instruction manual for ups

Manual 7001.410.28.000 Page 1 / 47

prepared: OU edition: 01 date: 28.02.2011 7001_410_28_000_Handbuch_Rev_01_eng.doc

UPS equipment USVCP

With microprocessor control

Manual 7001.410.28.000 Page 2 / 47


Table of Contents Page

1 GENERAL 4 1.1 Abbreviations and Definitions 5 1.2 Symbols and Pictograms 6

2 SAFETY PRECAUTIONS 7 2.1 Hazardous Areas 7 2.2 Safety Instructions 8 2.3 Leakage Current 9 2.4 Action in Emergencies 9 2.5 Battery 9 2.6 Transport 10 2.7 Storage 10 2.8 Unpacking 11 2.9 Installation 12 2.10 Environmental Conditions 13 2.11 Handling of Electrostatic Sensitive Devices 13

3 CONNECTIONS 15

4 BATTERY 16

5 COMMISSIONING 17

6 TAKING OUT OF SERVICE / RESTART 19 6.1 Taking out of Service 19 6.2 Restart 20

7 OPERATING INSTRUCTIONS 21 7.1 Operation Terminal 21 7.2 Handling Assistant 23 7.3 Block Schematic drawing (basic circuit) 24 7.4 Rectifier 25 7.5 Inverter 26 7.6 Static Bypass Switch 27 7.7 Battery Operation (basic circuit) 30 7.8 Manual Bypass (basic circuit) 30 7.9 Manual Bypass (Switching Instructions) 31

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7.10 Parallel Operation with Multiple Blocks 32

8 DESCRIPTION OF THE MODULES 33 8.1 A1 Auxiliary Power Supply Unit 35 8.2 A2 Rectifier Control Unit 36 8.3 A3 Inverter Control Unit 37 8.4 A4 Bypass Control Unit 38

9 INTERFACES, ALARMS AND INDICATIONS 39 9.1 Serial Interfaces 39 9.2 Floating Relay Contacts (UPS A70) 39

10 FAULT LOCATION 40

11 EMERGENCY OPERATION WITH EMERGENCY KEY 41

12 MAINTENANCE 42 12.1 General 42 12.2 Ventilators (Optional) 43 12.3 Battery 44 12.4 Battery Test (Option) 44 12.5 Change of Battery-Buffered Real-Time Clock 45

13 TECHNICAL DATA 46 UPS 10kVA 46

14 CONTACT WITH CUSTOMER SERVICE DEPARTMENT 47

15 REFERENCED DOCUMENTS 47

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1 General This user's manual contains information needed for the installation, operation and use of the uninterruptible power supply (UPS).

Read this instruction through from beginning to end to become familiar with the workings of the UPS equipment before starting the installation work. Dangerous situations could arise especially during

installation and operation of the equipment if you fail to do this.

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1.1 Abbreviations and Definitions

AC input External AC power supply obtained from the public electricity line or local diesel-electric generating set.

a.m.s.l. "Above mean sea level", an altitude reference. Bypass Electronic changeover facility: (see also "Manual bypass")

Thyristor switch capable of connecting the load directly to the AC input line. Also called static switch, static bypass, NUE or EUE in some documents.

CAN bus Controller Area Network bus Configurator Person ("User") authorized to make certain changes to the configuration of the

UPS equipment but only after entering the "configurator" password. EUE see under Bypass above Installation plan

Plan contained in the folder of information supplied by EGBK with the UPS equipment.

Manual bypass

Switch or set of fuse switch-disconnectors making it possible to continue supplying the load with the UPS equipment isolated.

NUE see under Bypass above Operator Person ("User") authorized to initiate certain UPS functions affecting only the

operation of the UPS equipment but only after entering the "operator" password.

Qualified personnel

Appropriately qualified persons who are familiar with the installation, putting into service and operation of this UPS equipment, who have read this operating instruction diligently and who fully understand its contents.

RS232 A communications serial interface conforming with the US EIA232 standard (EIA = "Electronic Industries Association")

Service Person ("User") authorized to have full unrestricted access to the UPS system but only after entering the "service" password.

Soft key An emulation of a hardware key on a display panel with context-appropriate labelling provided by the software.

Soft start A circuit arrangement that reduces the inrush current of an equipment on start-up.

Technical data

Information provided separately as a part of the EGB Gustav Klein installation documentation.

TFT "Thin Film Transistor", a type of LCD flat-panel display screen, sometimes also called "active-matrix LCD".

UPS Uninterruptible power supply. User Generic term including the Operator, Configurator and Service functions. VDE 0100 German electrical standard DIN VDE 0100: "Construction of high-voltage

equipment with rated voltages up to 1000 V" ("Errichten von Starkstromanlagen mit Nennspannungen bis 1000 V")

VDE 0510 German electrical standard DIN VDE 0510: "Batteries and battery installations" ("Bestimmung fr Akkumulatoren und Batterie-Anlagen")

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1.2 Symbols and Pictograms

Danger

Draws attention to sections which, if disregarded, could result in life-threatening situations or danger for personal safety, loss of the integrity of the equipment and data or result in serious material damage.

Note

Indicates additional information and useful tips.

Electrostatically sensitive components

Observe these instructions to avoid damage to electrostatically sensitive components (also see section 2.11)

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2 Safety Precautions

Some parts of this equipment carry dangerous electrical voltages. Disregarding the following warnings can therefore lead to death, serious physical injury or significant material damage. Only appropriately qualified personnel (see section 1.1) may install,

connect, put into service, maintain or repair this equipment. Such qualified personnel must be familiar with all the maintenance and repair work as described in this operating instruction. Disconnect the equipment from all supply voltages before starting any work inside this equipment. For the correct and safe operation of this equipment, it is essential that it be properly transported, stored, installed, fitted out, connected up, operated and maintained. Apart from the warning notices in the various chapters, ensure that the environmental conditions specified in the "Technical Data" are observed.

