User’s Guide UPS 20 - 30 kVA, 230 V 50/60 Hz output (3-phase input/1-phase output)
©2007 Eaton Corporation All Rights Reserved The contents of this manual are the copyright of the publisher and may not be reproduced (even extracts) unless permission granted. Every care has been taken to ensure the accuracy of the information contained in this manual, but no liability can be accepted for any errors or omission. The right to make design modifications is reserved.
User’s Guide UPS 20 - 30 kVA, 230 V 50/60 Hz output (3-phase input/1-phase output) 1026743 revision B 1. Safety instructions........................................................................................................................................................................ 5 Audience......................................................................................................................................................................................... 5 CE marking..........
8. User operations.............................................................................................................................................................................. 29 Display functions............................................................................................................................................................................ 29 User Settings.............................................................................................................
1. Safety instructions The UPS operates with mains, battery or bypass power. It contains components that carry high currents and voltages. The properly installed enclosure is earthed and IP20 rated against electrical shock and foreign objects. However, only qualified personal is allowed to install and service the UPS. Warning! Operations inside the UPS must be performed by a service engineer from the manufacturer or from an agent authorised by the manufacturer.
User precautions The only user operations permitted are: • Start up and shut down of the UPS, excluding the commissioning start-up. • Use of the LCD control panel and Maintenance Bypass Switch (MBS) • Use of optional connectivity modules and their software The user must follow the precautions and only perform the described operations. Any deviations from the instructions could be dangerous to the user or cause accidental load loss.
2 Introduction The product described in this manual is a transformerless Uninterruptible Power System (UPS). It is a true online, continuous duty, double conversion, solid state, three-phase system, providing conditioned and uninterruptible AC power to protect the customer’s load from all nine power failures.
Due to the active front rectifier, the UPS is comparable to a clean resistor load from the mains perspective. Thus, the high input power factor provides minimised cabling and fusing costs due to no reactive power consumption.
A parallel UPS system means the linking together of two or more UPS units in parallel so that in the unlikely event one fails the other can automatically take up the load. Traditionally a parallel redundancy configuration is achieved by having a random or fixed master-slave relationship among the UPS units. This master logic gives out individual commands to all the slaves units.
3. Mechanical installation The UPS and accessories are delivered on a specifically designed pallet that is easy to move with a forklift or a pallet jack. Keep the UPS always in upright position and do not drop the equipment.
Figure 3 Unloading the equipment from the pallet. Check the information on the type designation label of the equipment to verify that the unit is of the correct type. The type designation label includes ratings, a CE marking, a type code, a part number and a serial number. The serial number is important when making inquiries. It allows individual recognition of the equipment.
4. Planning before installation The equipment must be installed in upright position. The equipment requires space to front and back to enable cooling airflow. Service and maintenance require 500 mm clearance on right hand side. All cooling air enters at front and exits at unit rear. The required min. clearance from unit rear to an obstruction is 250 mm. Because the service and user access is in the front there should be reserved enough space (min 600 mm).
5. Cabinet installation The required distance for UPS units next to each other is ten millimetres. The same applies to the optional battery cabinets that should be installed next to the UPS cabinet. It is recommended to install the battery cabinet on the left hand side of the UPS. Figure 4 UPS and external battery cabinets. Note! UPS cabinets can fall over if the shipping brackets are not used. Both rear and front shipping brackets must be used to secure the UPS cabinet to the floor.
Figure 5 Powerware 9155 20-30 kVA layout: 1:Graphical LCD; 2:XSlot-1; 3:XSlot-2; 4:Fans; 5:Input (rectifier) breaker “F2 MAINS”; 6:Battery start button; 7:Battery breaker “F1 BATTERY”; 8-13: Connectivity terminals; 14:Ground terminal; 15:MBS; 16:Power cable terminals 14 UPS 20-30 kVA, 230 V 50/60 Hz output User’s Guide 1026743 Revision B
Maintenance bypass switch The maintenance bypass switch (MBS) shall be mounted in the bottom of the UPS cabinet. It can be ordered factory installed. External battery cabinet option It’s recommended to install external battery cabinet(s) next to the UPS unit. The external battery can be placed on either side of the UPS unit, but it is recommended to instal on left hand side.
6. Electrical installation The customer has to supply the wiring to connect the UPS to the local power source. The electrical installation procedure is described in the following text. The installation inspection and initial start up of the UPS and extra battery cabinet must be carried out by a qualified service personnel such as a licensed service engineer from the manufacturer or from an agent authorised by the manufacturer.
