assignments Pin Symbol Description Comments 5 CTS DSR 7 RTN Clear to Send Output from UPS 6 Data Set Ready Output from UPS 8 12V 12 volts Output from UPS always true 20 DTR Data Terminal Ready Input to UPS typically not used by UPS 22 12V 12 volts Output from UPS always true NOTE Pins 5 and 6 are tied together internally Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Configuring the Serial Ports You must configure the port for communications using the LCD screen and pushbuttons on the UPS Monitor Panel Select Port 1 or Port 2 optional from the Setup menu to display one of th
57. Press the and E gt pushbuttons to move through the menu titles on the menu bar Press them simultaneously to silence the horn or to test the lamps behind the status indicators e Press the ft and V pushbuttons to move through the options in a menu or to scroll through the list of alarms and notices in the event log Press the D pushbutton to toggle the use of the fanus pushbuttons between the menu box and the information area Adjusting the Contrast Use the pushbuttons to adjust the contrast on the LCD screen Hold down the J pushbutton then press the t pushbutton to increase the contrast or the pushbutton to decrease the contrast Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 53 164201261 Rev F 111503 Reading the Status Indicators The six lights on the left side of the monitor panel are status indicators They are backlit by colored light emitting diode LED lamps and work in conjunction with the alarm horn to let you know the operating status of the UPS Normal Battery Bypass Notice Alarm Standby This green indicator is lit when the UPS is operating in Normal mode The power processing unit PPU is supplying power to the critical load This yellow indicator is lit when the UPS is operating in Battery mode Because Battery mode is a normal condition of the UPS the Normal indicator also remains lit This yellow indicator is lit when the UPS is operating in Bypass
58. R INTERFACE RECTIFIER CHARGER INPUT BREAKER INVERTER OK BATTERY BREAKER INVERTER FAIL BYPASS INPUT BREAKER RECTIFIER OK MAINTENANCE ISOLATION BREAKER RECTIFIER FAIL MAINTENANCE BYPASS BREAKER UPS SYSTEM WITH 600 208 VOLT INPUT OUTPUT DESCRIPTION ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO 164201261 3 SHEET 4of4 REVISION A 053099 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation A 17 164201261 Rev F 111503 Maintenance Bypass Breaker MBP Bypass Input Breaker BIB Output Maintenance Bypass To Isolation Input Critical Gnd Switch MIS Source Load AC Input To UPS Rectifier boo Ole Neutral Rectifier Input Oo Ojo o Oke KONO e Breaker CB1 DC Input From o 8 amp 6 ages poses 2 8 8 Battery To UPS Battery Breaker
59. RFACE MOUNT FOR HANGING SUPERVISORY CONTACT MODULE 164201261 9 SHEET 1 of 1 DATE 953099 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 This Page Intentionally Left Blank Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 LIMITED FACTORY WARRANTY FOR THREE PHASE POWERWARE PRODUCTS Subject to the conditions herein Powerware Powerware warrants solely to the original end user the electronics the Unit and Powerware built battery cabinets against defects in material and workmanship for the warranty period of 12 months from the date of equipment start up or 18 months from date of shipment whichever occurs first Should service be necessary this warranty covers USA only The Powerware 9315 9320 9330 9335 BPIIl and BPIV three phase UPS products are sold with a standard factory warranty described below start up and extended labor service All three phase UPS installations will have an authorized Powerware Service Engineer perform startup or the factory warranty and extended labor service will be void The included first year extended labor service provides for a complete 12 months of onsite labor for your UPS purchase Worldwide All parts requiring replacement for the Factory Warranty period If in the opinion of Powerware the Unit fails to meet published specifications and the
60. RUPTIBLE POWER SYSTEM ee ee iii HARDWARE REMOVED Em BEFORE PLACING LUG GROUNDING CABLE OVER GROUND STUD eo FRONT PERMANENTLY ATTACHED CABINET BASE HARDWARE side view Figure 5 Cabinet to Cabinet Grounding Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 15 164201261 Rev F 111503 Installing UPS Internal Power and Control Wiring NOTE The cables used in steps 2 through 12 are coiled inside the Environmental 10 11 12 13 14 15 cabinet and are attached at the factory to the terminals inside this cabinet Wiring harness with connectors J20 J22 and J23 are coiled inside the UPS cabinet Wiring harness with connectors P20 P22 and P23 are coiled inside the Environmental cabinet Refer to Drawings 164201261 1 and 164201261 4 in Appendix A of this manual for wiring and termination requirements and terminal locations Remove the sheet metal shield covering the bottom half of the UPS cabinet Route DC input cables cables 205 and 206 from the Environmental cabinet through the cutout in cabinet sides to the DC UPS Input terminals in the UPS cabinet Connect positive DC power cable 205 to the DC input terminal E4 Refer to Appendix A of this manual for terminal locations and tightening torque Connect negative DC power cable 206
61. TION INSTALLATION NOTES DRAWING NO 164201261 1 SHEET ecorti REVISION B DATE 011500 A 6 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Battery voltage is computed at 2 volts per cell as defined by Article 480 of the NEC Rated battery current is computed at 1 8 volts per cell The battery wiring used between the battery and the UPS should not allow a voltage drop of more than 196 of nominal DC voltage at rated battery current A battery disconnect switch is recommended and may be required by NEC or local codes when batteries are remotely located The battery disconnect switch may be supplied as an accessory and should be installed between the battery and the UPS Table G lists the maximum rating for input circuit protective devices circuit breakers Source protection for AC input should be treated as if supplying a three phase transformer with a rating 1 4 times the UPS kVA rating to allow for transformer magnetization inrush current The input breaker CB1 has a trip rating of 150 amps AT for the 400 480 and 600 volt input UPS and 320 amps AT for the 208 volt input UPS The bypass feed into this equipment utilizes either three or four wires The rectifier feed into this equipment utilizes three wires However the phases must be symmetrical about ground i e from a Wye source for proper equipment operation Failure to follow these i
62. a problem with the indicator lamps 54 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Using the Menu Options The UPS menus allow you to display data in the information area to help you monitor and control UPS operation The following menus and options are available Meters Displays UPS performance meters for the system or critical load Events Displays the list of Active System Events and a historical log of system events Statistics Displays statistical information about UPS operations for the battery load or line Graphics Displays a real time graphic representation of the flow of current through the internal UPS components Setup Allows you to configure the UPS communications port and set the date and time for the timestamp Figure 25 shows the LCD screen as it appears when you first start the UPS The Meters menu is displayed in the menu box with the System option highlighted In the information area the system meters show their current readings Uninterruptible Power System System Normal 04 MAY 1998 14 25 45 Alarm None Notice None Battery Percent 100 Input Output VAB VBC VCA FREQ VBC VCA FREQ 480 480 480 60 0 480 480 60 0 IA IB Ic IB IC IN 88 88 88 90 90 000 KVA KW PF KVA KW PF 73 69 0 95 75 60 0 80 Meters Load Amps VBC VCA 480 480 Nase Events Statistics Graphics Setup Figure 25 Sys
63. an automatic transfer to Bypass mode an alarm condition will be recorded Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Battery Mode The UPS transfers to Battery mode automatically if a utility power outage occurs or if the utility power does not conform to specified parameters In Battery mode the battery through the DC to DC voltage converter provides emergency DC power that the inverter converts to AC power When the UPS switches to Battery mode the alarm indications depend on the cause and condition of the battery charge The length of time the system can operate in Battery mode depends on loading and the battery supply capacity Figure 20 shows the path of electrical power through the UPS when operating in Battery mode Bypass Input BIB closed BYPASS MBP open OUTPUT TRANSFORMER INVERTER 2 E 7 9 Output MIS i4 4 closed closed RECTIFIER Rectifier Input Input Isolation Transformer CB2 closed BATTERY Figure 20 Path of Current Through the UPS in Battery Mode Path of electrical power When the discharging battery voltage reaches the lower limit of UPS operation capability the critical load transfers to Bypass mode if it is available If Bypass input is not available a Shutdown Imminent warning occurs The warning time before critical load loss occurs is approximately 2 minutes depending o
64. ass Contactor K4 Open 32 Inverter Normal 4001 Room High Temperature Figure 44 Event History Log Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 93 164201261 Rev F 111503 Meters Printout Ctrl M This key sequence prints the current readings of the UPS system meters The Input area shows the phase to phase voltage frequency and phase current of the incoming utility followed by the kVA kW and power factor measurements The output area shows the same information for the power being output by the UPS The Bypass area shows the phase to phase voltage of the bypass source The Battery area displays the DC voltage V and the DC current I Figure 45 shows a sample Meters printout Uninterruptible Power System UPS System Normal Alarm None Notice None Input VAB VBC VCA FREO 480 480 480 60 0 IA IB IC 88 88 88 KVA KW PF 73 69 0 95 Bypass VAB VBC VCA 480 480 480 03 JAN 1994 14 22 49 Output VBC VCA 208 208 IB IC 222 222 KVA KW PF 80 64 0 80 Battery Figure 45 System Meters System Information Printout Ctrl A This key sequence prints a listing of all available serial data This printout contains the information shown on the Event History Log and Meters screens of the UPS both Figures 44 and 45 94 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Battery Test Printout Ctrl B This k
65. circuit breaker The UPS continually monitors itself and the incoming utility power and automatically switches between Normal Battery and Bypass modes as required with no operator intervention The Maintenance Bypass mode is a manual operation needing operator intervention The sophisticated detection and switching logic inside the UPS ensures that operating mode changes are automatic and transparent to the critical load The UPS switches automatic operating modes in response to these system events Acommand is an intervention that is externally initiated by an operator or by some site action A command causes the UPS to switch operating modes it usually does not require any further action by you Anotice is a minor system event that may or may not require your attention e Analarm is a system event that requires immediate operator intervention System events alarm horns and indicator lights are described in Chapter 12 Responding to System Events Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 39 164201261 Rev F 111503 Looking Inside the UPS The Powerware BPIII HE is a continuous duty solid state UPS that supports the following equipment process control data processing and telecommunications PBX The Powerware BPIII HE maintains power to the critical loads during commercial electrical power brownout blackout overvoltage undervoltage and out of tolerance frequency conditions In
66. e BPIII Harsh Environment UPS System Cabinet as Shipped with Outer Packaging and Pallet Removing Front and Rear Supports 000 UPS and Environmental Cabinets 000 Cabinet to Cabinet Grounding ssesussse Remote EPO Control 0 ccc e eee eee eee Remote Monitor Panel RMP 0 0c eee eee Terminal Block Bracket s ele eene Wiring an RMP to the UPS isuuusssesessseeseesss Relay Interface Module suuusseeusseusss Terminal Block Bracket sees Wiring an RIM to the UPS iisssulessesseeereeenes Supervisory Contact Module 0 0c cece e eee Terminal Block Bracket 0 0 c eee eee eee eee Wiring an SCM to the UPS 0 c eee eee Supervisory Contact Module TB2 000e eee Main Elements of the UPS System 0 0005 Path of Current Through the UPS in Normal Mode Path of Current Through the UPS in Bypass Mode Path of Current Through the UPS in Battery Mode Path of Current Through the UPS in Maintenance Bypass MOOdG c orit INED EI ee ees IH ODER Location of the Monitor Panel and the Control Panel UPS Monitor Panel eese Parts of the LCD Screen Typical for Powerware BPIII HE 75 480 480V Unit 10 12 13 15 21 24 25 26 29 30 31 33 34 35 36 40 41 42 43 44 45 51 52
67. e Setup Port screens The screens for Port 1 and Port 2 are identical and allow you to specify settings for the two serial communication ports Figure 43 shows the Setup Serial Port 1 screen Uninterruptible Power System UPS System Normal 03 JAN 1994 14 23 45 Alarm None Notice None Battery Percent 100 Setup Serial Port 1 Rate Data Stop Handshaking Save 9600 8 1 XON XOFF NO Port 2 Time Meters Events Statistics Graphics Fea gt Figure 43 Setup Serial Port 1 Screen A small return arrow d appears in the upper right corner of the Setup Port screen This arrow is a reminder that you can press the D pushbutton on the Monitor Panel to toggle the pushbuttons between the menu box and the information area If the scroll bar is in the menu box press the B pushbutton to toggle to the information area The first setting Mode is highlighted Press the or m pushbutton to move the highlight to the setting you want to change To scroll through the available options for that setting press the or pushbutton To save the settings upon exit from this screen be sure the Save field is set to YES Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 89 164201261 Rev F 111503 Table 4 shows which options are available for each port The sections that follow describe the configuration settings you can change Table 4 Options Available for Each Commun