2.1 Hazardous Areas

No voltage-carrying components can be touched while the UPS doors are closed. Some components, not required for operating the equipment, carry dangerous voltages and are not protected against contact but can be touched if the UPS doors are opened. The appropriate precautions should be taken if work is to be carried out on the UPS with the doors open.

The UPS equipment includes capacitors which continue to store energy for some time after the input supplies (AC and DC) have been disconnected. This voltage will be present on components of the intermediate DC circuit. Check therefore that the UPS is switched off, the external AC protection devices are opened and the battery fuses are removed. Before continuing with the work, measure the voltage on the UPS side of the battery disconnector and wait until it has been fallen below 10 VDC.

You could receive a fatal electric shock if you fail to take this precaution.

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2.2 Safety Instructions

Note that the loads will continue to be fed from the battery via the inverter when the AC input is disconnected from the UPS equipment.

Do not connect or disconnect data transmission lines during a thunderstorm. Do not allow foreign objects to enter the UPS equipment. You cannot come into contact with voltage-carrying parts of the UPS equipment

while it is properly closed. Connection terminals and bus bars, bare metal parts and other components carrying dangerous voltages are exposed when the cabinet doors are opened.

Take the appropriate precautions when working on the UPS equipment while it is open and connected to external supplies.

Even with the UPS equipment completely disconnected from external supplies, the following hazardous conditions remain: o The UPS equipment includes capacitors which continue to store electrical

energy for some time after the input supplies (AC and DC) have been disconnected.

o This voltage (>100 VDC, depending on the version) is always present at the battery terminals.

o Note that the battery terminals can also carry AC input potential in UPS equipment with rectifiers that are not isolated electrically from the AC input terminals

o Note that parts of the UPS equipment continue to carry dangerous voltages even while the equipment is operating with manual bypass.

o Check therefore that the UPS is switched off, the external AC protection devices are opened and the battery fuses are removed.

o Measure the voltage on the battery connection terminals and at the AC input and load terminals and wait until it has fallen below 10 VDC before continuing with the work. You could receive a fatal electric shock if you fail to take this precaution.

WARNING: Reverse voltage A reverse voltage can appear on the bypass network terminals and on the external AC distribution terminals even when the bypass network is switched off externally.

Switch the manual bypass to "Operation" and open the bypass protection devices (fuse-disconnectors or circuit breakers) during maintenance work on these terminals.

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Note All disconnectors in the input supply to the UPS (including those remote from the UPS) must carry in accordance with regulations (European standard EN62040-1-2) a sign with the following instruction:

SWITCH OFF THE INPUT TO THE UPS BEFORE WORKING ON THIS EQUIPMENT

2.3 Leakage Current

Danger Connect the PE protective earth conductor before all other cables. The cross-section is determined by the rated load of the equipment and the rectifier current but must be at least 16mm2.

2.4 Action in Emergencies

Take the following action if an emergency arises:

Open the input disconnection devices (rectifier, bypass and battery) Disconnect the load. Using methods appropriate for the batteries fitted, extinguish any fire that breaks

out.

Do not attempt to extinguish a fire with water because the batteries are carrying a dangerous voltage.

2.5 Battery

Battery maintenance should be carried out by qualified personnel only.

Read the battery manufacturer's instructions before putting the batteries into service.

Because of the danger of explosion and fire, do not bring open flames, glowing fire or sparks near the batteries.

Wear eye protection and protective clothing while working on the batteries. Rinse the eyes and skin well with clean water immediately if acid gets onto

them. Then obtain medical attention as soon as possible.

Voltage is always present at the battery terminals. A battery, even when discharged, can deliver a high short-circuit current which

can damage the battery itself and the associated cables and expose the personnel to the risk of burns.

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The battery terminal voltage can be dangerous. Although the voltage of individual cells is harmless, when a number of those cells are connected in series the total voltage can be dangerous. During maintenance work on the batteries, separate the blocks so that not more than 30 cells remain connected in series.

Do not exceed the maximum storage or idle time without recharging given in the battery manufacturer's instructions. Recharge the battery before this time elapses.

Since new batteries do not always deliver their full capacity immediately, it might be necessary to subject them to several charge/discharge cycles before putting them into service.

To protect the environment, dispose of waste batteries as prescribed by the applicable regulations for the disposal of toxic and hazardous materials.

2.6 Transport

Use only suitable methods for transporting the UPS equipment and the battery and secure it properly to prevent it from tipping or sliding during transport. Incorrect transport of the UPS equipment can result in it being damaged and to physical injuries being caused.

Transport the UPS equipment and the battery right up to the predetermined position in the store or installation site on the palette and in the original packing with a suitable fork-lift truck.

The permissible environmental and mechanical requirements for transport in accordance with EN60721-3-2 are 2K2 or 2M2.

2.7 Storage

The UPS equipment and the battery can be stored temporarily under the following conditions if they are not to be installed immediately:

Store the UPS equipment and the battery in their original packing. Store the UPS equipment and the battery in rooms that fulfil the environmental

conditions specified in the Technical Data.

Open the packing and recharge the battery after it has been stored for 3 months. The permissible environmental and mechanical requirements for storage in accordance with EN60721-3-1 are 2K2 or 2M2.

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2.8 Unpacking

NOTE: Do not unpack the UPS equipment and battery until it has been delivered to the final installation site.

4)

1)

2)

3)

3)

Unpack the UPS equipment and battery as follows:

Check for mechanical damage and if any is found, inform the carrier and supplier.

Compare the information on the rating plate with the information on the shipping papers and in the original purchase order.

Pinch off the steel bands with a pliers. The edge protection material is then no longer held in place and can be allowed to fall away.

Dispose of the edge protection. Remove the protective wrapping from the UPS cabinet. Slowly lift the UPS equipment from the palette. Heavy cabinets can be lifted off

the palette with a fork-lift truck.

Legend: 1) UPS cabinet 2) Edge protection 3) Steel band 4) Transport palette

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Preserve the palette in case the equipment needs to be repacked or transported without packing.