The UPS unit has the following power connections: • Three-phase (L1, L2, L3), Neutral (N) and protective earth (PE) connection for the rectifier input (Note: N is only an open tie point) • Single-phase (L1), Neutral (N) and protective earth (PE) connection for the bypass input (N is common for rectifier and bypass inputs) • Single-phase (L1), Neutral (N) and protective earth (PE) connection for the load output • Plus (+), minus (-) and protective earth (PE) connection for the external batteries Not
Wiring procedure The power cable terminals are located in the bottom of the UPS unit. The service personnel is responsible for the correct electrical installation. The installation procedure: 1. Remove the cover plate(s) at the bottom or back of the UPS cabinet to make a route for input and output wires. Refer to the dimensional drawing for the correct location at the back of the unit. 2. Route the cables through the hole at the bottom or back of the unit.
Figure 7 Wiring diagram of UPS N-model with integral MBS.
Figure 8 Wiring diagram of UPS N-model.
External Battery Cabinet (EBC) installation procedure The installation procedure is as follows: 1. The External Battery Cabinet (EBC) is recommended to be placed to left hand side of the UPS unit. 2. The required minimum distance for UPS unit and EBC is 10 millimeters, which is also required distance between two EBCs. 3. Turn F1 battery breaker from the UPS unit to OFF position. 4.
7. Software and connectivity The Software Suite CD-ROM that is bundled with the UPS contains software distributions and documentation in CD format. Furthermore, the comprehensive connectivity option portfolio includes Web/SNMP adapters for networked environments, Modem card for 24/7 remote monitoring, ModBus/Jbus card for building management system integration, relay interface cards for industrial and facilities use and RS-232 cards for serial communication to one or multiple computers.
Connection to the standard RS-232 port (X53) The standard RS-232 interface uses 9-pin female D-sub connector. It shall be used with the delivered cable for a computer or external modem connection. The data is transmitted with XCP protocol that includes status and meters information about the UPS.
External control connections The UPS has an input/output interface for direct communication with your computer system. It is located behind the front door of the UPS unit. The cables connected to these terminals should be connected to cable clips. Input and output terminals have a functional isolation from terminal to terminal. They are connected to the chassis through individual 1 MΩ resistors. Figure 11 External control cable connections to the UPS.
In order to have the UPS running again pins 1 and 2 of connector X52 have to be reconnected and the UPS started manually. The pins must be shorted in order to keep the UPS running. Maximum resistance is 10 ohm. The EPO shall not be galvanically connected to any mains connected circuits. Reinforced insulation to the mains is required. See also “Start-up after EPO”. If the use of normally open EPO operation is desired, the loop on X52 has to be retained and the normally open EPO switch connected to X12.
e) Request Normal If active the UPS transfers to inverter operation if not prohibited by EPO or alarm condition. f) Force Bypass If active the UPS is forced to static bypass operation regardless of the bypass status. g) External Battery Breaker Status If active the UPS knows that the batteries are disconnected. h) Building alarm 1-6 These can be activated separately or at the same time with other building alarms. i) Not in use (default) j) Shutdown If active the UPS will shutdown immediately.
The UPS supports two serial communication devices according to the table below. Configuration Default #1 Default #2 Default #3 Default #4 Independent XSlot-1 Any XSlot Module Any XSlot Module Any XSlot Module Any XSlot Module Multiplexed XSlot-2 Any XSlot Module Relay Module Not in use Hot Sync card Std. RS-232 port Not in use Available Available Available Table 3 Typical XSlot configurations for UPS communication.
Figure 14 AS400 Relay Module. Single Serial Port Module (optional) To establish communication between the UPS and a computer, connect your computer to the UPS communication port using the supplied communication cable. When the communication cable is installed, power management software can exchange data with the UPS. The software polls the UPS for detailed information on the status of the power environment.
8. User operations The UPS has a four-button graphical LCD with backlight. It provides useful information about the unit itself, load status, events, measurements, and settings. The LCD backlight is switched on by pressing any button. It has a timeout that automatically switches off after 15 minutes of inactivity. Display functions As default and after 15 minutes of inactivity the UPS is showing the selectable start screen: 1. 2.