68. e maintenance is required THIS WARRANTY IS THE PURCHASER S USER S SOLE REMEDY AND IS EXPRESSLY IN LIEU OF AND THERE ARE NOT OTHER EXPRESSED OR IMPLIED GUARANTEES OR WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PURPOSE WHICH ARE EXPRESSLY DISCLAIMED In no case will Powerware s liability under this Warranty exceed the replacement value of the Unit warranted Invensys Powerware s obligation under said warranty is expressly conditioned upon receipt by Powerware of all payments due it including interest charges if any During such time as Powerware has not received payment of any amount due it in accordance with the Contract terms under which the equipment is sold Powerware shall have no obligation under said warranty also during this time the period of said warranty shall continue to run and the expiration of said warranty shall not be extended upon payment of the overdue amount These limitations to said warranty apply even in the event that the equipment is sold initially by Powerware for resale to an ultimate end user In no event shall Powerware be liable for any indirect incidental special or consequential damages of any kind or type whatsoever or based on any claim or cause of action however denominated Powerware shall not be responsible for failure to provide service or parts due to causes beyond Powerware s reasonable control This limited warranty applies only to the original end user of
69. e major components of the Maintenance Bypass are described in the following paragraphs Maintenance Bypass MBP Circuit Breaker This breaker is normally open When closed it feeds utility power to the critical load when the MIS breaker is opened Maintenance Isolation MIS Circuit Breaker This circuit breaker is normally closed feeding UPS power to the critical load This breaker is opened to isolate the UPS after the MBP breaker is closed Maintenance Bypass MBP Circuit Breaker This circuit breaker is normally closed feeding bypass power to the UPS internal bypass circuit This breaker is opened to isolate the UPS bypass after the load is transferred to maintenance bypass The MBP and MIS breakers are electrically interlocked to limit the possibility of UPS system damage from improper operation 44 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Monitoring and Controlling UPS Operation After you start the UPS operator intervention is unnecessary except for periodic checks of the UPS status Manual operation is required only during routine maintenance or service Use the Monitor Panel and the Control Panel to monitor and control the UPS Figure 22 shows the location of these two panels on the front
70. e screen and you must scroll upward to view older event listings Figure 27 shows the Event History Log screen Uninterruptible Power System System Normal 04 MAY 1998 14 25 48 Alarm None Notice None Battery Percent Event History Log 1008 Date Time Event Description May 03 03 03 03 03 03 03 Active 03 03 COMMAND Keyswitch On STATUS Auto Mode COMMAND Rectifier Commanded On STATUS Inverter On STATUS Rectifier On STATUS Battery Contactor K2 Closed STATUS Inverter Contactor 3 Closed STATUS Bypass Contactor K4 Open O FP 5 00 Ul FP WwW STATUS Inverter Normal Meters Statistics Graphics Setup ilp Figure 27 Event History Log Screen A small return arrow d appears in the upper right corner of the information area of the Event History Log screen This arrow is a reminder that you can press the J pushbutton on the Monitor Panel to toggle the scroll bar between the menu box and the information area When the scroll bar is in the information area the return arrow is in the menu box When the scroll bar is in the menu box the return arrow is in the information area When the scroll bar is in the information area you can press the ft and amp pushbuttons to scroll through the Event History log Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 57 164201261 Rev F 111503 Select Active from the Events menu to
71. ease call Powerware at United States 1 800 843 9433 Canada 1 800 461 9166 Outside the U S Call your local representative Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 This Page Intentionally Left Blank Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Section I Installation Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 This Page Intentionally Left Blank Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 y Getting Started The Harsh Environment HE UPS system is shipped as two separate cabinets UPS Cabinet and Environmental Cabinet Each cabinet is shipped on a wood foam and steel pallet Use a forklift or pallet jack to move the packaged cabinets to the installation site or as close as possible to the site before unloading from the pallets This is the basic sequence of the installation steps 1 Create an installation plan for the UPS and Environmental cabinets Prepare your site for the UPS system Inspect unpack and unload the cabinets Wire the cabinets as applicable Chapter 2 X ee Complete the Installation Checklist Chapter 2 5 Have authorized service personnel perform preliminary checks and startup After wiring the UPS system to the facility power and critical load s be sure to g
72. ece eee eee eee 108 Basic Modem Configuration 000 c cece eee 108 Configuring the Modem to Call a Remote Computer 109 Configuring the Modem to Call a Numeric Pager 110 Configuring the Modem to Answer Incoming Calls 111 Final Modem Configuration 000 cece eee eee 111 UPS Setup Configuration 20 cece eee 112 User Selected Events 00 ccc eee cece eee eee eee 113 15 Maintaining the UPS System 117 Important Safety Instructions lisse 117 Performing Preventive Maintenance 00 cece ee eee eee 118 Maintenance Training uester RE Apu eum BITSCDAWE RR ve 119 16 Product Specifications lllllllesuuueee 121 System Input 5 oves petuum s hehe wens ens Wehner 121 System OUIDUL 212i sev feti dene eek eT SEE Sq Ein R BER MES 122 Environmental Specifications 0 cece eee eee 123 Battery Specifications 00 c cece cee ees 123 Append A ederet d xe aloe Yel Ba a ee Rote A 1 vi Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Powerwar
73. ed Ensure there is at least six inches of clearance behind the unit for proper air circulation Ensure the operating environment is within the parameters specified in the Product Specifications section of Chapter 16 Ensure the UPS is in Normal mode Normal status indicator is lit If an alarm lamp is lit or the Normal status indicator is not lit contact Customer Support Perform the following checks MONTHLY Ensure all status indicator lamps are operative Press the 4 ana y pushbuttons simultaneously to test the lamps Monitor system parameters as described in Chapter 9 Using the Monitor Panel Record the results of your checks and any corrective actions in a suitable log ANNUAL maintenance Annual preventive maintenance should be performed only by authorized service personnel familiar with maintenance and servicing of the UPS system Contact your nearest field service office for more information about service offerings FILTER maintenance Pleated disposable filters installed inside of three filter assemblies located on the right side of the Environmental cabinet eliminate particles from the air which is used to cool the UPS system Filters should be checked or replaced at least every thirty days in a clean environment and at least every seven days in a dirty environment The replaceable filter size is 20 inches x 20 inches x 1 inch with an ASHRAE rating of 52 2 An AmAir 62 Plus meet these requirements To
74. eet 1 z 00000 ores e Main Bonding Jumper INTERCABINET WIRING NOTE Connections shown are between the UPS cabinet and Environmental cabinet External connections are shown on DESCRIPTION AC Input to Bypass Transformer E13 E14 E15 A B C Left to Right Connect cables 227 228 and 229 AC Input to UPS Rectifier E1 E2 E3 A B C Top to Bottom Connect cables 250 251 and 252 Output Neutral Connection E12 Connect cable 600 2 AC Output E9 E10 E11 A B C Top to Bottom Connect cables 237 238 and 239 LOCATION OF UPS POWER TERMINALS DRAWING NO 164201261 4 SHEET 2 of 2 REVISION DATE 953099 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 TOP VIEW UNIT WEIGHT 4 100 LBS
75. energize your critical load right away you can energize your critical load without the benefit of backup To turn the UPS on in Bypass mode 1 2 Turn the START switch to the right momentarily Turn the MODE switch to BYPASS The remaining switches can be in any position Ensure the Emergency Power Off PUSH TO RESET pushbutton is pressed in Power to the critical load is supplied by the bypass source No backup is available To Transfer the Critical Load to Maintenance Bypass from UPS Bypass T 2 Confirm BIB circuit breaker is closed Turn MODE switch to BYPASS The UPS switches to Bypass mode If the bypass source is not available the power processor remains on and an alarm sounds Close MBP circuit breaker Caution Failure to close the MBP circuit breaker will result in loss of power to the critical load Open MIS circuit breaker The critical load is now on maintenance bypass Open the BIB circuit breaker to electrically isolate the UPS bypass When the transfer is complete move the CB2 breaker switch to OFF Then move the CB1 breaker switch to OFF The maintenance bypass source supplies the critical load and the power processor de energizes To Transfer the Critical Load to UPS Bypass from Maintenance Bypass 1 2 Confirm BIB circuit breaker is closed Turn the MODE switch to BYPASS The UPS switches to Bypass mode If the bypass source is not available the power processor remains on and
76. entarily After the rectifier reaches 540 VDC the DC to DC converter begins to turn on After the converter reaches full voltage the OK To Close CB2 notice is displayed on the Monitor Panel LCD screen When the OK To Close CB2 notice is displayed on the Monitor Panel LCD screen close circuit breaker CB2 The inverter begins to turn on When the inverter reaches full voltage it turns on and supplies power to the critical load If a bypass source is available when you turn the START switch on the critical load is immediately supplied by the bypass source in Bypass mode until the inverter turns on and the UPS transfers to Normal mode The status indicators on the Monitor Panel indicate when the UPS is in Bypass mode and Normal mode To Shut Down the UPS from Normal Mode 1 Turn the MODE switch to BYPASS The UPS switches to Bypass mode If the bypass source is not available the power processor remains on and an alarm sounds When the transfer is complete the LCD screen reads On Bypass move the CB2 breaker switch to OFF Then move the CB1 breaker switch to OFF The bypass source supplies the critical load and the power processor de energizes The Bypass mode indicator illuminates on the Monitor Panel 66 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 To Start the UPS in Bypass Mode If the power processing unit PPU of the UPS is not available and you need to
77. ery Test Failed Battery Test Aborted Load or Battery Test Aborted Utility If the test ran to completion Battery Passed Test will appear in the UPS Event History Log Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 95 164201261 Rev F 111503 System Configuration The System Configuration mode allows you to modify special functions in your UPS These functions include programming of building alarms customizing building alarm messages adjusting the nominal output voltage and scheduling battery tests The menus provided and their function are described in this section System Configuration Mode Main Menu When the System Configuration mode is selected with a terminal attached you will be prompted to enter the password for this mode Please Enter Password The default password is IPMBP3 You may modify this password using the change password function in the following menu When the valid password is entered the main menu will be displayed Program Mode Main Menu Program Building Alarms Program Unit Name Adjust Output Voltage Change Password Battery Test Setup Modify Low Battery Time Exit Program Mode Enter Selection NO oO 2 WD gt Program Building Alarms This menu provides access to all the functions available in the system configuration mode If 1 is entered at the prompt you can program the building alarm functions Program Building Alarms 1 Enable Disable Default Function
78. ev F 111503 CONVERTER NOTICES Converter Shutdown Converter In Startup OK To Close CB2 Converter Logic Power OK CONVERTER STATUSES Converter Normal Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 83 This Page Intentionally Left Blank 84 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 EN E GENESIS Serial Communications This chapter describes the serial communications feature of the Powerware BPIII HE UPS One RS 232 RS 485 serial communication port and an optional RS 232 serial communication port allow the connection of equipment to view system event information The following sections describe the serial communications feature and provide information about connecting hardware setting up the ports changing settings and changing modes Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 85 164201261 Rev F 111503 Locating the Communications Panel The Communications Panel inside the UPS contains two serial communications ports one DB 9 and one optional DB 25 The ports provide a computer interface to a Remote Monitor Panel RMP Relay Interface Module RIM or remote terminal and or printer The Communications Panel also contains terminals TB1 and TB2 for connecting your equipment to the UPS Figure 40 shows the location of these items inside the UPS TB1 and TB2
