User’s and Installation Guide UPS 40–160 kVA, 400V 50/60 Hz output
©2008 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.
UPS 40-160 kVA, 400 V 50/60 Hz output User’s and Installation Guide 1023294 Revision C 1 Safety Instructions.............................................................................................................5 1.1 Audience...........................................................................................................................5 1.2 CE marking......................................................................................................................5 1.
7 Operating instructions.....................................................................................................41 7.1 Starting the UPS in Normal Mode..................................................................................41 7.2 Starting the UPS in Bypass Mode....................................................................................41 7.3 Starting the Power Module.............................................................................................42 7.
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 grounded to earth 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.
1.3 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, static state, three-phase system, providing conditioned and uninterruptible AC power to protect the customer’s load from all nine power failures. 2.
2.2 Feature: Active-Front Technology Traditional input THD filters are no longer needed with this UPS product. The build-in advanced rectifier technology of UPS modules provides perfect sinusoidal input power quality at 0.99 input power factor with harmonic content less than 5% THD(i). This leads to more reliable total system operation and savings in generator and transformer sizing as losses in the windings are minimised.
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 UPS installation Before installing the UPS systems read and understand how this manual applies to the system being installed. Use the procedures and illustrations in the following chapters to create a logical plan for installing the system. 3.1 Planning installation The UPS and accessories are delivered on a specifically designed pallet that is easy to move with a forklift or a pallet jack. Make sure that the floor surface is solid and suitable for the wheeling and heavy weight.
Figure 3. Minimum clearance in top and front of UPS 40-160 kVA 3.2 Unpacking and visual inspection The UPS cabinet is bolted to a wooden pallet supported by wood skids. To remove the pallet, perform the following procedure: 1. If not already accomplished, use a forklift or other material handling equipment to move the cabinet to the installation area, or as close as possible, before unloading from the pallet. Insert the forklift jacks between the skids on the bottom of the unit. 2.
Figure 4. Removing bolts and shipping brackets. Unpack the equipment by removing the packing and shipping materials. If the equipment has been transported in the upright position the outside ’Tip&Tel’ indicator should be intact. Make a visual inspection and check that there are no signs of shipping damages. The inside ‘Drop&Tell’ indicator shall be intact if the equipment has been handled properly.
3.4 UPS cabinet installation UPS cabinets must be permanently bolted or welded to the floor using the shipping brackets. 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. 3.5 Unloading the Battery Cabinet from the Pallet The battery cabinet is bolted to a pallet consisting of four angle metal supports secured to two four-inch by six-inch wood supports. 1.
Warning SERIOUS INJURY MAY OCCUR. Battery cabinets are extremely heavy. If unloading instructions are not closely followed, cabinet may tip. 5. Turn each jacking bolt consecutively, two full turns, until the 4×6 supports clear the floor by approximately 3 mm (1/8I). Warning RISK OF INSTABILITY. Turning the jacking bolts unevenly may cause the cabinet to become unbalanced. To prevent tipping the cabinet, raise and lower the jacking bolts evenly. Note CABINET MAY TIP.
4 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.
Figure 6. UPS (40-80, 100-160 kVA) power and communication terminal locations 4.2 UPS wiring procedure The proper connection order is as follows: 1. Switch off the supply to the distribution point to which the UPS unit is to be connected. 2. For extra safety, also remove the fuses from the selected lines. Make absolutely sure with measurement that there is no power. 3. A readily accessible disconnect device must be incorporated in all fixed input wiring.
6. Connect phase L1, L2, and L3 rectifier input power wiring from source to the Rectifier Input Terminals in the UPS cabinet. See wiring diagram for cable and fusing requirements. Note! The rectifier requires a Neutral to operate. It’s connected internally from the bypass terminal to the rectifier, see wiring diagram. 7. Connect phase L1, L2, L3, and Neutral bypass input power wiring from source to the Bypass Input Terminals and Neutral Terminals in the UPS cabinet. 8.