Dispose of the remaining packing material in accordance with the applicable local regulations.

2.9 Installation

When selecting the installation site, check that the following environmental conditions are met:

Ambient temperature between 0C and +50C for the UPS equipment. Ambient temperature between +10C and +30C for the battery. Ensure that the rooms in which the equipment cabinets are installed are adequately cooled so that the ambient temperature is maintained within those limits.

Ensure that the room in which the equipment is installed is adequately ventilated for the batteries used.

The equipment should be installed only in closed rooms. The protection class is given in the "Technical Data". Observe the relevant regulations for the operation of electronic equipment using dangerous voltages.

In particular, observe the following:

The installation, operation and maintenance should be carried out only by qualified personnel (see chapter 1).

Potentiometers on the modules have been set in the factory and may not be altered (except for settings that have been made available on the operating unit).

The protection ground connection must be made with cable having an adequate cross-section.

Note that a dangerous voltage can remain present on filter capacitors in the intermediate DC circuit for a certain time after the equipment has been switched off and check that this voltage has fallen below 10 VDC before starting maintenance work.

Transport the equipment in a vertical position only. Install the equipment as shown on the installation plan (installation documentation). Install the equipment so that the heat produced by inductors, transformers and semiconductors during operation can escape without obstruction. Install the equipment cabinets with adequate space (as defined in VDE 0100 or local regulations) in front of them for an operator to work comfortably.

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2.9.1 Operating Altitude

As a consequence of the reduced cooling effect obtained from the air, the rating of the UPS equipment is reduced at altitudes of more than 1000 m a.m.s.l. (contact the customer service department).

2.9.2 Floor Conditions

Ensure that the floor at the position in the room at which the UPS equipment and the battery are to be installed is flat and level and that its load-bearing capacity is sufficient for the purpose.

2.10 Environmental Conditions

Ensure that the equipment is not exposed to adverse environmental conditions such as:

Shock and vibration Dust Aggressive atmosphere Elevated relative humidity. The permissible environmental and mechanical requirements for operation in accordance with EN60721-3-1 are 3K3 or 3M2.

2.11 Handling of Electrostatic Sensitive Devices

Generally, handle electronic modules only when that is unavoidable for the work to be carried out on them.

Before touching electronic modules, remove the electric charge from your own body. This is best done by touching a conducting and well-grounded object immediately beforehand.

Electronic modules should not be brought into contact with highly insulated materials such as plastic foil, insulated tabletops, or clothing made of synthetic fibbers.

Electronic modules and components should be stored and transported only in conducting packaging (e.g. metallized plastic bags, metal enclosures).

Electronic modules should be wrapped in conducting material before being packed if the packaging is not itself conducting.

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The essential safety precautions against electrostatic discharge (ESD) are shown clearly in the following illustrations:

a = conducting floor d = ESD coat

b= ESD table e = ESD chain

c = ESD shoes f = ground connection to the cabinet

b

a

e d

f f f

c

fb

c

ed

f

SITTING POSITION

STANDINGPOSITION

COMBINATION (SITTING / STANDING)

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3 Connections

Ensure that the source of input voltage is disconnected from the UPS equipment during the installation and is secured against being reconnected.

Note The installation work should be carried out only by appropriately qualified technical personnel and in accordance with the relevant safety regulations. The electrical installation should not exceed the capacity of the input power source.

Connect the equipment and the battery in accordance with the connection and terminal plan included with the installation documentation.

Ground the equipment at the place marked for that purpose (PE bus).

Carry out the installation in accordance with the relevant regulations.

Use wire cross-sections dimensioned under consideration of the cabling method employed and provide input protection devices as recommended in IEC278 / DIN VDE 0298.

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4 Battery

The battery operates together with the rectifier and the inverter in standby/parallel mode.

The number of cells in the battery is determined in such a way that the battery will receive sufficient charge when the AC mains return after a failure. The capacity of the battery has been selected to obtain the required autonomy when the battery is discharged by the inverter.

The battery is an important component of the UPS equipment and to ensure the autonomy of the power supply and its freedom from interruptions, the battery should be regularly checked and a capacity test should be performed. The battery should be maintained in accordance with the battery manufacturer's instructions.

Warning: The ungrounded battery cabinet and/or the ungrounded battery rack could carry a voltage in the event of a fault. The battery will be at AC mains potential except the rectifier is fitted with an isolation-transformer.

The battery room should meet the requirements of EN 50272-2.

If the equipment is to be switched off or taken out of service, disconnect the battery, to prevent continuous discharge by the UPS equipment.

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5 Commissioning

Ensure that there is no trace of condensation on the equipment as a consequence of a prolonged period of storage or of an installation carried out immediately after transport of the equipment. The equipment must be completely dry before being installed.

A high impedance multimeter and a phase rotation meter are required for the commissioning work. It is essential to carry out the instructions in the following sequences.

Step no.

Description of work to be performed Location Compo-nent

1 Visually inspect all components for damage. Check that all terminals are tight. Remove all transport fittings that might still be inside the cabinets.

2 Check the condition of the protective measures provided (e.g. secure attachment of the grounding cable, etc.).

3 Check the load cables and the interconnection cables for short-circuits.

4 Open all MCCBs, MCB and fuse-disconnectors. UPS

5

Switch Manual Bypass to Operation (refer to section 7.9) Insert and close the load-disconnector Q2 for OPERATION. Remove the load-disconnector Q22 for BYPASS Warning: If you have to restart the UPS during a repair and the UPS

is on MANUAL BYPASS, do not change over to OPERATION before the inverter is switched on and the system is switched to STANDBY OPER.

UPS Q2/Q22

6

Make sure that battery fuse-disconnector F1-F2 in the UPS is open. The electrolytic filter capacitor of the inverter should be charged by the rectifier (soft start) otherwise the very quick-acting inverter fuse will blow.