User Settings The UPS has the following typical settings that are user configurable. Note that some of the settings become effective at the next start-up of the UPS. User settings can configured via the front panel. Select: SETTINGS -> USER SETTINGS.
Battery information and settings: ABM charging cycling disable Charging temp compensation Battery size setting Number of 36 pcs. battery strings Battery low alarm level Automatic battery support test Maximum charging current Output on, automatic delay time before turning the output on Output off, automatic delay time on battery after which output is turned off [Enabled], [Disabled] [Enabled], [Disabled] Step: 1 Watts/cell 0 (no batteries), 1, 2, 3, 4... Step: 0.01 V/cell [Enabled], [Disabled] Step: 0.
Changing language Pressing and holding down the first button on the left for about 3 seconds is a shortcut to the language menu. This action is possible from any LCD menu screen. The default firmware has four main languages: English, Spanish, French and German. Other local language packages including Chinese, Greek and Russian can be requested from the local service representative. Using relay outputs Relay outputs can be used for remote alarm indications.
You are then ready to proceed with the starting up the UPS: 1. 2. 3. 4. 5. Turn the battery breaker (F1 BATTERY) and input circuit breaker/switch (F2 MAINS) to ON position. UPS will enter a stand-by mode and starts to charge batteries with three upper cooling fans operational. Output is without the voltage in the stand-by mode. Push any key of the control panel to enable the functions of the LCD screen Select “TURN UPS ON” from the LCD menu (see: Display Functions) Press and hold ↵ button for 2 sec.
9. Maintenance All operations inside the unit must be performed only by a service engineer from the manufacturer or from an agent, authorised by the manufacturer. The troubleshooting procedure gives simple remedial if a malfunction occurs in the UPS. The operator should start the trouble shooting if there is an active alarm indicated on the LCD screen. Service should be contacted if the active alarm is abnormal and displayed as a service code. Call service if you are not able to solve the problem.
Batteries The condition of the batteries is crucial for operation. The UPS will indicate by audible and visual alarms if the capacity of the battery bank has decreased. The UPS units are provided with the automatic battery test and ABM management function to continuously monitor the condition of the battery bank. Servicing of batteries should be performed or supervised by personnel knowledgeable about batteries and required precautions.
Maintenance bypass switch (MBS) operation The maintenance bypass switch may be as standard or as optional in your system depending on the ordered configuration. The operation of the MBS is allowed for a trained person only who is familiar with the UPS behaviour and functions. The full UPS wiring diagram with a MBS switch is presented in the installation part of the manual.
2. Use LCD to turn the UPS on internal static bypass mode. Select: CONTROL -> GO TO BYPASS MODE. Remember to verify the transfer before proceeding the next step. 3. Remove the locking plate of the S1-3 switches. 4. Turn ON the S1 switch to bypass UPS: 5. Turn OFF the S3 switch to disconnect UPS output: 6. Use LCD to turn UPS OFF. 7. Turn F1 battery breaker and F2 input to OFF position. 8. Turn OFF the S2 switch to disconnect UPS bypass input: 9.
No break transfer from Maintenance Bypass to normal mode: 1. The normal start position should be following: 2. Turn ON S2 switch to connect bypass input to UPS: 3. Turn the F1 battery breaker and F2 input breaker/switch to ON position. 4. Use LCD to “Turn UPS on” and wait until fully started. - Make sure the UPS is not displaying alarms or notices alarm with the green LED lit. - You may verify the output voltage from the meters screen of the LCD. 5.
10. Parallel systems Overview Parallel UPS configurations are recognised as either redundancy or capacity systems. The redundancy system is used to improve the system reliability with N+1 redundant UPS module. The capacity system for its part provides the maximum output power without focusing to the highest system reliability. A parameter selection is used to switch between the redundancy and capacity modes.