Figure 7. Five-wire installation of the UPS system 40 – 80 kVA with MBS Figure 8. Five-wire installation of the UPS system 40 – 80 kVA without MBS UPS rating 40 kVA 60 kVA 80 kVA 3-phase 3-phase 3-phase Maximum 3-phase Table 1.
Figure 9. Five-wire installation of the UPS system 100 – 160 kVA without MBS UPS rating 100 kVA 120 kVA 160 kVA 3-phase 3-phase 3-phase Rectifier input Fusing Cable 3x160 A 3x95 mm2 3x200 A 3x120 mm2 3x250 A 3x185 mm2 Maximum 3-phase n/a Table 2.
Figure 10. UPS 40-80 kVA with integral Large battery cabinet. The battery cabinet is designed for industrial or computer room applications and should be handled with appropriate care. Observe these precautions when working on or around battery cabinets: • Remove watches, rings, or other metal objects. • Use tools with insulated handles. • Wear rubber gloves and boots. • Do not lay tools or metal parts on top of batteries or battery cabinets. • Do not tilt the cabinets more than +/-10° during installation.
4.3.1 Integral battery cabinet installation procedure This procedure assumes the battery cabinet is located to the left of the UPS cabinet. Warning! The battery cabinet contains lethal voltages. Qualified service personnel should perform installation and service only. 1. Make sure that the UPS is properly installed and secured with its levelling feet. 2. Roll the battery cabinet to an area near the left-hand side of the UPS. 3. Remove the field kit.
11. Locate the large flat bracket from the field kit. Place one end of the bracket over the bolt on the bottom side of the lower right-hand hinge on the battery cabinet and the other end over the bolt on the bottom side of the lower left-hand hinge on the UPS cabinet. 12. Secure the bracket to the hinges with hardware from the field kit. 13.
Figure 14. Battery cabinet hanger brackets. 4.3.2 Integral battery cabinet electrical connections All battery cabinets will arrive at the site with each battery connection string electrically disconnected. If you are installing more than one battery cabinet, the battery cabinet adjacent to the UPS will be the only cabinet directly connected to the UPS. Figure 15. General battery cabinet wiring installation. Use this procedure to wire an integral battery cabinet to the UPS cabinet: 1.
Note! Install the control wiring in separate conduit from the power wiring. The installation cable should have double insulation and rated at Uo/U = 300/500 volts, 1.5 mm2 minimum (e.g. MMJ type or equivalent). Terminal TB1 1 2 3 4 5 6 7 8 9 10 11 12 Name Description CB1 Aux switch NC CB1 Aux switch COM Aux. battery breaker dry contacts. Not used.
6. 7. 8. 9. 4.3.3 After making sure that all battery breakers are in the OFF position, connect the string of battery trays together by mating the loose red connector from each tray to the fixed black connector mounted on the front edge of the tray above. Connect top and bottom tray connectors to mating cabinet connectors to complete battery string connections. Repeat Step 6 for each battery cabinet, and then proceed to Step 8. Secure all battery cabinets by closing and latching the doors.
8. Two cabinet attachment brackets are provided for securing each cabinet at the top and bottom. A flat bracket joins the top of the cabinets and a larger flat bracket joins the cabinets at the bottom. Attach the flat bracket to the cabinet tops first. 9. Remove the left-hand and right-hand screws from the adjacent top door hinges of the battery cabinets. Align the holes in the small flat bracket from the field kit over these screw holes.
7. After making sure that all battery breakers are in the OFF position, connect the string of battery trays together by mating the loose red connector from each tray to the fixed black connector mounted on the front edge of the tray above. Connect top and bottom tray connectors to mating cabinet connectors to complete battery string connections. 8. Repeat Step 7 for each battery cabinet, and then proceed to Step 9. 9. Secure all battery cabinets by closing and latching the doors. 10.