Connect the battery cables to terminal X5. Check the battery cables.

UPS X5

7 Check the battery voltage for correct value and polarity UPS X5

8 Connect the AC mains for rectifier to terminal X1. Check the voltage for correct value and the phase for clockwise rotation. UPS X1

9 Connect the AC mains for bypass to terminal X2. Check the voltage for correct value. UPS X2

10 Switch on the MCCB for rectifier control. UPS Q1

11

Switch on the rectifier (refer to 7.4). The rectifier will regulate to the float charge voltage and the electrolytic filter capacitor will be charged. Check the rectifier output voltage and the DC-voltage with the multimeter or on operating unit.

UPS Operating unit

12 Check the polarity at the battery fuse-disconnector. If the correct DC voltage is present, close the battery fuse-disconnector. UPS F1/F2

13 Close the fuse-disconnector for DC control. UPS F3/F4

14 Close the fuse-disconnector for static bypass switch. UPS F7

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Step no.


15 Switch on the MCCBs for inverter and mains control. UPS F8,F9

16 Switch on the MCB for Modbus. UPS F12

17 Switch on the inverter (refer to 7.5). UPS Operating

unit

18 Set the operating mode of the bypass control unit to continuous operation (refer to 7.6). UPS

Operating unit

19 Check the measured values. UPS Operating

unit

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6 Taking out of Service / Restart

6.1 Taking out of Service

Step no.


1

Switch the manual bypass from OPERATION to BYPASS (refer to 7.9); if the loads have to be supplied further on after the UPS has been taken out of service.

Warning: If the manual bypass is located in UPS cabinet, the components of the manual bypass and the input and output terminals will continue to carry dangerous voltages after the changeover.

UPS

Operating unit,

Q2/Q22

2 Switch off the inverter (refer to 7.5). UPS Operating

unit

3 Switch off the rectifier (refer to 7.4 ). UPS Operating

unit

4 Remove the fuse-disconnector for static bypass switch UPS F7

5 Remove the battery fuse-disconnector UPS F1/F2

6 Remove the fuse-disconnector for DC control UPS F3/F4

7 Switch off the AC mains supply of the UPS if necessary.

WARNING: A voltage (due to the charge on the filter capacitors) remains present in the intermediate circuit for some time after the UPS has been taken out of operation.

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6.2 Restart

Step no.


1 Switch on the AC mains supply UPS

2 Insert and close the fuse-disconnector for static bypass switch UPS F7

3

Switch on the rectifier (refer to 7.4). The rectifier will regulate to the float charge voltage and the electro-lytic filter capacitor will be charged. Check the rectifier output voltage and the DC-voltage with the multi-meter or on operating unit.

The electrolytic filter capacitor of the inverter should be charged by the rectifier (soft start) otherwise the very quick-acting inverter fuse will blow.

UPS Operating unit

4 Insert and close the battery fuse-disconnector UPS F1/F2

5 Insert and close the fuse-disconnector for DC-control UPS F3/F4

6 Switch on the inverter (refer to 7.5). UPS Operating

unit

7 Switch the manual bypass from "BYPASS" to "OPERATION" (refer to 7.9) if necessary.

UPS

Operating unit,

Q2/Q22

8 Check the measured values. UPS Operating

unit

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7 Operating Instructions

The UPS equipment is operated and configured from the operating unit.

A detailed explanation is given in the separate instruction for the operation terminal (refer to description of operation terminal [1]).

7.1 Operation Terminal

7.1.1 General

The operator element with VGA TFT touch screen display panel is the interface between UPS equipment and its user. Measured values can be called up, set points can be changed and the operating mode can be selected on it. Several UPS equipments can be configured from one control unit. Remote communication takes place via an RS232 interface and an independent CAN bus. Connection to a computer network is possible.

The flow of energy through the UPS equipment is displayed on a user-friendly multicoloured mimic diagram with colour-coded symbols. Included is the representation of an internal or external manual bypass switch. Measured values appear alongside the associated measuring points. The measurement accuracy is 1% and the measurements are updated approximately once every second.

A 3-level password system protects the UPS equipment configuration against unauthorized manipulation.

7.1.2 Introduction

NOTE: All graphic representations of the display panel in this document are provided as typical examples. Real values and the number and layout of the soft keys can vary according to the operating mode and the type of plant. The equipment is operated by touching the operator element display panel. Most of the equipment parameters and equipment status indications can be displayed and changed in this way. The basic display panel layout is as follows:

Manual 7001.410.28.000 Page 22 / 47


Measured values and utilization bar diagrams can also be displayed. Failures affecting the flow of energy are shown in red.

7.1.3 Mimic Diagram Starting condition

~

= ~

=

Dale-Erskine 08:33:41 07.01.03 User: Operator

Company logo Energy flow marked in blue System time User logged-on as

Soft keys for changing the parameters and conditions.

A flashing red mark at the lower right of the affected module indicates failure.

A functional module can be selected by touching its symbol. A blue frame indicates that the module has been selected.

?

~

= ~

=


log IN / OUT

events config. mainten.- intervalsoverview

Clear the peak UPS load current value in the "stay-set" indicator.

Access the password input level - see section 6.1.4: "Log on/log off"

Configure the display, the remote alarms and the modem.

Display a selection of the available menu levels.

Display the contents of the message store.

Rectifier operation and status

Inverter operation and status

Bypass operation and status

?

Assistant

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7.1.4 Logging On and Logging Off Access to the controller for operation, configuration and service purposes is restricted by password. The 3-level password system (Operator, Configurator and Service) ensures that only authorized access to the control facilities is possible. Configuration menus and soft keys to which access has not been authorized are not displayed at all. Soft key bar on the log-on/log-off screen A change to a different password level can be made by touching the appropriate softkey. After "Change password" has been selected, first the old password must be entered and then the new password twice. A delay can be set for an automatic forced log-off after the last entry (0 = no automatic log off). The default passwords are: Operator level: EGB Configurator level: EGB The operator-level password can be reset to EGB by the configurator. To do this first log on at the configurator level. This gives access to the "Reset operator password" soft key. Pressing this soft key resets the operator password to EGB.