79. ev F 111503 Remote Notification Features Remote Notification provides the UPS with the capability to utilize a standard off the shelf PC modem as a telephone interface The features provided by this option are as follows Call out to a remote terminal or pager based on programmable events and alarms Two separate programmable notification groups phone numbers Programmable number of redial attempts Programmable time delay between call out attempts Automatic answering user configurable for access to the Terminal mode of the UPS Remote and local ability to clear Call Out alarms and events Error detection and correction for misconfigured and disconnected modems Uses standard modems and cables available at your local computer supply center 104 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Description of Operation The Remote Notification option performs three basic functions Call Answer into Terminal mode Call Out to a remote terminal and Housekeeping Remote Notification also allows access to any functions available in the Terminal mode from a remote computer or terminal Call Answer To use the Call Answer function the modem is configured to automatically answer by having the user program the SO register of the modem to a non zero number When the modem receives a call the UPS is alerted to wait for a connect signal from the modem When the modem ans
80. ey sequence prints the Battery Test Log The log consists of a history of the last 30 battery tests that were run and the results of those tests The most recent test will appear at the bottom of the log Figure 46 shows a sample of the Battery Test Log Uninterruptible Power System UPS 1 UPS System Normal 12 APR 95 15 39 31 Alarm None Notice None Battery Test Log Date Time Volts Health Data AUG 14 23 45 498 0 1 00 0000 SEP 11 23 45 498 0 1 00 0000 OCT 9 23 45 498 0 1 00 0000 NOV 13 23 45 498 0 0 99 0000 DEC 11 23 45 498 0 0 99 0000 JAN 23 45 498 0 0 98 0000 FEB 23 45 498 0 0 98 0000 MAR 23 41 000 0 0 00 0003 Figure 46 Battery Test Log The Date Time field is the date and time of the battery test The Volts field is a measured value of the battery voltage during the test This field will display 000 0 if the test did not run to completion The Health field is a relative measurement of your batteries condition This number can be used to chart the condition of your batteries If a sudden change of this number occurs relative to the previous test results it is an indication that your batteries may need attention This display is 0 00 if the test does not run to completion The Data field is a value to be used by your field service engineer to gain more information about the battery tests If the battery test does not complete the Volts and Health field will read zero and the UPS Event History Log will report either Batt
81. f the UPS equipment Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 19 164201261 Rev F 111503 Notes 20 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Installing a Remote EPO Control The Remote EPO control arrives as shown in Figure 6 See Drawing 164201261 7 in Appendix A for enclosure dimensions side views and knockout patterns UNINTERRUPTIBLE POWER SYSTEM EMERGENCY OFF EMERG OFF D to UPS to other equipment Figure 6 Remote EPO Control To install a Remote EPO control 1 Securely mount the Remote EPO station Recommended locations include operator s consoles or exit doors 2 Install wiring from the Remote EPO station using 1 2 in conduit through the 7 8 in knockout in either the top or bottom of the UPS 3 Connect the Remote EPO wiring as shown in Tables A and B Table A Remote EPO Wire Terminations To Communications From REPO Station s Panel in UPS Remarks Twisted wires 2 14 18 gauge Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 21 164201261 Rev F 111503 4 Table B Remote EPO i TWISTED WIRES 2 REMOTE EPO SWITCH Remote EPO switch rating is 24 VDC 1 Amp minimum if supplied by user NOTE T
82. f the UPS system e Chapter 14 Remote Notification contains instructions for using the remote notification feature of the UPS system e Chapter 15 Maintaining the UPS System contains maintenance instructions for the UPS system e Chapter 16 Product Specifications provides detailed specifications for the UPS system e Appendix A Customer Information contains important information on wiring requirements and recommendations and important diagrams of the cabinet s mechanical details and electrical access Read through each procedure before you begin Conventions Used in This Manual The text in this manual uses these conventions Bold type highlights important concepts in discussions key terms in procedures and menu options e Rectangular boxes containing bold type are warnings or cautions that pertain to the UPS system or its electrical connections This important information alerts you to possible dangers pertaining to personnel safety UPS or equipment damage critical load protection or operational concerns e Italic type highlights notes and new terms where they are defined In this manual the term UPS or UPS system refers to the UPS cabinet and its internal elements and the environmental cabinet The rectifier and inverter are internal UPS components that are together referred to as the power processing unit PPU of the UPS 4 Powerware BPIII Harsh Environment UPS 50 75 kV Installation a
83. g the cabinets from the pallets 4 Cut the steel bands around each cabinet 5 Remove the protective cardboard covering from the cabinets cutting where indicated using a knife blade no longer than 25 mm 1 in NOTE Do not discard the packaging material yet Instructions for unloading the cabinet from the pallet are printed on the cardboard and you will need to refer to them 6 Remove the plastic bag and foam packing material and discard or recycle them in a responsible manner Unloading the UPS System From the Pallet The UPS and Environmental cabinets are each bolted to sheet metal pallets consisting of four supports secured to foam cushions The foam cushions act as shock absorbers for the cabinet during shipment WARNING UPS cabinets are extremely heavy If unloading instructions are not closely followed the cabinet may tip and cause serious injury Turning the jacking bolts unevenly may cause the cabinet to become unbalanced To prevent tipping raise and lower the jacking bolts evenly The cabinet should only be raised approximately 3 mm 1 8 in above the floor just enough to remove foam cushions 1 Starting with the UPS cabinet open and remove the cabinet door Remove the retaining screw located inside the door at the bottom hinge pivot point then lift the door off Save the retaining screws for reinstallation of the door 2 Locate the field kit packed inside of the cabinet or communication panel
84. h OK or 0 zero Key in A T S 0 zero then press ENTER Confirm that the modem responds with OK or 0 zero and a value of 002 Oo N O oa A WO PD Connect a telephone line to the modem Test the modem by using another PC equipped with a modem to dial the first modem 9 Confirm that the UPS modem responds with 2 when the phone is ringing and a 1 after the UPS modem has answered and the carrier has been detected 10 Key in A T amp W 0 zero then press ENTER 11 Confirm that the modem responds with OK or O zero Final Modem Configuration The final step in configuring the PC modem for use with the UPS is to turn off the echo feature of the modem This procedure is performed automatically by the UPS Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 111 164201261 Rev F 111503 UPS Setup Configuration Connect the modem to the UPS by connecting one end of the serial cable to the optional UPS Port 2 DB 25F connector and the other to the modem refer to Chapter 13 Serial Communications If using a standard serial cable a null modem adapter is required for the connection to the modem The Powerware BP III HE UPS can only use optional serial Port 2 DB 25F for the Remote Notification option This connection is located in the serial communications panel at the base of the UPS cabinet behind the front doo
85. he Monitor Panel on the left front of the UPS continually indicates the present mode of UPS operation This panel contains an LCD screen backlit status indicators and the EMERGENCY POWER OFF pushbutton Use the LCD screen on the Monitor Panel to view performance meters or graphic representations of UPS operation The Monitor Panel is described in detail in Chapter 9 Using the Monitor Panel A quick reference label describing how to use the Monitor Panel is located below the Monitor Panel The Control Panel located to the right of the Monitor Panel contains various controls and switches These control power to and from the UPS and allow you to change the UPS mode manually The Control Panel is discussed in Chapter 10 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 45 164201261 Rev F 111503 This Page Intentionally Left Blank 46 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Controls and Features UPS Controls The UPS has three primary control areas as described in the following paragraphs Control Panel The Control Panel on the front of the UPS see Figure 22 contains the operator controls to start and stop the UPS and change the operating mode The Control Panel is described in Using the Operating Controls section of Chapter 10 Monitor Panel The Monitor Panel on the front of the UPS see Figure 22 contains an LCD screen to di
86. his switch must be a dedicated switch not tied into any other circuits If installing multiple Remote EPO stations wire additional stations in parallel with the first Remote EPO If required install 1 2 in conduit and wiring from the Remote EPO station to trip circuitry of upstream protective devices A normally open contact is provided as shown in Table B Remote EPO switch wiring must be in accordance with UL Class II requirements Secure the UPS by reversing all steps taken to prepare it for Remote EPO installation 22 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Installing a Remote Monitor Panel As an option a Remote Monitor Panels RMPs can be installed to monitor the operation of the UPS system from virtually any location within the facility up to 500 feet from the UPS Flush mount or surface mount an RMP on a desktop or on a wall wherever you have a serial interface line A maximum of two monitoring accessories RMPs RIMs or SCMs can be installed See Table C for the number of accessories permitted Figure 7 shows an RMP Drawing 164201261 7 in Appendix A shows the enclosure dimensions and knockout patterns Table C Optional Monitoring Accessories Number and Type of Accessories Permitted Remote Monitor Panel Relay Interface Panel Supervisory Contact Module 2 Powerware BPIII Harsh Environment UPS 50 75 kVA Installati
87. ication Port eO Calibration Mode System Configuration Ros qu Remote Monitor Mode Baud rate of 300 1200 2400 4800 9600 or 19 200 Data size stop bits of 8 1 or 8 2 ae ia oe Data size stop bits of 7 1 or 7 2 Disabled handshaking XON XOFF handshaking Mode Rate The operational mode of the port Each communications port operates in one of the following modes Terminal mode System events are logged immediately as they occur Calibration Used only by service personnel System Config Allows you to set building alarms battery tests etc Check with your Sales or Service Representative for availability Computer Provides a proprietary Binary Computer Mode BCM Interface Remote Monitor Sends all system event information to an RMP RIM or Supervisory Contact Module SCM Available for Port 1 only Port 1 and Port 2 cannot be in the same mode simultaneously they must always be operating in different modes The modes are described later in this chapter The baud rate of the equipment connected to this port The baud rate determines the speed of data transferred between the UPS and the connected equipment For Remote Monitor mode the baud rate must be set to 300 All other modes should operate at the highest baud rate available with the connected equipment 300 baud is not recommended for any mode except Remote Monitor You can select a baud rate of 300 1200 2400 4800 9600 or 19 200 90 Powerware BPIII Harsh
88. id U c TEETEDOL Relay Interface Module Ji J2 J3 J4 CONTINUES 15 PIN D SUB CONNECTORS AT UPS Figure 10 Relay Interface Module Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 29 164201261 Rev F 111503 Before installing an RMP be sure you have prepared the UPS according to the instructions in Chapter 2 To install an RIM 1 Securely mount the RIM 2 Install wiring from the RIM using 7 in conduit through the 7 amp in knockout in either the top or bottom of the UPS cabinet The top entry connection requires installation of 1 in flexible conduit within the UPS Bottom entry connection requires no additional routing of conduit within the UPS 3 If not already installed locate the RMP adapter cable assembly see Figure 11 in the spare parts kit Mate the DB 9 connector on the back of the terminal block into the DB 9 connector on the Communications Panel of the UPS see Figure 12 Use two screws from the spare parts kit to secure the terminal block bracket to the Communications Panel Connect to Port 1 DB 9 on Communications Panel Q E s TERMINAL L BLOCK gl TB3 A Q Figure 11 Terminal Block Bracket 30 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 DB 9 CONNECTOR ON COMMUNICATIONS PANEL OF THE U
89. il 42 4 375 E33 Phase A 4 300 kemil 42 4 875 E34 Phase B 4 300 kemil 42 4 375 E35 Phase C 4 300 kcmil 42 4 375 AC Input to E19 Phase A 4 300 kcmil 42 4 375 Bypass E20 Phase B 4 300 kcmil 42 4 375 375 375 375 375 275 375 375 E21 Phase C 4 300 kcmil 42 4 375 AC Output to E25 Phase A 444 300 kcmil 42 4 375 Critical Load E26 Phase B 444 300 kcmil 42 4 375 E27 Phase C 444 300 kcmil 42 4 375 E12 Neutral Gnd 2 44 500 kcmil 31 1 275 DC Input from E31 Battery 3 2 0 400 kcmil 42 4 375 Battery E32 Battery 3 2 0 400 kcmil 42 4 375 Customer Ground Ground 2 446 350kcmil 31 1 275 Ground 11 The UPS and the Environmental cabinets are normally crated separately for shipping and are bolted together on site 12 Do not tilt cabinets more than x 10 during handling 13 Dimensions are in millimeters inches 14 Table F lists the ventilation requirements for full load operation Table F Air Conditioning or Ventilation Requirements During Full Load Operation Ratings Heat Rejection BTU hr Kg cal hr 50 75 KVA 23 000 5796 15 Recommended minimum clearance over the UPS module is 304 8 mm 12 in Required for cooling air exhaust approximately 614 0 liters sec 1300 cfm DESCRIP