5 UPS communication interface The UPS has a standard, factory-installed XSlot communication bay with two slots. An optional second bay is available, providing two additional slots. Communications XSlot option cards are hot pluggable and quickly installed at the front of the unit. Figure 20. Communication interface location.
5.1 XSlot communication The UPS is compatible with the following XSlot cards. Refer to the manual supplied with the X-Slot card for user instructions. • • • • • ConnectUPS -X Web/SNMP/Hub Card - provides remote monitoring through a Web browser interface, e-mail, and a network management system (NMS) using SNMP; connects to a twisted-pair Ethernet (10/100BaseT) network.
The procedure for connecting the control cables is the following: 1. Remove the front cover by lifting the cover from the bottom outwards by releasing the retaining clip. It’s located in the bottom part of the bezel. 2. Locate the control terminal or XSlot module where you want to install the communications cable. 5.1.2 LanSafe LanSafe continuously monitors single UPS systems and automatically notifies users locally and remotely of any events.
Terminal TB 1 1 2 3 4 5 6 7 8 9 10 Table 4. Name External EPO NC External EPO Com External EPO NO External EPO Com Battery Aux + Battery Aux Battery Uvr + Battery Uvr Building Alarm Building Alarm Return Description Normally Open and Normally Closed dry contacts used to activate EPO of UPS from a remote switch. Contacts used to indicate whether UPS battery breaker or disconnect is open or closed Contacts used to open battery breaker or disconnect Programmable UPS alarm.
4. If installing interface wiring from the bottom of the cabinet, proceed to step 5; otherwise, proceed to step 7. 5. Remove screws securing top internal safety shield panel and open panel to gain access to bottom entry wire way. 6. Remove screws securing bottom internal safety shield panel and remove panel to gain access to bottom entry conduit landing plate. 7. Remove UPS cabinet top or bottom wire entry conduit landing plate to drill or punch conduit holes. 8.
5.3 Remote emergency power off A remote EPO switch can be used in an emergency to shutdown the UPS and remove power to the critical load from a location away from where the UPS is installed. Figure 23 An example of Remote Emergency Power Off station. 5.3.1 Installation 1. Securely mount the Remote EPO station. Recommended locations include operator‘s consoles or near exit doors. 2. Be sure the UPS system is turned off and all power sources are removed. 3.
Figure 24. Remote EPO wiring diagram. 11. If you are installing multiple Remote EPO stations, wire additional stations in parallel with the first Remote EPO. 12. If required, install wiring from the Remote EPO station to trip circuitry of upstream protective devices. A normally open contact is provided between terminals 6 and 7 of remote EPO. 13. When all wiring is complete, reinstall safety shield panels removed in previous steps. 14. Close door and secure with latch.
6 Control Panel The control panel, located on the front door of the UPS, contains LCD screen and pushbutton switches to control the operation of the UPS, and to display the status of the UPS system. Figure 25. UPS Control panel. The Control Panel consists of the following: • • • A Liquid Crystal Display (LCD) screen (1) A horizontal row of pushbutton switches (2) A vertical column of status indicators (3) When the unit powers up, the screen displays the Powerware logo.
A The UPS status area automatically scrolls between the Powerware model number, current date and time, active alarms, active notices, and load percent and battery run time for the UPS. Shown is a typical alarm message. B The information area contains data about UPS status and operations. Select a menu option to display the desired information. C The menu bar lists the titles of the available screens. To select a screen, press the pushbutton underneath the desired screen.
Press the HISTORY pushbutton on the Active Events Menu bar to display the History Log. The History Log lists up to the 500 system events in chronological order, with the most recent event listed last. The History Log lists the events in the following groups: • • • • • • • User and service status User instruction User alarm Check UPS Schedule service UPS shutdown Service alarm The end of the log, i.
The Output Current Screen displays a real-time bar graph of the output current of the UPS. The graph shows the current for each phase. 6.2.3 Controls screen Press the CONTROLS pushbutton on the Main Menu bar to display the System Controls screen. LOAD OFF, normal operation, transfer to bypass, charger control, and power module start-up and shutdown functions are controlled from this screen.