7.2 Handling Assistant

The assistant can be activated by pressing the question mark soft key. The user gets then detailed information for commissioning und decommissioning. The assistant suggests the next expedient activity and controls it. The user executes the switching operation and is full responsible for it.

esc log out Login user Login config. Login

Service password Change

Operator is currently logged in as user.

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7.3 Block Schematic drawing (basic circuit)

BYPASS

~

INVERTER

~

~

RECTIFIER

OPERATION

BYPASS

BATTERY

3

3 3

MANUAL BYPASS

The UPS comprises the following components:

Rectifier Battery Inverter Bypass Manual bypass

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7.4 Rectifier

The rectifier can be selected either on the mimic diagram or on the menu summary. Depending on the rectifier operating facilities provided and on the log-on level, the following soft keys may appear: A new screen will appear when the "Boost charge" or "Capacity test" soft keys are touched. If the special charge is activated but not the capacity test then the "Capacity test" soft key will be replaced by a soft key allowing configuration of the "Special charge."

7.4.1 Change of Condition

The following switching operations are provided:

Rectifier ON Rectifier OFF Boost charge (on/off) Battery capacity test

~

= ~

=

Dale-Erskine 08:33:41 07.01.03 User : operator

esc rectifier ON/OFF

rect. remote

boost charge batt. test

state

Rectifier is selected

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7.5 Inverter

The inverter can be selected either on the mimic diagram or on the menu selection. Depending on the inverter operating facilities provided and on the log-on level, the following soft keys may appear:

7.5.1 Change of Condition

The following switching conditions are available:

Inverter ON Inverter OFF

~

= ~

=


esc inv ON/OFF inv. remotestate

Inverter is selected

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7.6 Static Bypass Switch

The static bypass switch can be selected either on the mimic diagram or on the menu summary. Depending on the bypass operating facilities provided and on the log-on level, the following soft keys may appear:

7.6.1 Changing the Conditions

The following switching conditions are provided:

Continuous operation Standby operation Start-up operation Elec. sw. remote

(bypass reset is appearing at this position, if change back to inverter is inhibited)

~

= ~

=


esc standby operationstartup

operationElec.

sw. remotestate

Bypass is selected

cont. operation

The selected switching condition Release of remote switching

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7.6.1.1 Continuous Operation

BYPASS

~

INVERTER

~

~

RECTIFIER

OPERATION

BYPASS

BATTERY

MANUAL BYPASS

The inverter supplies the load during normal continuous operation. The rectifier provides the supply to the inverter. The UPS output voltage is continuously monitored and an uninterrupted changeover to the AC input supply is initiated within 2.5 ms if it deviates by more than 10% from the nominal value provided that a bypass supply is available that is in-phase with the inverter output.

The changeover is initiated only upon shut-down of the inverter (for over voltage, over current or overheating) and with an interruption of approximately 30 ms if there is a phase error. A delayed change back to the inverter output takes place without interruption after the inverter output voltage is restored. After a repeated failure of the inverter output voltage (e.g. in the event of a recurring overload of the inverter), the change back is inhibited after four attempts (can be reset by pressing "Bypass reset" in the Bypass menu).

Continuous operation is to be selected when multiple blocks are operated in parallel in the n+1 operating mode (one block more than is required to supply the load).

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7.6.1.2 Standby Operation

BYPASS

~

INVERTER

~

~

RECTIFIER

OPERATION

BYPASS

BATTERY

MANUAL BYPASS

The AC input supplies the load during normal standby operation. The inverter runs in synchronism with the AC input supply but is not loaded. The loads are changed over to the inverter output within 12 ms after the AC input supply fails. The loads are automatically changed back to the AC input supply with a delay after the supply is restored.

7.6.1.3 Start-up Operation

BYPASS

~

INVERTER

~

~

RECTIFIER

OPERATION

BYPASS

BATTERY

MANUAL BYPASS

The AC input supplies the load during normal start-up operation. The inverter is switched on and takes over the load within approximately 500 ms after a failure of the AC input supply. The loads are automatically changed back to the AC input supply with a delay after the supply is restored and the inverter is then shut down.

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7.7 Battery Operation (basic circuit)

BYPASS

~

INVERTER

~

~

RECTIFIER

OPERATION

BYPASS

BATTERY

MANUAL BYPASS

The loads are supplied by the inverter and the inverter is supplied by the battery in this mode of operation. The loads continue to be supplied from the battery via the inverter after a failure of the AC input supply.

7.8 Manual Bypass (basic circuit)

BYPASS

~

INVERTER

~

~

RECTIFIER

OPERATION

BYPASS

BATTERY

MANUAL BYPASS

The UPS is equipped with a manual bypass so that the inverter and the electronic bypass can be isolated from the AC input supply. The manual bypass is located either in the distribution cabinet or in the UPS-cabinet itself. A changeover without interruption can take place only if the AC mains and the inverter output are synchronized (zero phase difference) and their voltages are within limits.

Manual 7001.410.28.000 Page 31 / 47


7.9 Manual Bypass (Switching Instructions)

WARNING: It is essential to carry out the instructions in the following sequence, if the changeover has to take place without interruption.

Changeover from OPERATIONto BYPASS Logging On at the display (see section 7.1.4) Change the UPS to "STANDBY OPERATION" on the operating unit display

(see section 7.6 ).

Verify that AC mains operation is indicated (LED indicator H5 MAINS OPERATION on bypass control unit A4 is on).

Insert and close the load-disconnector Q22 "BYPASS" Remove immediately the load-disconnector Q2 "OPERATION"

Changeover from BYPASSto OPERATION Logging On at the display (see section 7.1.4) Change the UPS to "STANDBY OPERATION" on the operating unit display

(see section 7.6).