Figure 20 Example of wiring diagram for parallel systems 40 UPS 20-30 kVA, 230 V 50/60 Hz output User’s Guide 1026743 Revision B
UPS module Bypass Input X2 Rectifier Input X1 Cable A Cable B Fuse 1 Cable C Cable D Fuse 2 20 kVA 35 mm 16 mm 100 A 10 mm 10 mm 35 A 30 kVA 70 mm 35 mm 160 A 10 mm 10 mm 50 A 2 2 2 2 2 2 2 2 System Bypass SPM Cable E Cable F Fuse 3 40 kVA 2 95 mm 50 mm 200 A 60 kVA 120 mm 70 mm 2 2 315 A 2 80 kVA 2 2x95 mm 2x50 mm 400 A 90 kVA 2x150 mm 2x70 mm 500 A 120 kVA 2x185 mm 2x95 mm 630 A 2 2 2 2 2 Table 9 Minimum cable and fuse ratings for the different
Figure 21 Bypass wiring diagram and cable length notes Aux. MBS contacts Position data connection between SPM and UPS should also be done before taking system in operation. Follow the procedure below to build up position data connection: 1. Remove the door from the UPS. 2. Connect the cables in UPS’s programmable input terminal X44 or X45. 3. Connect communication cables to terminals 1 and 2 for UPS Module #1 and to terminals 3 and 4 for UPS Module #2 in the SPM.
6. First select “SETTINGS”, then “USER SETTINGS” and finally “SIGNAL INPUT” from LCD menu. 7. Select “INPUT 1” (X44) or “INPUT 2“ (X45). 8. Browse the menu and select “FORCE BYPASS”. 9. Finally check that all the connections have been made correctly and test the fuctioning of the bypass switch. Check also from the UPS that it goes to bypass mode.
Communication Wiring Termination From UPS 1 CAN card To UPS 2 CAN card To UPS 3 CAN Card (If installed) To UPS 4 CAN Card (If installed) J3-8 (L) J3-9 (H) J3-8 (L) J3-9 (H) J3-8 (L) J3-9 (H) J3-8 (L) J3-9 (H) Figure 23 Communication cabling wiring Note! XSlot Hot Sync card has built-in termination resistor enabled by a jumper J7. The default jumper setting without termination resistor is J7: Pin 2-3.
Start-up and operation Start-up procedure Note! Before start-up make sure that UPS installations have been carried out correctly and ground connections of both UPS units and parallel module have been connected. Check also that the XSlot HotSync cards are installed correctly an the communication line between UPSs is connected according to figure Communication cabling wiring. When installation is completed correctly the start procedure can be started.
Operating system bypass switch The system bypass switch is used to bypass the parallel system during maintenance or servicing. Using the switch does not cause any break in the output voltage, if the input voltage and frequency are accepted and the system is synchronised to the input mains. In the example wiring diagram for parallel systems.
Figure 25. System bypass switch of the optional SPM Shutdown procedure While system is running and UPSs are supporting load, there are two different ways to perform a shutdown. The user can select either to shutdown the whole system or only one UPS. 1. Select TURN SYSTEM OFF from the main menu Õ All the UPSs in the system will go to stand-by mode. 2. Select TURN UPS OFF Õ Only the selected UPS will go stand-by mode. Either 1 or 2 is selected ¿ button needs to be pressed for 5 seconds.
11. Recycling the used UPS or batteries Before scrapping UPS or its battery cabinet, the battery bank must be removed. Local requirements must be followed in battery recycling or discard. The removal of batteries is allowed only by authorised service personnel due to high energy and voltage. Do not discard waste electrical or electronic equipment in the trash. For proper disposal, contact your local collecting/recycling/reuse or hazardous waste center and follow the local legislation.
12. Dimensional drawings Figure 26 Dimensions of the UPS cabinet.
13. Technical data Standards UPS Safety EMC Product 20 kVA 30 kVA IEC 62040-1-1, EN 62040-1-1 and EN 60950 EN 50091-2 IEC 62040-3 and EN 62040-3 Environment UPS Amb. temperature Relative humidity Altitude Vibration 20 kVA 30 kVA 0 to +40°C (electronics), 15 to +25°C (batteries) 0 to 95%, no condensation allowed <1000 m above sea level IEC 68-2-6; max. 0.3 mm (2 to 9 Hz), max.
AC input Powerware 9155 Rectifier input Bypass input Voltage (L-N) Frequency Power factor Input distortion Rated input current 20 kVA 30 kVA 3 phases + N 1 phase + N 192 to 276 Volts without using battery 45 to 65 Hz 0.99 < 5% THD(I) 29 A 43 A 20 kVA 30 kVA DC circuit Powerware 9155 Management Nominal voltage Battery qty Float voltage Battery type Cut off voltage Battery charging Advanced Battery Management 432 Volts 36 / string 2.30 VPC VRLA 12 Volts 1.
14. Warranty The product is warranted against defects in design, materials and workmanship for a period of twelve (12) months from its original date of purchase. The local office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract.