90. ironmental cabinets Each component of the Harsh Environment UPS system is housed in a free standing cabinet The system configuration consists of the UPS and the Environmental cabinets Figure 1 shows the Powerware BPIII Harsh Environment UPS system Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 1 164201261 Rev F 111503 SN SS WR RRQ QALY SSSNSNNNS NNNNNNSNNNNSNNNNNNNNNNNNSNNNNNNNANNYW NIIIN SSSSSSSSSSSNSS SS SS SS ENVIRONMENTAL CABINET Figure 1 Powerware BPIII Harsh Environment UPS System Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Using This Manual This manual describes the Powerware BPIII HE UPS installation operation and routine maintenance The information in this manual is divided into the sections and chapters listed Introduction The Introduction provides a brief description of the UPS system a description of the content of each chapter safety text conventions used in the manual and reference information Section Installation Chapter 1 Getting Started tells you how to prepare your site for the installation of your UPS system It discusses equipment environmental requirements inspecting and unpacking cabinets Chapter 2 Installing the Harsh Environment UPS System describes how to install the UPS system Chapter 3 Installing a Remo
91. isory Contact 33 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation iii 164201261 Rev F 111503 Section IL Operation o roots ETC eb Ete Ee 37 7 Understanding UPS Operation 39 Looking Inside the UPS 0 0 cece eee eee 40 Normal Mode citro ce Me eho eee iw aes oa 41 Bypass M de o 422 526 bndice e be dion Bieten bosse dae 42 Battery MOS 5a sre dr e eed e edd e dum m Rt 43 Maintenance Bypass Mode 22 05 00 cece eee ences 44 Monitoring and Controlling UPS Operation sse 45 8 Controls and Features ccc eee e eee eee ees 47 UPS COMUOIS udi retreat taut ape e ete deae ebd epe 47 Monitor Panel 225 0 es d eeu d ou e n een Ex xq ie 47 Control Panel 2 55 quede Arr IR Fak eels eee eas Ge sae Rees 47 Maintenance Bypass cca digs ee epe am bee ee dees 47 UPS Standard Features nnana cece eee eee eee eee 47 Communication Panel 000 e cece eee eee eee 47 Irput Filter ost Mette eee eee Pe eU LE usd tits 47 Emergency Power Off 000 cece eee eee eee eee 48 Automatic Battery Charge Current Limit 48 Installation Features eue qe Sem dees aren se tr ace pue ene e 48 Options and Accessories 00 c eee eee eee 48 Remote Monitor Panel lees 48 Relay Interface Module sluuuselusseeesseeessss 48 Supervisory Contact
92. itoring This standard feature lets you connect the UPS to your building alarms such as smoke detectors or overtemperature alarms The terminals for external connections are located inside the UPS on the customer interface panel see Figure 35 TB1 TB2 1 BLDG ALARM 1 1 REMOTE EPO 2 BLDG ALARM 1 RTN 2 REMOTEEPORTN AD RS485 3 BLDG ALARM2 3 T p gt gt 4 1 BLDG ALARM 2 RTN 4 ON INV NOTE D s BLOGALARM 3 SONN RIN i All building alarm inputs or remote C BEBE EARMIS RM 6 on ByPass features require an isolated normally 7 BLDG ALARM 4 7 ON BYPASS RTN open contact or switch rated at 24 Vdc 9 BLDG ALARM amp RTN 8 BATTERY CONTACTOR CLOSED 20 mA minimum connected between 9 BLDG ALARM 5 9 BATTERY CONT RTN the alarm input terminal and common fa 10 BLDG ALARM 5 RTN 10 RELAY TNO terminal as shown All control wiring NU 11 BLDG ALARM 6 TA RELING relay and switch contacts are customer 12 BLDG ALARM 6 RTN 12 ALARM RTN provided n 18 13 RELAY 2 NO 14 14 RELAY2NC HS232 15 15 NOTICERTN Optional LS Figure 35 External Connections for Building Alarm Monitoring Regardless of how you assign the
93. le C INPUT OUTPUT Ratings amp External Wiring Requirements for Powerware BPIII HE 50 and 62 5 kVA 400 Volt s Rating o mw 000 e Basic unit rating at KVA 50 62 5 0 8 lagging PF load KW 40 50 INPUT OUTPUT AC Input to UPS Rectifier 120 140 Full Load Batt Chg Amps max 95min PF 3 0 1 gnd Minimum conductor size AWG or number per kcmil ea AC Input to Bypass Full Load Current Amps Nom 3 0 1 gnd Minimum conductor size AWG or 3 1 number per kcmil ea 1 1 DC Input from Battery to UPS 1 positive 1 negative VDC 120 120 Float VDC 135 135 Amps 360 455 2 0V cell Minimum conductor size AWG or 3 0 250 number per pole kcmil ea 3 3 AC Output to Critical Load Full Load Current3 Amps Nom 72 3 1 Neutral 1 gnd Minimum conductor size AWG or 3 1 number per 0 kcmil ea 1 1 OU AHACVvACO o acouoz DESCRIPTION LLATION NOTE NOTE Callout letter O O 9 ana EANNGNO mele ON NOIES SHEET map to drawing 7164201261 3 164201261 1 8of 11 REVISION c DATE 115103 A 4 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 10 Refer to Table D for internal power cable terminations and Table E for external power cable terminations Drawing 164201014 4 shows the location of these power cable terminals inside the UPS cabinets Terminals E9 through E15 and E19 through E35 are UL and CSA rated at 90 C
94. left column shows the number of UPS incidents for the current month and since the start date shown at the top of the screen The top right column shows the time that the UPS was on bypass battery or generator and the amount of time the UPS logic has been functioning since the start date The lower right column shows the percent of availability of the UPS and the bypass source Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 59 Select Mimic from the Graphics menu to display a real time graphical representation of the flow of current through the UPS Figure 30 shows the Mimic screen Uninterruptible Power System UPS System Normal Alarm None Notice None Battery Percent 100 Graphics 04 MAY 1998 14 25 55 Bypass Rectifier Inverter Battery Meters Events Statistics Graphics Setup Figure 30 Mimic Screen The Mimic screen shows the internal components of the UPS cabinet The flow of current through the components is highlighted 60 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Select Time from the Setup menu to display the Time Setup screen The Time Setup screen allows you to set the internal timestamp of the UPS The timestamp is used for logging events in the Eve
95. lity Battery Test Requires Calibration Battery Time Low Building Alarm 1 Active Building Alarm 2 Active Building Alarm 3 Active Building Alarm 4 Active Building Alarm 5 Active Building Alarm 6 Active Inverter Network Down Monitor Logic Pwr Fail Monitor Network Down No Active Events Output AC Over Voltage Output AC Under Voltage Output Over Frequency Output Under Frequency Power Off Switch Rectifier Network Down Testing Battery Three Wire AC Over Voltage Three Wire AC Under Voltage Three Wire Over Freq Three Wire Under Freq Group Group Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 115 This Page Intentionally Left Blank 116 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 NN AL Maintaining the UPS System The components inside the UPS cabinet are secured to a sturdy metal frame that is supported by the UPS magnetics This design allows authorized service personnel to remove repairable components with very little disassembly All repairable parts and assemblies are located in the front of the UPS allowing all routine maintenance and servicing to be performed with front panel access You must schedule periodic performance checks of your UPS to keep it running properly Regular routine checks of operation and system parameters will enable your UPS system to function
96. m or a computer terminal The equipment you connect to these contacts alerts you to a UPS alarm Input Filter Your unit may be equipped with an input filter An input filter yields power factor correction that allows you to save on your initial installation and operating costs The filter also reduces input harmonic current distortion and minimizes upstream interference that can damage sensitive hardware components Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 47 164201261 Rev F 111503 Emergency Power Off An EMERGENCY POWER OFF pushbutton is provided for situations where you must immediately remove all power to your critical load The pushbutton is located on the Monitor Panel for quick access and is covered with a clear plastic shield to prevent inadvertent operation The shield must be raised before pressing the pushbutton The EMERGENCY POWER OFF pushbutton is described in detail in Chapter 10 Using the EMERGENCY POWER OFF Pushbutton Automatic Battery Charge Current Limit A preset limit restricts battery charging current to protect batteries from damage due to high current charging Charging at high currents can overheat and damage batteries Installation Features Power and control wiring can be routed through the top of the Environmental cabinet The cabinet has an internal wireway Options and Accessories Contact your sales representative for information about any of these available
97. make sure that the modem not the remote terminal at the remote terminal end of the connection is configured for either hardware handshaking or none at all This is required so that the modem does not attempt to trap the XON XOFF characters and prevent them from being transmitted to the UPS 112 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 User Selected Events Insert a check at each alarm or notice in the appropriate Group 1 or Group 2 block to indicate the configuration of your UPS INVERTER MESSAGES ALARMS Inverter AC Over Voltage Inverter AC Under Voltage Inverter Calibration Required Inverter Contactor K3 Failed Inverter DC Over Voltage Inverter Failure Inverter Over Frequency Inverter Phase Rotation Inverter Setup Required Inverter Under Frequency 100 Overload Shutdown 125 Overload Shutdown Over Temperature Shutdown Shutdown Imminent Load Off Bypass Contactor K4 Failed Bypass Control Failed Bypass Phase Rotation Go To Bypass Active Battery Contactor K2 Failed Battery Ground Fault Group 1 Group 2 INVERTER MESSAGES NOTICES Inv Logic Power Failed Bypass AC Over Voltage Bypass AC Under Voltage Bypass is Not Available Bypass Mode Bypass Over Frequency Bypass Under Frequency Input Breaker CB1 Open Battery Contactor K2 Open Battery DC Under Voltage Batte
98. mit Phase B Current Limit Phase C Current Limit Battery Voltage Low Inv Logic Power Failure Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 RECTIFIER NOTICES Input AC Over Voltage Input AC Under Voltage Input Over Frequency Input Under Frequency Power Supply Over Voltage Power Supply Under Voltage Input Transient DC Voltage Low DC Voltage High Equalizing Battery Testing Battery Battery Test Failed Input Battery Current Limit Reduced Input Current Limit Rct Logic Power Failure Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 MONITOR NOTICES Output AC Over Voltage Output AC Under Voltage Output Over Frequency Output Under Frequency Three Wire AC Over Voltage Three Wire AC Under Voltage Three Wire Under Freq PowerNode Network Down Power Off Switch Rectifier Network Down Inverter Network Down Monitor Network Down Battery Time Low Batt Test Requires Calibration Battery Time Low Monitor Logic Power Failure Building Alarm 1 Active Building Alarm 2 Active Building Alarm 3 Active Building Alarm 4 Active Building Alarm 5 Active Building Alarm 6 Active Testing Battery Battery Test Aborted load Battery Test Aborted utility Battery Passed Test Printing Sampled Data Other UPS Bypass Not Available Loss of Redundancy 82 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 R
99. n 1 3 is selected Enter Starting Month 1 12 Enter Day of Week Sunday 1 1 7 Enter Week of Month 1 5 Enter Hour of Test 0 23 Enter Minute of Test 0 59 NOTE Follow each entry with CR CR with no entry will return to Battery Test Setup Menu Enter the information at the prompt with a carriage return to schedule the battery test If entry 4 is selected from the Battery Test Setup menu you will be prompted to enter Y to cancel all pending tests This selection will only cancel pending tests and will not stop a test currently in progress If entry 5 is selected from the Battery Test Setup menu and if a Battery Test is scheduled the following menu is displayed Next Battery Test Scheduled WK DAY MON HR MN 4 FRI MAR 15 34 NOTE Enter CR to return to Battery Test Setup Menu If 5 is selected and there are no tests scheduled the following will be displayed No Battery Test Scheduled Enter CR to return to Battery Test Setup Menu NOTE The unit will only perform one battery test in any 24 hour period 100 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Modify Low Battery Time This menu allows you to modify the low battery time warning When selected the following menu will be displayed Modify Low Battery Time Low Battery Time Minutes 004 Enter New Low Battery Time NOTE Low Battery Time should be no greater than 999 E
100. n battery capacity and the amount of loading If incoming power returns to within specified parameters the UPS automatically returns to Normal mode and alarm indications clear However the process of returning to Normal mode is not instantaneous The rectifier gradually draws increasing power from the incoming utility until Normal mode is achieved Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 43 164201261 Rev F 111503 Maintenance Bypass Mode The UPS can be manually switched to Maintenance Bypass mode allowing the UPS to be electrically isolated from the critical load The bypass source supplies the commercial AC power to the load through an internal circuit breaker CAUTION Critical load is not protected while the UPS is in Maintenance Bypass mode Figure 21 shows the path of electrical power through the UPS system when the UPS is operating in Maintenance Bypass mode LLLE Bypass Input BYPASS BIB open OUTPUT TRANSFORMER MBP closed lt RECTIFIER INVERTER Output MIS open Rectifier Input Input Isolation Transformer closed Path of electrical power BATTERY Figure 21 Path of Current Through the UPS in Maintenance Bypass Mode The wrap around maintenance bypass is useful during routine UPS maintenance or repairs by suppling utility power to the critical load while the UPS inverter and bypass are de energized Th