The System Setup Level 1 screen can be used to set the UPS date and time, the serial ports, change the Level 1 password, and logout of Level 1. In addition, the Level 0 functions are available. Use the UP or DOWN pushbuttons to highlight the setup function screen desired, then press the SELECT pushbutton to display the function screen. For example, select COM PORT SETUP from the System Setup Level 1 menu to display the Serial Port Setup screen. This screen allows selection of the serial COM port to set up.
6.3 Mimic Screen To select the Mimic screen from the Events, Meters, Controls, or Setup screens, press the RETURN pushbutton on the current menu bar. The Mimic screen shows the internal components of the UPS cabinet and a real-time graphical representation of the operating status of the system. Figure 33. Mimic screen and Main Menu. 6.4 Status Indicators The four symbols on the left side of the control panel are status indicators.
7 Operating instructions The following procedures provide instructions for operating the UPS system. 7.1 Starting the UPS in Normal Mode To start the UPS system, perform the following procedure: 1. Close the UPS input feeder circuit breaker. 2. Close UPS Bypass input feeder circuit breaker. 3. Observe UPS Control Panel display screen becoming active as an indication of logic power. 4. Press the CONTROLS pushbutton on the Main menu bar. The System Controls screen appears. 5.
2. Close UPS Bypass input feeder circuit breaker. 3. Observe UPS Control Panel display screen becoming active as an indication of logic power. 4. Press the CONTROLS pushbutton on the Main menu bar. The System Controls screen appears. 5. On the System Controls screen, the Power Module (PM) status should indicate SHUTDOWN. 6. Press the BYPASS pushbutton on the System Controls menu bar. The critical load is immediately supplied by the bypass source, in Bypass mode. 7.
7.4 Transfer from Normal to Bypass Mode Note! In Bypass Mode, the critical load is not protected from commercial power interruptions and abnormalities. To transfer the critical load to bypass mode, perform the following procedure: 1. Press the CONTROLS pushbutton on the Main menu bar. The System Control screen appears. 2. Press the BYPASS pushbutton on the System Controls menu bar. The UPS switches to Bypass mode and the critical load is immediately supplied by the bypass source.
7.6 Transfer from Normal to Bypass Mode with UPS Shutdown 1. Transfer critical load to bypass by performing procedure in paragraph 7.4. 2. Press the CONTROLS pushbutton on the Main menu bar. The System Control screen appears. 3. Press the pushbutton to display System Controls Screen 2. 4. Press the PM OFF pushbutton on the System Controls menu bar. The Power Module (PM) status indicates SHUTDOWN.
7.9 Using the LOAD OFF Pushbutton The LOAD OFF pushbutton from the Main menu bar or the System Controls screen menu bar initiates an UPS Load Off. This pushbutton can be pressed to control the UPS output. The UPS LOAD OFF pushbutton de-energizes the critical load and powers down the UPS. The UPS (including Bypass) remains off until restarted. To Use the LOAD OFF Pushbutton: 1. Press the LOAD OFF pushbutton.
1. Press the REPO pushbutton switch. The input, output, and bypass backfeed contactors open, the battery breaker or disconnect is tripped, and the Power Module is turned off immediately, without asking for verification. Note! Do not attempt to restart the system after Load Off until the cause of the shutdown has been identified and cleared. 2. To restart the UPS after using the REPO pushbutton, reset the REPO switch and then follow the procedure, in paragraphs 7.1 or 7.2. 7.
7.11.1 Turn UPS from normal mode to mechanical bypass The procedure to turn the UPS to mechanical bypass switch is described below. 1. The normal start position should be following: 2. Perform transfer from normal mode to bypass mode as described in paragraph 7.4. Remember to verify the transfer before proceeding the next step. 3. Turn ON the S3 switch to bypass UPS. 4. Turn OFF the S4 switch to disconnect UPS output: 5. Perform LOAD OFF procedure contained in paragraph 7.9. 6.