Verify that AC mains operation is indicated (LED indicator H5 MAINS OPERATION on bypass control unit A4 is on).

Insert and close the load-disconnector Q2 "OPERATION" Remove immediately the load-disconnector Q22 "BYPASS" Select the required bypass operating mode on the operating unit display.

The disconnectors Q2 / Q22 may both be closed at the same time only during the brief time in which the changeover is being made. Only one of the disconnectors may be in the closed position during normal operation.

Manual 7001.410.28.000 Page 32 / 47


7.10 Parallel Operation with Multiple Blocks

Two types of parallel operation are possible, if provided by the UPS equipment configuration. Parallel operation mode can be changed only by the EGB Gustav Klein customer service.

7.10.1 Parallel Operation to Increase Total Rated Power (n operation)

The UPS equipment is configured for this type of parallel operation when all paralleled UPS blocks are required to be present in order to supply the full rated load or when they are operated in standby or start-up mode.

7.10.2 Parallel Operation with a Redundant Block (n+1 operation)

All paralleled UPS blocks have to be set to continuous operation mode for this type of parallel operation. When one block fails it will be separated from the load and the remaining blocks will continue to supply the load. Only the failure of a further block, will initiate the transfer of the load to the AC mains

Manual 7001.410.28.000 Page 33 / 47


8 Description of the Modules

The modules provided for supply, the supervision and control of the UPS are located in the A50 sub rack.

Do not remove a module or modules from the sub rack while the UPS is still switched on.

The status of all the important operating conditions is displayed visually by means of LED indicators on the front panels of the individual modules. The colours of the LEDs have the following significance:

green LEDs indicate normal operating conditions (e.g. battery voltage >2.1V/cell)

yellow LEDs indicate an unusual operating condition (e.g. the battery is receiving a boost charge)

red LEDs indicate a malfunction (e.g. inverter over voltage)

The setting values for the modules are shown on the circuit drawings.

H1

H3

H1H2H3

H4H5H6

R1

H1H2H3H4H5H6

H4H5

H3

H1H2

H7

+15V

-15V

A1AUXIL. POWERSUPPLY

RECT.ONMAINS FAILURE

A2RECT. CONTROL

+14V-14VFAILURE

MANUAL CONTROL

RESETS1

PROGRAMMINGINTERFACE

A3INV. CONTROL

S1

INV.VOLT.O.K.MAINS O.K.INV.READY FOR OPER.INV.OPERATIONMAINS OPERATION

A4SBS-CONTROL

RESET

INV.ONINV. LEADINGMAINS SYNCHRON.

S1RESET



X3 X3 X3

P ONPHASE POSITION O.K.P ON

P ONPHASE FAILURE INV.

Modules in the A50 sub rack

Manual 7001.410.28.000 Page 34 / 47


Basic construction:

The UPS controller uses a double-height Euro card sub rack holding the individual plug-in cards for power supply, rectifier control, inverter control, and bypass control. The operating unit with touch screen TFT display is accommodated in the door. Each of the three control units and the operating unit has a Siemens C167 16-bit microprocessor and function independently of each other so that in the event of a failure of one unit, the others continue to operate. The units communicate with each other via a CAN bus to obtain maximum reliability.

The essential UPS control loops within the control units use analogue technology to ensure that continuous operation is maintained even after a microprocessor failure. Only the supervision, measurement and value-setting functions are affected by a microprocessor failure.

The pluggable microprocessor modules in the control units are physically identical but differ functionally.

Block diagram of control circuit:

WARNING: Switch off the complete UPS equipment before removing a plug-in card from the sub rack, or inserting a plug-in card into the sub rack, i.e. "hot plugging" is not supported!

A1: Auxiliary power supply

unit

A2: Rectifier control

unit

A3: Invertercontrol

unit

A4: Bypasscontrol

unit

Operating unit with TFT touchscreen

display CAN bus

Auxiliary power supply

Manual 7001.410.28.000 Page 35 / 47


8.1 A1 Auxiliary Power Supply Unit

The auxiliary power supply unit A1 supplies the control units with regulated 15 V and 14 V respectively, taken from the battery circuit and additionally supplies the bypass control unit A4 with a voltage obtained from the bypass network.

LED on the front panel:

H1 DC supply +15 V OK green LED indicator H3 DC supply -15 V OK green LED indicator H4 AC input supply +14 V OK green LED indicator H5 AC input supply -14 V OK green LED indicator H6 DC or AC input supply failed red LED indicator

Manual 7001.410.28.000 Page 36 / 47


8.2 A2 Rectifier Control Unit

The rectifier control unit generates firing impulses for a 6- or 12-pulse thyristor rectifier and regulates the battery charging voltage and the battery current. A synchronization control circuit ensures symmetrical current distribution for paralleled rectifier operation. Various charging voltage characteristics with automatic changeover, temperature control of the charging voltage and voltage reduction for a battery capacity test can be programmed via the microprocessor. A battery room ventilator can also be controlled.

Integrated supervision facilities (some optional):

Phase rotation Phase failure AC input voltage deviation DC output voltage deviation Battery room ventilator supervision Battery temperature supervision temperature supervision of rectifier power section The following measured values are available (some optional):

AC input voltage AC input current AC input frequency Rectifier DC output voltage Rectifier DC output current Rectifier power section temperature Battery terminal voltage Battery current Battery temperature Charging condition Operating elements:

R1 Manual control potentiometer S1 Reset microprocessor pushbutton switch H1 Firing impulses enabled green LED indicator H2 AC input failed red LED indicator H3 Microprocessor running green LED indicator X3 Programming (RS232) RJ-45 connector

Manual 7001.410.28.000 Page 37 / 47


8.3 A3 Inverter Control Unit

The inverter control unit generates a pulse train for the sinusoidal control of a single- or 3-phase transistor bridge circuit and regulates and monitors the AC output voltage and AC output current. Synchronous parallel operation is possible. The microprocessor enables adaptation of the AC output voltage and frequency (50 or 60 Hz) to the requirements, controls optional charging of filter capacitors and assumes other measurements and monitoring functions. The synchronization function can be deactivated during operation with an AC input obtained from a diesel-electric generator.