101. nd Operation 164291261 Rev F 111503 Safety Considerations The UPS and Environmental cabinets are designed for industrial applications in harsh environments However the UPS system is a sophisticated power system and should be handled with appropriate care following these guidelines Keep surroundings clean and free from excess moisture Do not operate the UPS system close to gas or electric heat sources The system is not intended for outdoor use The operating environment should be maintained within the parameters stated in this manual Keep the cabinet doors closed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit The system contains its own power source Lethal voltages are present even when the UPS is disconnected from utility power WARNING Only AUTHORIZED SERVICE PERSONNEL should perform service or maintenance on the parallel redundant system If service or routine maintenance is required Ensure all power is disconnected before performing installation or service Ensure the area around the UPS system is clean and uncluttered Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment Getting Help If you need to schedule initial startup need regional locations and telephone numbers have a question about any of the information in this manual or have a question this manual does not answer pl
102. nd outlets are on the top of the UPS cabinet You must allow clearance in front of and above each cabinet for proper air circulation Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 9 164201261 Rev F 111503 Environment Considerations The UPS system must be installed on a sealed concrete floor WARNING Installation should be performed by qualified personnel Inspecting and Unpacking Each Cabinet The first task in preparing for installation is inspecting and unpacking each cabinet Cabinets arrive covered with protective packaging material as shown in Figure 2 FRE OUTER PACKAGING FOAM CUSHION Figure 2 Cabinet as Shipped with Outer Packaging and Pallet 1 Carefully inspect the outer packaging for evidence of damage during transit CAUTION Do not install a damaged cabinet Report any damage to the carrier and contact your local sales or service office immediately 10 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 2 Use a forklift or other material handling equipment to move the cabinets to a convenient unpacking area Insert the forklift jacks between the foam cushions on the bottom of the unit CAUTION DO NOT tilt cabinets more than 10 degrees from vertical 3 Set each pallet on a firm level surface allowing a minimum clearance of 4 6m 15 ft on each side for removin
103. ng to System Events B The battery charge box shows the percentage of battery capacity available C The menu box shows the currently selected menu and lists the options available on that menu The title at the top of the menu box is also shown below on the menu bar E Press the ft and 9 pushbuttons to scroll up and down through the options in the menu box 52 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 D The currently selected option is highlighted in the menu box Press the ft and pushbuttons to move the highlight up or down The data in the information area G changes accordingly E The menu bar lists the titles of the menus The title of the menu currently displayed in the menu box is highlighted When you press the and m pushbuttons to move the highlight right or left the data in the menu box and the information area change accordingly F The timestamp shows the current date and time This date and time are recorded in the Event Log when a notice or alarm is activated G The information area contains data about UPS status and operations Select a menu option to display statistics or graphics You can use the LCD screen and the pushbuttons beneath it to Monitor UPS operation Lookata log of UPS events alarms notices and commands Using the Pushbuttons The pushbuttons below the LCD screen are labeled with arrows indicating their t V E mp J
104. nly 600 VAC for operation from 510 VAC to 660 VAC 60 Hz only Operating Input 3 Hz of nominal 60 Hz Frequency Range Operating Input Battery Charge Current 125 of full load for overload battery charge Actual load 25 of full load for battery charge Reduced for Generator Adjustable set to 102 Input Current 10 maximum over zero to full load based on 10 THD at full Harmonic Content load with input filter option installed Power Walk in Typically 15 20 second rectifier ramp up to full utility load Power Factor Minimum 0 9 Line Surges 6 kV OC 3 kA SC per ANSI 62 41 and IEC 801 4 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 121 164201261 Rev F 111503 System Output Rectifier Charger Capacity 135 6 Kw DCFiltering Ripple voltage less than 0 5 peak to peak UPS Output Capacity 10096 current at 0 8 power factor Output Voltage Regulation 1 10 to 100 load Output Voltage Adjustment 480 VAC nominal adjustable from 452 VAC to 508 VAC 60 Hz only Output Voltage Harmonic Content 2 max THD 2 max single for linear load Output Voltage Balance 2 for 100 maximum load imbalance Output Voltage Phase Displacement 2 for 100 maximum load imbalance Output Transients 5 for 100 load step or removal Frequency Regulation 0 005 Hz free running Synchronous to Bypass Bypass within
105. nstructions will void the product warranty The line to line unbalanced output capability of the UPS is limited by the full load per phase current values for AC output to critical load shown in Tables A through C The recommended line to line load unbalance is 50 or less Table H lists the maximum rating for output circuit protection devices circuit breakers Table H Maximum Output Circuit Breaker Ratings Bd E eun Output Voltage Rating Rue E 208V 400V 480V Balanced Power 75 Balanced Power 62 5 Balanced Power 50 ws 90 8 DESCRIPTION INSTALLATION NOTES DRAWING NO 164201261 1 SHEET 6 of 11 REVISION c DATE 093001 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation A 7 164201261 Rev F 111503 25 Table lists the maximum rating for DC input circuit protection devices circuit breakers BalancedPowere25 OO 26 Your UPS equipment s operating environment must meet the size and weight requirements shown in Table J according to your UPS system configuration Table J Equipment Weight and Point Loading Weight Point Loading Component Kg Ib Kg Ib UPS and Environmental Cabinets 1878 4140 8 at 235 518 27 The basic environmental requirements for operation of the UPS system are Ambient Temperature Range 0 50 C 32 122 F Recommended Operating Range 20 25 C 68 77 F Maximum Relative Humidity 9596 DESCRIPTION INSTALLAT
106. nt History Log Figure 31 shows the Time Setup screen Uninterruptible Power System UPS System Normal 04 MAY 1998 14 25 55 Alarm None Notice None Battery Percent 100 Set Time amp Date DAY DT MON YR HR MN SAVE MON 07 APR 98 15 06 YES Meters Events Statistics Graphics Rae Figure 31 Time Setup Screen The small return arrow d appears in the upper right corner of the Time Setup screen This arrow is a reminder that you can press the B pushbutton on the Monitor Panel to toggle the pushbuttons between the menu box and the information area When the scroll bar is in the information area the return arrow is in the menu box When the scroll bar is in the menu box the return arrow is in the information area When the scroll bar appears in the information area you can use the pushbuttons to change the timestamp settings To change a setting in the timestamp press the and pushbuttons to highlight the setting you want to change To increase the setting make it a higher value press the pushbutton To decrease the setting make it a lower value press the pushbutton If you want to save the settings upon exit from this screen be sure the SAVE field is set to YES Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 61 164201261 Rev F 111503 Select Port 1 or Port 2 from the Setup menu to display one of the Port Setup screens The Port Setup screen
107. nt log for each attempted call out If the phone number that the UPS is calling does not answer the UPS delays for a time period programmable from 1 to 60 minutes and then reattempts the call If answered the UPS ceases further attempts to call Each call group can be programmed for a separate number of attempts to call and delay between calls Each unsuccessful attempt to call causes an unsuccessful notify event to be logged into the UPS event log If both call groups are active the UPS alternates between calling the groups The Call Out process can be terminated at any time by calling into the UPS and sending the reset command press and hold CTRL and press R or by turning the key switch on the front of the UPS Housekeeping When the modem is idle the UPS pings tests for connection the modem by sending an AT to the modem at five minute intervals If the modem does not respond correctly by sending either OK or 0 to the UPS the UPS attempts to re initialize the modem After a successful re initialization the UPS returns to the Housekeeping function If the re initialization is unsuccessful two more attempts to re initialize the modem are made before the UPS disables all Call Out attempts Re initialization is then attempted every ten minutes or until the communications mode is changed by the UPS front panel controls or the modem re initializes For each unsuccessful attempt the UPS logs a modem failure event
108. nter CR to return with no change Enter the new time desired to change the warning level Calibration Mode Calibration mode is used by factory and field service personnel to calibrate system meters Factory test engineers calibrate the UPS meters prior to shipping so the UPS arrives at your site correctly calibrated After use field service personnel may need to use Calibration mode to recalibrate one or more meter settings NOTE Calibration mode is for use by service personnel ONLY To prevent inadvertent modification this mode can be accessed only by trained personnel Computer Mode This mode provides a computer interface which gives your system compatibility with system monitoring and network products For a list of products available contact your sales representative Remote Monitor Mode This mode provides the interface for the RMP RIM or SCM described earlier Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 101 164201261 Rev F 111503 This Page Intentionally Left Blank 102 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 ri Optional Remote Notification NOTE The optional RS 232 serial communication port is required to use this feature Remote Notification provides the user with the option of receiving alarms and notices at a remote location Remote Notification also provides some basic controls that can be perfo
109. ntrols BEER A the UPS This chapter describes how to start and stop the UPS and how to transfer the system to maintenance bypass Figure 33 shows the NOTE Before starting the UPS ensure all installation tasks are complete and a preliminary startup has been performed by authorized service personnel The preliminary Startup verifies all electrical interconnections to ensure the installation was successful and the UPS system operates properly
110. number of leading spaces should be included when entered 98 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Adjust Output Voltage If Adjust Output Voltage is selected from the main menu the following menu is displayed Adjust Output Voltage Output Voltage Setup 208 Output Voltage Range 197 218 Enter Desired Output Voltage Setup The output voltage desired can then be entered or a carriage return for no change Only values within the range will be accepted Change Password If Change Password is selected from the main menu the following menu is displayed Change Password Enter New Password Verify New Password NOTE Password must be six characters in length CR to return with no change The password will be changed if the user enters and verifies the password The entry must be six characters Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 Battery Test Setup If Battery Test Setup is selected from the main menu the following menu is displayed Battery Test Setup 1 Setup One time Delayed Battery Test 2 Setup Monthly Battery Test 3 Setup Quarterly Battery Test 4 Cancel Pending Battery Test 5 Display Next Scheduled Battery Test 6 Return to Main Menu Enter Selection This menu allows you to schedule review schedule or cancel pending battery tests The following menu is displayed whe
111. on To use the EMERGENCY POWER OFF Pushbutton Resetting the UPS System after Emergency Power Off 11 Using Features and Options L L e Building Alarm Monitoring 0 0 cece eee Summary Alarm Contacts 0 00 c cece eee Remote Monitor Panel 2 22 5 252s Relay Interface Module 0 0 cece ee eee tees Supervisory Contact Module 0 00 cece eee eee 12 Responding to System Events System Event Horns 2c ee rr RR e OC dre REA IU a NU Tu System Event Lights oso er Ex Coh esee adeb oe tlle es System Event Messages ssssssseseseese eere 13 Serial Communications eee nnn Locating the Communications Panel uuselssuus Connecting Equipment to a Serial Port 0 000 e eee eee Configuring the Serial Ports 0 cece eee eee ee Mod s eee Fete at WAM ale tata ata ce Teo che REN Da ta StO Em Handshaking riia mene oet dete e Qe sesh ede arce tuc Disabled No Handshaking 00 cece eee eee eee XON XOFF i5 ER REA UnIEie eU RISE CUSLRi uds Default Settings 29 8 cee o ist aee esee Eoo ax ot E ose Terminal Mode s 5i nit Ec i e C E kha bbw een Printing Selected Information 00 cee eee eee Entire Log Gl x B awl cutie Fea tees ERR Gena SER aH Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Ope