Monitoring functions (some optional):

DC over voltage Battery deep-discharge (DC) Battery discharging (warning) (DC) AC output over voltage and under voltage AC output over current temperature supervision of inverter power section

The following measured values are available (some optional):

DC input voltage Inverter input current AC output voltage AC output frequency AC output current (UPS) Inverter power section temperature One additional free available 3-phase measurement input Operating elements:

S1 Reset microprocessor Pushbutton switch H1 Inverter on (firing impulses enabled) green LED indicator H2 Inverter leading green LED indicator H3 Inverter synchronized to AC input green LED indicator H4 Phase relation between inverter output and

AC input OK green LED indicator

H5 Microprocessor running green LED indicator X3 Programming (RS232) RJ-45 connector

Manual 7001.410.28.000 Page 38 / 47


8.4 A4 Bypass Control Unit

The bypass control unit monitors the instantaneous values of inverter output voltage and AC input voltage and controls the thyristor switch in accordance with the selected operating mode and the status of the available voltage sources. Either continuous operation mode, standby operation mode or start-up operation mode can be selected. In addition, redundant (n+1) mode or power-raising (n) mode can be selected for UPS equipments operated in parallel.

Monitoring functions:

AC input under voltage with delayed return after restoration to within limits. Voltage deviations at the UPS output (instantaneous value) with changeover

within 2.5 ms. The following measured values are available (some optional):

AC input voltage AC input frequency UPS output voltage UPS output frequency Bypass power section temperature One additional free available 3-phase measurement input.

Operating elements:

S1 Reset microprocessor Pushbutton switch H1 Inverter OK green LED indicator H2 AC input OK green LED indicator H3 UPS block ready for operation green LED indicator H4 Inverter operation green LED indicator H5 Mains operation yellow LED indicator H6 Phase difference between inverters (only

for multiple units) red LED indicator

H7 Microprocessor running green LED indicator X3 Programming (RS232) RJ-45 connector

Manual 7001.410.28.000 Page 39 / 47


9 Interfaces, Alarms and Indications

9.1 Serial Interfaces

There is a sub-D connector for an RS-232 interface on the back of the operating unit. This interface is used for programming of optional software and for the connection of additional optional hardware items such as an SNMP adapter. The interfaces on the plug-in cards are for factory internal use only.

9.2 Floating Relay Contacts (UPS A70)

The following table lists the remote alarm contact functions and their application. The LED indicator associated with each relay is on when that relay is energized. Relay unit A70:

Relay Designation Parameter

K1 Inverter Operation The relay is energized if the load is supplied by the Inverter.

K2 Mains Operation The relay is energized if the load is supplied by the bypass mains.

K3 Battery discharge The relay is energized under normal conditions and release in case of: Battery voltage below float charge voltage.

K4 Warning deep discharge

The relay is energized under normal conditions and release in case of: Battery voltage below deep-discharge warning level Inverter will be switched off after a short time to extend autonomy for DC-load. (no more battery capacity is spend on AC-load).

K5 Mains Failure

The relay is energized under normal conditions and release in case of: When the mains voltage for the rectifier, or for the static bypass switch, is out of limits.

K6 UPS Failure

The relay is energized under normal conditions and release in case of:

Rectifier failure Inverter failure Bypass failure.

Manual 7001.410.28.000 Page 40 / 47


10 Fault location

General Check the following points before contacting the responsible customer service organization if, despite the high reliability of the equipment, problems should occur:

Is the AC supply present at the input to the UPS?

Has the input fuse blown or have circuit breakers tripped out?

Keep the following information ready when you call the customer service organization:

Equipment identification (type, type number, factory serial number, as given on the rating plate).

An exact description of the problem (which loads are affected, whether the problem occurs regularly or only occasionally, etc.)

The status indication shown on the LEDs fitted to the front panels of the modules in the sub rack:

o Which red LEDs are lit? o Which yellow LEDs are lit? o Which green LEDs are not lit?

Manual 7001.410.28.000 Page 41 / 47


11 Emergency Operation with Emergency Key

On failure of display control unit, the UPS equipment can be operated with an emergency key (attached to the component side of the display control unit).

Switching the rectifier on and off: Insert the emergency key in socket X3 of A2 and press the reset switch S1 on A2. Switching the inverter on and off: Insert the emergency key in socket X3 of A3 and press the reset switch S1 on A3. Changing the bypass operating mode: Insert the emergency key in socket X3 of A4 and press the reset switch S1 on A4. Do not leave the emergency key in any X3 socket and secure it against unauthorized use if necessary.

Manual 7001.410.28.000 Page 42 / 47


12 Maintenance

12.1 General

The UPS equipment requires very little maintenance. For safety reasons, we recommend that the functions of the UPS be regularly checked by our customer service department. In general, avoid an accumulation of dust inside the equipment. If cleaning should become necessary, use only an insulated brush and vacuum cleaner.

If fuses need to be replaced, use replacement fuses of the same type and rating only. Check the nominal value settings of the UPS equipment output voltage and frequency occasionally.

Over voltage arrester (if equipped) and appropriate line-side NH-fuses in rectifier and bypass AC input, have to be checked regarding condition (tripping) at regular intervals.

If the equipment is to be switched off or taken out of service for a long time, disconnect the battery, to prevent continuous discharge by the UPS equipment.