112. on and Operation 23 164201261 Rev F 111503 IDOIECOIORDSAUTJS TD MS do B bk WD the shel ee le ST ger FLUSH MOUNT SURFACE MOUNT FOR HANGING 24 WIRES MUST BE TWISTED Figure 7 Remote Monitor Panel RMP 24 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Before installing an RMP be sure you have prepared the UPS according to the instructions in Chapter 2 To install an RMP 1 Securely mount the RMP s 2 Install wiring from the RMP using 12 in conduit through the cable entry panels in either the top or bottom of the UPS cabinet The top entry connection requires installation of 1 2 in flexible conduit within the UPS Bottom entry connection requires no additional routing of conduit within the UPS 3 In the spare parts kit locate the RMP adapter cable assembly see Figure 8 Mate the DB 9 connector on the back of the terminal block into the DB 9 connector on the Communications Panel of the UPS see Figure 9 Use two screws from the spare parts kit to secure the terminal block bracket to the Communications Panel Connect to Port 1 DB 9 on Communications Panel z 9 TERMINAL Z BLOCK p TB3 5 Figure 8 Terminal Block Bracket
113. ore detailed safety precautions described in Important Safety Instructions section of Chapter 15 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 49 164201261 Rev F 111503 Symbols Controls and Indicators These symbols may appear on your UPS system or on labels inside the UPS They are accepted by most international safety agents Everyone in your organization who works with your UPS should understand the meaning of these symbols 2 A A ON The principal power switch is in the On position OFF The principal power switch is in the Off position PHASE The word phase CAUTION REFER TO MANUAL Stop and refer to the Operator s Manual for more information RISK OF ELECTRIC SHOCK There is a risk of electric shock present and you should observe associated warnings The UPS contains high voltages 50 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 a8 Using the Monitor Panel This chapter describes the Monitor Panel and how to monitor and control UPS operation The Monitor Panel is a black rectangular area on the front of the UPS see Figure 23 e i aS POW ERWARE TE EMERGENCY POWER OFF 4 1 2 EB Normal El L m m EE Battery EE Bypass Press Any Button 3 EN Notice To Silence Horn EB Alarm EB Standby UNINTERRUPTIBLE POWER SYSTEM Figure 23 UPS Monitor Panel Powerware BPIII Harsh Environment UPS 50
114. our seconds Turn BATTERY switch to NORMAL The converter restarts Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 69 164201261 Rev F 111503 Using the EMERGENCY POWER OFF Pushbutton Emergency Power Off is initiated by the covered red EMERGENCY POWER OFF pushbutton on the Monitor Panel This pushbutton is protected by a clear plastic shield to prevent accidental activation In an emergency you can press this pushbutton to instantaneously open the input breaker and interrupt UPS output The UPS is cut off from utility power and your critical load is de energized All power to the critical load is lost The UPS including Bypass remains locked off until you reset the EMERGENCY POWER OFF pushbutton WARNING All power to the critical load is lost when you press this pushbutton You should use this feature only in an emergency or when you want to de energize the critical load To restart the UPS after pressing the EMERGENCY POWER OFF pushbutton follow the procedure Resetting UPS System after Emergency Power Off of this chapter before starting the UPS NOTE The Remote EMERGENCY POWER OFF option functions the same way as the EMERGENCY POWER OFF pushbutton on the Monitor Panel To Use the EMERGENCY POWER OFF Pushbutton 1 Raise the clear plastic shield covering the red EMERGENCY POWER OFF pushbutton on the Monitor Panel 2 Press the EMERGENCY POWER OFF pushbutton The breakers open you
115. r The modem operates at only one baud rate because there is no handshaking between the modem and the UPS Select the lowest common baud rate less than or equal to 2400 baud compatible with the capability of the UPS interface equipment For example if the computer only has a 2400 baud modem then the UPS should be set for 2400 baud Remember the remote computer modem can always slow down to the UPS baud rate e g a 14400 baud modem can run at 2400 baud but a 2400 baud modem cannot run at 14400 baud Following the instructions in Chapter 9 Using the Monitor Panel and Chapter 13 Serial Communications use the LCD screen and pushbuttons on the Monitor Panel to access the setup screen and configure Port 2 as follows NOTE The modem should be connected to the UPS as described in the modem manufacturer s manual before configuring the UPS communications port MODE Remote Notify RATE The baud rate at which the modem will communicate to other modems 2400 baud maximum lt DATA STOP gt 8 1 Standard 8 data bits 1 stop bit no parity lt HANDSHAKING gt Disabled lt SAVE gt Yes To save new configuration The handshaking feature listed is for UPS to terminal handshaking not UPS to modem handshaking Setting the handshaking to modem has no effect If the remote terminal has buffering problems because of excessive data transfer rate from the UPS XON XOFF handshaking can be selected to resolve this issue The user must
116. ration 164201261 Rev F 111503 Meters Printout Ctrl M ssuuuseeeeeeeeseenneee 94 System Information Printout Ctrl A luuuseuuuussss 94 Battery Test Printout Ctrl B suuusllsesseeeeeresess 95 System Cotnnqgulratiolf d uoo cett d Means tere des EXS 96 System Configuration Mode Main Menu 0055 96 Program Building Alarms 0 0 0 cece eee 96 Enable Disable Default Functions 2 0 cee eee eee 97 Customize Alarm Messages 0 c cece eee eee ee 98 Program Unit Name 4 epu ter deret e an rece po ein 98 Adjust Output Voltage 0 cece ees 99 Change Passwords inccotseetieoe bedi ee hone akin Mies 99 Battery Test Setup cscs tee auton denen oe eee acct ney eto e Ru en 100 Modify Low Battery Time 0 0 00 cece eee eee 101 Calibration MOG ou pp LERRA ERRARE ERIEEER UD REX Ti 101 Computer Mode a x serch cos te ee fang arth ede x aac rh vba d x e 101 Remote Monitor Mode ssssusseseee nne 101 14 Remote Notification uuleeeeeee eere 103 Remote Notification Features 00 cece eee 104 Description of Operation 0 cc eee ees 105 GSILADSWEE 14 take wees tate Daas Madan ase Pane aut 105 Call QUE cace tae coat ete ewe eee meee bas etd depu 105 Housekeepllig mi ci ecce dct str e etm toe rie t oc a 106 Hardware Requirements ellieeeeeeeeee eee 107 Configuring the Modem c c
117. ration 164291261 Rev F 111503 RECTIFIER ALARMS Rectifier Failure Rectifier DC Over Voltage Rectifier DC Under Voltage Input Phase Rotation Over Temperature Over Temperature Warning Temperature Sensor Failure Rectifier Calibration Required Rectifier Setup Required MONITOR ALARMS Overload Warning Load Over 10096 Load Over 125 Battery Test Failed Battery Test Failed EEPROM Write Failed Logic Power Supply Failure Fan Failure UPS Failure Other UPS is On Bypass Other UPS Status is Unknown Emergency Bypass Failure Redundant Module Failure Check KW Sensing Check Parallel Setup Parallel System Overload On Battery more than 30 Seconds Check UPM Breaker CBS AUX Check Bypass Breaker CBP AUX Monitor Calibration Required Monitor Setup Required Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 ENVIRONMENTAL CABINET ALARMS Converter Offline Converter Failure Converter Fan Failure Converter Fuse Blown Converter Overtemp Converter Link OV Converter Link UV Converter Battery OV Converter Battery UV Converter Overcurrent Converter Calibration Required Converter Setup Required Converter Board Failure INVERTER NOTICES Input Breaker CB1 Open Bypass Mode Bypass AC Over Voltage Bypass AC Under Voltage Bypass Over Frequency Bypass Under Frequency Bypass is Not Available Battery Discharged Battery DC Under Voltage Battery Disconnected Battery Not Charged Phase A Current Li
118. re BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 41 164201261 Rev F 111503 Bypass Mode The UPS automatically switches to Bypass mode if it detects an overload load fault or internal failure The bypass source supplies the commercial AC power to the load through an internal switch and an internal transformer CAUTION The critical load is not protected while the UPS is in Bypass mode Figure 19 shows the path of electrical power through the UPS system when the UPS is operating in Bypass mode CCCCCCCOCoCCCOCCOCCOCCOCCOCCCCCCoCCC CC CC CCC CC C o c ccc Bypass BIB Input closed 2222777222222 j TPUT TRANSFORMER K 3 3 RECTIFIER INVERTER MBP open f gt Output MIS closed Rectifier Input Input Isolation Transformer closed Path of electrical power BATTERY Figure 19 Path of Current Through the UPS in Bypass Mode You can transfer the UPS from Normal mode to Bypass mode manually However the UPS switches automatically to Bypass mode whenever the inverter can no longer supply the critical load If the UPS transfers to Bypass mode from Normal mode due to any reason other than operator intervention the UPS automatically attempts to transfer back to Normal mode up to three times within a 10 minute period Bypass mode is a normal operating mode and not an alarm condition However if the UPS is unable to return to Normal mode following
119. re in millimeters inches DESCRIPTION WIRING CONDUIT AND CONTINUES AT UPS RELAY INTERFACE MODULE PRAWINGNO 164201261 8 SHEET 1of2 REVISION A DATE 053099 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 15 PIN D SUB CONNECTORS w Jj Gm ge u KNOCKOUTS PROVIDED ON FIVE SURFACES Dimensions are in millimeters inches DESCRIPTION RELAY INTERFACE MODULE PRAWING NO 164201261 8 SHEET 2 of 2 REVISION A DATE 053099 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 KNOCKOUTS PROVIDED ON FIVE SURFACES FLUSH MOUNT A MAX WIRE SIZE NO 14 AWG MIN WIRE SIZE NO 18 AWG Co CONDUIT AND WIRING SUPPLIED BY CUSTOMER MAX DISTANCE BETWEEN REMOTE MONITOR AND UPS NOT TO EXCEED 500 FEET Se Dimensions are in millimeters inches WIRES MUST BE TWISTED SU
120. rmed remotely on the UPS Remote Notification operates through a standard computer modem Using the Terminal mode the user calls the UPS to perform basic monitoring and control In the event of a UPS alarm or notice the user is notified at the remote location The UPS calls through the modem to the user s computer or pager and leaves a message Remote Notification is an extension of the Terminal mode with the additional support algorithms necessary to control an external modem refer to Chapter 13 Serial Communications Connection to the UPS is made when a user calls the UPS on the phone The user has exactly the same capabilities as if using a terminal connected directly to the optional UPS RS 232 port Remote Notification differs from the basic Terminal mode with the addition of Call Answer Call Out and Housekeeping functions The Call Answer function allows the user to call into the UPS from a remote location and enter Terminal mode The Call Out function allows the UPS to be configured to call either a remote computer or numeric paging service over the phone line Call Out allows the UPS to call a remote computer and leave a one line descriptive message of the alarm or notice condition Numeric paging support allows the UPS to call a paging service and send numeric messages The Housekeeping function maintains the link between the UPS and modem Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 103 164201261 R
121. rmt rte ar Re 0 3 Conventions Used in This Manual ssssseseessssss 4 Safety Considerations 2e scinivitesd ave RR RELIER weds AS 5 Getting Help nee tos Bee AO rec o am tuuc ER etuer mare UA xs 5 Section I Installation 0 0 ccc eects 7 1 Getting Started 0r oed bie gabe ves baee dea x a eco 9 Creating an Installation Plan 0 cece eee 9 Preparing Your Site ace eesex ve hr er REROOORETREFREUE RE ase sees 9 Environmental Considerations sssssseees seres 10 Inspecting and Unpacking Each Cabinet ssuuu 10 Unloading the UPS System From the Pallet L suu 11 Wiring Requirements 2 2 2 0 6 ec ee eee I e 12 2 Installing the Harsh Environment UPS System 13 Installing the UPS Cabinet Sections 000 c eee eee ee 14 Grounding Joined Cabinets 0 0 c cece 15 Installing UPS Internal Power and Control Wiring 16 Installing UPS External Wiring lessen 17 Preparing the UPS for Installing Optional Accessories 17 Initial StA HUp v 42 eon a Se ee ea Ga es 17 Completing the Installation Checklist 00 0c eee eee 18 Installation Checklist 0 0 0 c cece eee 19 3 Installing a Remote EPO Control Lusueeee 21 4 Installing a Remote Monitor Panel 23 5 Installing a Relay Interface Module 29 6 Installing a Superv
122. ro then pressing ENTER 10 The modem dials the telephone number stored in step 4 or 5 The number is displayed on the terminal screen as it is dialed Repeat steps 4 or 5 through 9 as necessary to modify the telephone number 11 Confirm that the modem responds with 1 one when the connection is made NOTE To set up a group one or group two pager number refer to Configuring the Modem to Call a Numeric Pager section of this chapter Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 109 164201261 Rev F 111503 Configuring the Modem to Call a Numeric Pager To configure the modem to call a numeric pager system perform the following procedure NOTE Perform this procedure only after completing Basic Modem Configuration section of this chapter The brackets in the following steps indicate characters that require keying in prior to pressing ENTER Connect the modem to the PC through the serial port as described in the modem manufacturer s manual Key in A T then press ENTER Confirm that the modem responds with OK or 0 zero NOTE In steps 4 and 5 the xxxxxxx is the pager system number and yyyyyyy is the N Oo numeric message usually a phone number The three provide a delay while the pager system computer answers The xxxxxxx entry should include all local line and long distance access numbers needed to
123. round the system according to local and or national electrical wiring codes using your own cabling and conduit NOTE Startup and operational checks should be performed only by authorized service personnel This service is usually offered as part of the sales contract for your UPS system Creating an Installation Plan Before beginning to install your UPS system you should be sure you understand the instructions in this manual Use the procedures and illustrations in the following sections to create a logical plan for installing the UPS system The information in this chapter and Chapter 2 will help you plan the installation Preparing Your Site For your UPS system to operate at peak efficiency your installation site should meet the environmental parameters outlined in this manual If you intend to operate the UPS at an altitude higher than 1500 meters 5000 feet contact your local sales or service office for important information about high altitude operation The operating environment must meet the size and weight requirements shown in Table J of Appendix A The basic environmental requirements for operation of the UPS system are Ambient Temperature Range 0 50 C 32 122 F Recommended Operating Range 20 25 C 68 77 F Maximum Relative Humidity 9596 The UPS and Environmental cabinets use forced air cooling to regulate internal component temperature Air inlets are on the right side of the Environmental Cabinet a
124. ry Discharged Battery Not Charged Battery Voltage Low Phase A Current Limit Phase B Current Limit Phase C Current Limit Group 1 Group 2 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 113 RECTIFIER MESSAGES ALARMS Input Phase Rotation Over Temperature Over Temperature Warning Rectifier Calibration Required Rectifier DC Over Voltage Rectifier DC Under Voltage Rectifier Failure Rectifier Setup Required Temperature Sensor Failure Group Group RECTIFIER MESSAGES NOTICES Battery Test Failed DC Voltage High DC Voltage Low Equalizing Battery Input AC Over Voltage Input AC Under Voltage Input Over Frequency Input Transient Input Under Frequency Input Battery Current Limit Logic Power Failed Power Supply Over Voltage Power Supply Under Voltage Rectifier 1 12 Reduced Input Current Limit Testing Battery Group Group 114 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 MONITOR MESSAGES ALARMS Battery Test Failed Battery Test Failed Fan Failure Load Over 10096 Load Over 12596 Monitor Calibration Required Monitor Setup Required Overload Warning Power Supply Failure Group Group MONITOR MESSAGES NOTICES Battery Passed Test Battery Test Aborted load Battery Test Aborted uti
125. s 2 Customize Alarm Messages 3 Return to Main Menu Enter Selection 96 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Enable Disable Default Functions From this menu you may either enable the building alarms for general functions or special functions such as On Generator Go To Bypass and Go To UPS You may also customize the alarm messages from this menu When 1 is selected from this menu the following menu is displayed Enable Disable Default Functions 1 Enable Disable Go To Bypass 2 Enable Disable Go To UPS 3 Enable Disable On Generator 4 Enable Disable Building Alarm 5 Return to Program Building Alarms Menu Enter Selection If you select entry 1 3 from this menu the following menu will be displayed Enable Disable Function Enabled Building Alarm Number s 14 Enter EZ to Enable Building Alarm Number Enter D to Disable Building Alarm Number Enter CR for No Change Enter Selection Where Function indicates the function the building alarm is being programmed for The line following the Enabled Building Alarm Number s label indicates which building alarms are currently enabled for the function In this example Building Alarms 1 and 4 are enabled A building alarm can only be programmed for one special function at a time from these menus Enabling a building alarm for a special function automatically enables the alarm If you disable a special f
126. s allow you to specify settings for the two serial communication ports on the UPS Figure 32 shows the Setup Serial Port 1 screen Uninterruptible Power System UPS System Normal 04 MAY 1998 14 25 58 Alarm None Notice None Battery Percent Setup Serial Port 1 100 RATE DATA STOP HANDSHAKING SAVE 9600 8 1 XON XOFF NO Meters Events Statistics Graphics Fea Figure 32 Port Setup Screen The small return arrow d appears in the upper right corner of the Port Setup screen This arrow is a reminder that you can press the lj pushbutton on the Monitor Panel to toggle the pushbuttons between the menu box and the information area When the scroll bar is in the information area the return arrow is in the menu box When the scroll bar is in the menu box the return arrow is in the information area When the scroll bar appears in the information area you can use the pushbuttons to change the port configuration To change a setting press the 4 amp and gt pushbuttons to move the highlight to the setting you want to change To scroll through the available options for that setting press the or amp pushbutton To save the settings upon exit from this screen be sure the SAVE field is set to YES The setup screens for Port 1 and Port 2 are identical 62 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 location of the operating co
127. s of the UPS Remove the lower sheetmetal shield Set the shield and hardware aside for later reuse Initial Startup Startup and operational checks should be performed only by authorized service personnel Contact service in advance usually a two week notice is required to reserve a preferred startup date Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 17 164201261 Rev F 111503 Completing the Installation Checklist The final step in installing the UPS system is completing the following Installation Checklist This checklist ensures that all hardware cables and other equipment have been completely installed Completing all items on the checklist will ensure a smooth installation Make a copy of the Installation Checklist before filling it out and retain the original After the installation is complete a service representative will be able to verify the operation of the UPS system and commission it to support the critical load The service representative cannot perform any installation tasks other than verifying software and operating setup parameters Service personnel may request a copy of the completed Installation Checklist to be sure you have completed all applicable equipment installation NOTE The Installation Checklist MUST be completed prior to starting the UPS system for the first time Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 11
128. s together placing the UPS cabinet on the left side of the Environmental Cabinet Secure the UPS and Environmental cabinets with the leveling feet provide on each cabinet Locate the field kit and remove cabinet joining brackets and hardware from the kit Install the brackets to the front and rear of each cabinet base using the threaded holes provided Brackets should be mounted so that the tabs at end of the brackets meet between the two cabinets Install bolts through the tabs at front and back and secure with washers and nuts Secure cabinet sides to each other at the top front and top back with 1 2 inch bolts washers and nuts from the field kit Use the holes provide in the cabinet sides Attach a ground to the joined cabinets using the procedure Grounding Joined Cabinets in this chapter 14 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Grounding Joined Cabinets Open the door of each cabinet Locate the grounding stud at the front side of each frame Remove the top nut lock washer and flat washer from each stud if attached see Figures 5 1 Locate the grounding cable part of the field kit located in a small bag which is fastened to the UPS cabinet in the customer terminal area 2 Mount the grounding cable as shown in Figure 5 attaching it to the frame of each cabinet using the hardware previously removed UNINTER
129. source is supplying the critical REDUNDANCY load Usually this means that the UPS is not energized The load is not protected in Bypass mode and a horn sounds after 30 seconds BATTERY UPS ALARM The UPS system is issuing an alarm Conditions that affect the current UPS mode are indicated by the alarm lamps and horn on the UPS BYPASS GENERATOR UNAVAILABLE ON BATTERY The UPS battery backup is supplying the critical load The utility power is either interrupted or out of specification The SYSTEM NORMAL indicator is also lit SHUTDOWN BYPASS UNAVAILABLE The UPS system is in Normal mode but BYPASS a bypass source is not within specification A horn sounds after 30 seconds IMMINENT SHUTDOWN IMMINENT The UPS is preparing to shut down because the UPS is in Battery mode and the DC voltage is approaching its low limit This light is accompanied by an audible alarm horn 74 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Relay Interface Module An optional Relay Interface Module RIM uses relay contact closures to indicate the operating status and alarm condition of the UPS system A maximum of two monitoring accessories RMPs RIMs or SCMs can be installed See Table 1 for the number of accessories permitted Figure 38 shows the RIM with its four 15 pin connectors labeled J1 through J4 Figure 38 Relay Interface Module The RIM can provide these signals
130. splay the current status of the UPS You can view a statistical history and log of UPS events and display a real time graphic representation of power flowing through the UPS components Backlit status indicators show the operating mode of the UPS and alert you to system events Maintenance Bypass Maintenance Bypass MBP Circuit Breaker This breaker is normally open When closed it feeds utility power to the critical load when the MIS breaker is opened Maintenance Isolation MIS Circuit Breaker This circuit breaker is normally closed feeding UPS power to the critical load This breaker is opened to isolate the UPS after the MBP breaker is closed Maintenance Bypass MBP Circuit Breaker This circuit breaker is normally closed feeding bypass power to the UPS internal bypass circuit This breaker is opened to isolate the UPS bypass after the load is transferred to maintenance bypass UPS Standard Features The UPS has many standard features that provide cost effective and consistently reliable power protection Communication Panel Computer Interface One combination RS 232 RS 485 serial communication port is standard on all units and is electrically isolated from the UPS An additional RS 232 serial communication port is available as an option and is also electrically isolated from the UPS Summary Alarm Contacts Alarm contacts are provided for connection to equipment at your facility such as a light an audible alar
131. t the input terminals The circuit breaker CB2 switch controls the application of battery power to the UPS If CB2 is closed the rectifier charges the battery through the DC to DC converter during normal operation If utility power is lost battery power is supplied to the inverter through the DC to DC converter Maintenance Bypass MBP Circuit Breaker This breaker is normally open When closed it feeds utility power to the critical load when the MIS breaker is opened Maintenance Isolation MIS Circuit Breaker This circuit breaker is normally closed feeding UPS power to the critical load This breaker is opened to isolate the UPS after the MBP breaker is closed Bypass Input BIB Circuit Breaker This circuit breaker is normally closed feeding bypass power to the UPS internal bypass circuit This breaker is opened to isolate the UPS bypass after the load is transferred to maintenance bypass Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 65 Operation The following sections describe how to operate the controls to start stop or change the operating mode of the UPS To Place the UPS in Normal Mode 1 gu Si 095 Ju Close BIB circuit breaker Close CB1 circuit breaker Turn the BATTERY switch to NORMAL Turn the MODE switch to NORMAL Ensure the Emergency Power Off PUSH TO RESET pushbutton is pressed in Turn the START switch to the right mom
132. te EPO Control discusses installing the optional Remote Emergency Power Off EPO control Chapter 4 Installing a Remote Monitor Panel contains information for installing the optional Remote Monitor Panel RMP Chapter 5 Installing a Relay Interface Module contains information for installing the optional Relay Interface Module RIM Chapter 6 Installing a Supervisory Contact Module contains information for installing the optional Supervisory Contact Module SCM Section Il Operation Chapter 7 Understanding UPS Operation provides information on understanding the operation UPS Chapter 8 Controls and Features describes the standard features and controls of the UPS system Chapter 9 Using the Monitor Panel describes the controls and indicators found on the Monitor Panel and shows the various information screens displayed on the LCD screen Chapter 10 Operating the UPS contains startup and shutdown procedures for the UPS system Chapter 11 Using Features and Options contains descriptions and instructions for the UPS system features and options Chapter 12 Responding to System Events lists all the alarm messages and notices that occur during operation of the UPS system Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 e Chapter 13 Serial Communications describes the serial communications features o
133. tem Meters Screen Typical for Powerware BPIII HE 75 480 480V Unit The Input area shows the phase to phase voltage frequency and phase current of the incoming utility followed by the KVA KW and power factor measurements The output area shows the same information for the power being output by the UPS The Bypass area shows the phase to phase voltage of the bypass source The Battery area displays the DC voltage V and the DC current I at the inverter side of the DC to DC voltage converter Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 164201261 Rev F 111503 55 Select Load Amps from the Meters menu to see a real time bar graph of the output current of the UPS The graph shows the current for each phase Figure 26 shows the Load Amps Meters screen Uninterruptible Power System System Normal 04 MAY 1998 14 25 45 Alarm None Notice None Battery Output Current Percent 100 land Meters EE System Phase A Phase B Phase C Events Statistics Graphics Setup Figure 26 Load Amps Meters Screen Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Select History from the Events menu to display the Event History Log The Event History Log lists up to 400 system events in chronological order with the most recent event listed last The end of the log the most recent events appears when you display th