Manual 7001.410.28.000 Page 43 / 47


12.2 Ventilators (Optional)

12.2.1 General

The ventilators that might be used in the cooling system for the semiconductors of power sections have an expected life of 40000 hours. Regularly check that they are functioning adequately (air is flowing) and change them in any event at the end of their useful life, to ensure the availability of the UPS system

12.2.2 Change of Ventilators

Loose screw connection loose screw connection

1. Switch UPS-system to manual bypass (refer to switching instruction, section 7.9). 2. Take UPS-cabinet out of service and disconnect it from voltage supply

(refer to section 6.1). 3. Remove connector X1 at ventilator drawer. 4. Loose four screw connection according to sketch above. 5. Remove ventilator drawer. 6. Insert new ventilator drawer (or drawer with new ventilators) and fix it again. 7. Plug on connector X1. 8. Start up the UPS-system according to operation instruction (refer to section 6.2).

Manual 7001.410.28.000 Page 44 / 47


12.3 Battery

Battery maintenance should be carried out by qualified personnel only. Maintain the battery in accordance to the battery manufacturer's maintenance instructions.

Wear eye protection and protective clothing while working on the batteries.

The battery terminal voltage can be dangerous. Although the voltage of individual cells is harmless, when a number of those cells are connected in series the total voltage can be dangerous. During maintenance work on the batteries, separate the blocks so that not more than 30 cells remain connected in series.

12.4 Battery Test (Option)

To ensure the continued availability of the UPS equipment, check every 6 months that the battery is still able to supply the maximum load.

For this purpose use the optional battery test feature, which can be started on the operating display (refer to description of operation terminal [1]). The following instructions have to be considered:

1. Check availability of bypass mains. The AC-loads will be supplied by the bypass, in case of battery fault.

2. The UPS equipment has to operate in Continuous Operation (refer to 7.6) and the AC-load has to be supplied by the inverter (inverter operation)

3. Select the rectifier at TFT-display and start Battery Test (refer to 7.4). Loads are supplied by battery now.

4. After completion of battery test the rectifier output voltage is raised again. The results of the test are presented on the TFT-display. Error messages in case of an aborted test can be removed by pressing the stop button (5 sec).

5. If the UPS equipment has not been operated in Continuous Operation before, select the suitable operation mode (standby-, start-up-operation) at TFT-display (refer to 7.6).

WARNING: For testing the battery capacity, the battery has to supply the load. There-fore the battery test will cause the rectifier to be stopped by pulse lock. After the test the rectifier pulses will be released. In case that battery test fails because of a breakdown of battery voltage, this may cause a voltage dip on DC-voltage. Loads connected to DC-voltage may be affected.

Manual 7001.410.28.000 Page 45 / 47


12.5 Change of Battery-Buffered Real-Time Clock

A battery-buffered real-time clock is provided for storing data even if the complete equipment is switched off. Change this hardware clock IC latest after 10 years. Procedure:

1. Logon at display (configuration) 2. Change to maintenance interval 3. Read out the stored data , using soft key Start RTC change 4. Disconnect auxiliary power supply from the display (remove X1, X2 and X3). 5. Replace the real-time clock D3 with a new hardware IC. 6. Reconnect auxiliary power supply to the display (plug in X1, X2 and X3). 7. Repeat Logon 8. Restore data, using soft key End RTC change. 9. Check the clock. 10. Logoff

(Fig.: Display control component layout plan)

real-time clock

auxiliary power supply connectors for display control

language module

Manual 7001.410.28.000 Page 46 / 47


13 Technical Data UPS 10kVA

Rated power 10 kVA (0.8 power factor) Rectifier type Thyristor, 6-pulse, Inverter type Transistor-inverter, PWM, galvanic separation

Rectifier input Input voltage 380/220 V 5%, 3-phase, N, PE Frequency 60 Hz 5% Power drawn from AC input supply at

battery charged battery under charge

12,3 kVA 23 kVA

Bypass Input voltage 220 V 10%, N, PE Frequency 60 Hz 5%

Intermediate DC circuit DC-Voltage 220 V -15% / +20% Voltage tolerance 1% Rectifier rated current 65 A Battery charging current 28 A Inverter power consumption at 0.8 power factor 8,9 kW

UPS output Output voltage 220 V, 1-phase, N, PE Voltage tolerance

static dynamic with unbalanced load

1% 4% with 100% load step 2% with 0 to 100% unbalanced load

Control time < 4 msec. Overload performance 1.50 Inom for 60 seconds

1.25 Inom for 10 minutes 1.10 Inom for 20 minutes

Short-circuit performance short-circuit-proof, short-circuit current 2 Inom for 5 sec. inverter stop after 5 sec acc. to EN/VDE

Output frequency 60 Hz 0.1% (crystal-oscillator controlled) Synchronization range 60 Hz 3% (synchronized to the AC input) Waveform sinusoidal Distortion 3% (at linear load) Permissible power factor 0.0 lagging to 0.0 leading

reduced rating on deviation of cos = 0.8 lag. Permissible crest factor of load current 2.3 with rated load

General EMC in accordance to EN 62040-2 Noise level approx. 60 dB(A) Permissible ambient temperature 0 +46C Permissible climate 3K3 in accordance to EN 60721 Permissible operating altitude at rated load 1000 m a.m.s.l. Protection IP 20 in accordance to EN 60529 Finish RAL 7035, textured Cooling AN forced air cooling Loss power in continuous operation 1,5 kW Overall efficiency at rated load 85,5 % Dimensions Cabinet (B x W x H) 800 x 700 x 1900 mm

Manual 7001.410.28.000 Page 47 / 47


14 Contact with Customer Service Department ERSKINE SYSTEMS A division of DALE POWER SOLUTIONS plc Salter Road, Eastfield Industrial Estate Scarborough YO11 3DU, UK Tel +44 (0) 1723 583511 Fax+44 (0) 1723 581231 e-mail: [email protected] Website: www.erskine-systems.co.uk

15 Referenced Documents

[1] Operation of the UPS controller 4608.000.00.002

Record of installation and change

edition date name sector position change (deleted, changed, added)

01 12.01.11 Uhl installed

instruction manual for ups

Documents

manual bypass thyristor

manual bypass basic

users manual

ou edition

microprocessor control

static bypass switch

a4 bypass control unit

emergency operation