134. thin 2 seconds an alarm sounds Prevent transfer to Normal mode when the UPS is in Bypass mode Shut down the power processing unit inverter and rectifier of the UPS NORMAL OFF PUSH d TO RESET BATTERY l NORMAL A A BYPASS START MODE Figure 34 UPS Control Panel The BATTERY switch is a two position rotary switch that allows you to manually enable or disable the Battery Breaker CB2 The battery switch is also used to reset the DC to DC converter if the converter shuts down during normal operation The PUSH TO RESET pushbutton is described in the Resetting UPS System after Emergency Power Off section of this chapter 64 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 The START switch activates the power controls on the Control Panel The START switch is center biased the key will rest only in the upright position Its operation is similar to that of an automobile ignition switch After setting the operator controls you turn the START switch to the right momentarily to activate the controls When you release it it returns to the upright position The following paragraphs describe the controls and indicators found in the Environmental cabinet see Figure 33 The circuit breaker CB1 switch supplies power to the rectifier and inverter If CB1 is on closed the rectifier turns on when the START switch is activated and the proper voltage is a
135. to let you know when the UPS is operating in any mode other than Normal Only the Normal indicator is visible during normal UPS operation The others light to indicate alarms or events When an alarm occurs you should first check these indicators to see what type of event has taken place For descriptions of the status indicators see Reading the Status Indicators section of Chapter 9 Using the Monitor Panel Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 77 164201261 Rev F 111503 System Event Messages When a system event occurs a message is added to the Event History Log A message may also appear on the Monitor Panel of the UPS The Event History Log contains all system event messages whether or not they were displayed on the Monitor Panel INVERTER ALARMS Inverter Failure Inverter AC Over Voltage Inverter AC Under Voltage Inverter Over Frequency Inverter Under Frequency Inverter DC Over Voltage Bypass Phase Rotation Inverter Phase Rotation Service Required UPS Tripped Shutdown Imminent UPS Off Battery Contactor K2 Failed Bypass Contactor K4 Failed Inverter Contactor K3 Failed Bypass Control Failed Check Unit Setup Bypass Contactor K4 Fail Battery Ground Fault 100 Overload Shutdown 125 Overload Shutdown Over Temperature Shutdown Network Sync Failure Inverter Calibration Required Inverter Setup Required Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Ope
136. to save any changes Default Settings The following are the default configuration settings for the serial communications ports Port 1 Remote Monitor 300 baud 8 1 Handshaking Disabled Port 2 Terminal 9600 baud 8 1 Handshaking Disabled Each communications port on the UPS operates in one of five modes which you select when configuring the port using the Setup Port screen Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 91 164201261 Rev F 111503 Terminal Mode In this mode system events are continually logged through the serial port to the device connected to the port Port 2 operates by default in Terminal mode The printed log entries contain a time and date stamp and the alarm text message Terminal mode uses this format for printing alarm entries MMM DD Symbol MM DD HH MM SS hh KYWD KKK lt CF gt lt LF gt HH MM SS hh KYWD MESSAGE kKKK o CF lt LF gt Description Month 3 letters Day 2 digits Hour 2 digits Minute 2 digits Second 2 digits Hundredths of Second 2 digits Keyword ALARM NOTICE COMMAND or STATUS System Diagnostic Information Carriage Return Character ASCII 13 Line Feed ASCII 10 An alarm message is prefixed by the word CLEAR whenever an alarm is entered into the Event History Log with a cleared status Printing Selected Information If a port is operating in Terminal mode and is connected to a computer you can use ke
137. tor the operation of the UPS system from virtually any location within your facility up to 500 feet from the UPS Each RMP contains backlit status indicators and a local horn You can flush mount or surface mount an RMP on a desktop wall or wherever you have a serial interface line A maximum of two monitoring accessories RMPs Relay Interface Modules RIMs or Supervisory Contact Modules SCMs can be installed See Table 1 for the number of accessories permitted Figure 37 shows an RMP UNINTERRUPTIBLE POWER SYSTEM STATUS NO REDUNDANCY Figure 37 Remote Monitor Panel Table 1 Optional Monitoring Accessories Number and Type of Accessories Permitted Remote Monitor Panel Relay Interface Module Supervisory Contact Module Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 73 164201261 Rev F 111503 The RMP contains a local horn and the following backlit status indicators SYSTEM NORMAL The UPS is energized either with utility power or battery backup and is supplying conditioned power to the critical load NO REDUNDANCY SYSTEM This indicator applies only to parallel systems when one cabinet is not NORMAL functioning This feature is not available on this system ON GENERATOR This alarm means that the UPS input and bypass are being supplied by the power from the generator instead of from the utility power ON BYPASS The bypass
138. unction the building alarm is also disabled If you select entry 4 from this menu the following menu will be displayed Enable Disable Building Alarm Enabled Building Alarm Number s 14 Enter EZ to Enable Building Alarm Number Enter D to Disable Building Alarm Number Enter CR for No Change Enter Selection The line following the Enabled Building Alarm Number s label indicates which building alarms are currently enabled In this example Building Alarms 1 and 4 are enabled Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 97 164201261 Rev F 111503 Customize Alarm Messages If Customize Alarm Messages is selected from the Program Building Alarm menu you can select a custom message for a building alarm or disable a previously enabled building alarm custom message When this entry is selected the following menu is displayed Customize Alarm Messages Enabled on Building Alarm Number s 23 Enter Building Alarm Number This example indicates that there are custom messages enabled for Building Alarms 2 and 3 When a building alarm number is entered the message being used by the software is displayed either a custom message or the default message indicated by the list of enabled custom messages If 1 was entered at the prompt the following will be displayed Building Alarm Active Message Building Alarm 1 default message Enter New Message or CR for No Change At this level
139. voltage limits of 5 8 of output setting bypass within 0 5 Hz Frequency Slew Rate 1 Hz per second maximum Overload Capability Up to 125 for 15 minutes Above125 for 30 seconds 1000 for 10 cycles with bypass Maximum Output Capability 300 peak for 10 cycles without bypass 122 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Environmental Specifications Operating Temperature 0 to 50 C without derating However operating at or near 50 C will adversely affect battery life refer to your battery specifications for more information The recommended operating temperature is 25 C Operating Altitude Maximum 1500m 5000 ft at 50 C without derating Storage Temperature 20 to 70 C prolonged storage above 40 C will cause rapid battery self discharge Relative Humidity operating and 9596 maximum noncondensing storage Acoustical Noise 75 dBA at a 1m distance EMI Supression Meets FCC Part 15 for class A devices Electrostatic Discharge ESD Meets IEC 801 2 specifications Withstands up Immunity to 25 kV without damage and with no disturbance or adverse effect to the critical load Battery Specifications These specifications are for batteries supplied by the customer Refer to Battery Data section for more information Nominal Battery String 120 VDC 60 cells Voltage Float Charging 2 25 VDC per cell
140. wers and finishes handshaking the UPS acknowledges the modem connect signal and allows the caller into the Terminal mode refer to Chapter 13 Serial Communications In this mode the user can request four items and perform one command NOTE The brackets in the following steps indicate standard keyboard characters e Display all screens B M P Press and hold CTRL then press A Display battery test results by pressing and holding CTRL then pressing B Display meters screen by pressing and holding CTRL then pressing M Display event history by pressing and holding CTRL then pressing P Reset Call Out Alarms by pressing and holding CTRL then pressing R The Reset Call Out Alarms command causes the UPS to cease Call Out attempts on a currently active alarm and resets that alarm call Refer to the Call Out section of this chapter for more information Call Out The Call Out function contains programmable alarms and status events refer to Chapter 12 Responding to System Events The notification groups tell the UPS to notify a remote computer or pager for each selected event Refer to the Configuring the Modem section of this chapter for information on the modem configuration Refer to the User Selected Events section of this chapter to note which events are designated as group one or two These events are selected when the UPS is purchased The Call Out function activates as follows
141. y 6 To test the indicator lamps press the horn silence button and hold it for 3 seconds All lamps should light and the horn will sound continuously until you release the button 7 Repeat steps 1 2 and 4 through 6 for each RMP you are installing 8 If you are installing an RIM or SCM in addition to an RMP proceed to Chapter 5 or 6 respectively otherwise secure the UPS cabinet by reversing the steps contained in procedure To Prepare the UPS for Wiring to an RMB RIM SCM or Remote EPO of Chapter 2 Powerware BPIII Harsh Environment UPS 50 75 kVA Installation and Operation 27 164201261 Rev F 111503 This Page Intentionally Left Blank 28 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 am Installing a Relay Interface Module The optional Relay Interface Module RIM uses relay contact closures to indicate the operating status and alarm condition of the UPS system The module uses an RS422 serial interface line and may support up to eight critical loads A maximum of two monitoring accessories RMPs RIMs or SCMs can be installed Refer to Chapter 4 Table C for the number of accessories permitted Figure 10 shows the RIM with its four 15 pin connectors labeled J1 through J4 Drawing 164201261 8 in Appendix A outlines the enclosure dimensions FLUSH MOUNT SURFACE MOUNT FOR HANGING tuom d
142. y combinations at any time to print only selected information Ctrl P Ctrl M Ctrl A Ctrl B Prints the entire log with a header Prints the current system meters with a header Prints all system information Prints Battery Test Log To use a key combination hold down the Control key and press the letter key 92 Powerware BPIII Harsh Environment UPS 50 75 kV Installation and Operation 164291261 Rev F 111503 Entire Log Ctrl P This key sequence prints the entire Event History Log of the UPS at the time the data is requested The printout begins with the oldest alarm entry in the queue and ends with the most recent Any alarms that occur while the Event History Log is printing are included in chronological order The Event History Log lists up to 400 system events in chronological order with the most recent event listed last Figure 44 shows a sample Event History Log printout Uninterruptible Power System UPS System Normal Alarm None Notice None 16 16 16 16 16 16 16 16 16 03 JAN 1994 14 22 49 Event History Log 19 29 42 05 46 154 42 29 36 Are 4 00 00 Ul 4 S W Event Description COMMAND STATUS COMMAND STATUS STATUS STATUS STATUS STATUS STATUS JUN 04 12 16 35 9 NOTICE Keyswitch On 0421 Auto Mode 1000 Rectifier Commanded On 2030 Inverter On 2202 Rectifier On Battery Contactor K2 Closed Inverter Contactor 3 Closed Byp
143. you can enter a custom message 30 characters maximum to display when Building Alarm 1 is activated If a custom message is entered to activate the building alarm a custom message should also be entered to deactivate After the message or a carriage return is entered the following is displayed Building Alarm Clear Message Clear Building Alarm 1 default message Enter New Message or CR for No Change At this prompt the user should enter the custom message for the building alarm deactivation state When a message or a carriage return is entered the following will be displayed Enter E to Enable Custom Message Enter D to Disable Custom Message Enter CR for No Change Enter Selection If an E is entered at the prompt the custom messages will be used for the building alarm If a D is entered the default messages will be used for the building alarm Program Unit Name If Program Unit Name is selected from the main menu the following is displayed Program Unit Name Unit Name Enter New Name or CR No Change NOTE Unit Name is 45 characters maximum The current unit name is displayed This name will be displayed on the second line of the display and in the headers of prints from Terminal mode If a change is desired the new unit name should be entered at the prompt The unit name is 45 characters maximum and includes spaces and any punctuation If the user wants to center the text portion of the name the appropriate

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