7.11.2 Turn UPS from mechanical bypass to normal mode The procedure to turn the UPS back to normal mode is described below. 1. The normal start position should be following: 2. Turn ON rectifier switch to connect rectifier input to UPS. 3. Turn ON S2 switch to connect bypass input to UPS: 4. Perform UPS start-up procedure (bypass mode) contained in paragraph 7.2. 5. Turn ON S4 switch to connect UPS output to load. 6. Turn OFF S3 switch to disconnect bypass output. 7.
8 Maintaining the UPS System 8.1 General The components inside the UPS cabinet are secured to a sturdy metal frame. All repairable parts and assemblies are located for easy removal, with very little disassembly. This design allows authorised service personnel to perform routine maintenance and servicing quickly. You must schedule periodic performance checks of your UPS system to keep it running properly.
8.3 Performing Preventive Maintenance The UPS system requires very little preventive maintenance. However, the system should be inspected periodically to verify that the units are operating normally and that the batteries are in good condition. 8.3.1 DAILY Maintenance Perform the following steps daily: 1. Check the area surrounding the UPS system. Ensure the area is not cluttered, allowing free access to the unit. 2.
8.4 Advanced maintenance In Terminal Mode (e.g. HyperTerminal program in Windows operating system) and with serial RS232 communication interface (Settings: 19200-8-N-1-N), the user can request the following: • • • • • Display UPS control panel by pressing and holding [ESC], then press [V].* Display Event History by pressing and holding [ESC], then press [H]. Display Node Bits Setup by pressing and holding [ESC], then press [N]. Display any new event by pressing and holding [ESC], then press [L].
The printed log entries contain a time and date stamp and the alarm text message. Terminal mode uses this format for printing alarm entries: MM DD YYYY HH:MM:SS.
9 Wiring Parallel systems The system parallel module (SPM) is recommended and has input connections up to four parallel UPS modules and make-before-brake type of system bypass switch.
Figure 36. Wiring diagram for HotSync Parallel UPS system up to (4) UPS with SPM.
UPS module Cable A Cable C Fuse 1 40 kVA 35 mm² 16 mm² 80 A 60 kVA 50 mm² 25 mm² 100 A 80 kVA 70 mm² 35 mm² 125 A 100 kVA 95 mm² 50 mm² 160 A 120 kVA 120 mm² 70 mm² 200 A 160 kVA 185 mm² 95 mm² 250 A SPM Cable B Cable D Fuse 2 40 kVA 16 mm² 16 mm² 63 A 50 kVA 25 mm² 16 mm² 80 A 60 kVA 35 mm² 16 mm² 100 A 80 kVA 50 mm² 25 mm² 125 A 90 kVA 70 mm² 35 mm² 160 A 100 kVA 95 mm² 50 mm² 200 A 120 kVA 95 mm² 50 mm² 200 A 150 kVA 120 mm² 70 mm² 250 A 160
Figure 37. Bypass wiring diagram and cable lenght notes. 9.2. Installation instructions for 120/160 kVA Tie cabinet Warning! Some components inside the cabinet contain high voltage, which can injure or kill personnel or damage equipment. All operations inside the cabinet must be carried out only by a qualified electrician. The wiring between UPS units and the Tie cabinet shall be connected accordingly to the wiring diagram and the wiring procedure below.
Cartridge fuse list (S11, S21, S31) UPS size Type Rating 120 kVA gL/gG 200 A 690 VAC 160 kVA gL/gG 250 A 690 VAC Size (IEC269) 2NH 2NH P/N 8052350 1024563 Figure 38. Wiring diagram of the 120 and 160 kVA Tie cabinet Please refer to main User’s and Installation Guide (1022403) for sizing cables Wiring procedure: 1. If not already open, unfasten front door latch and swing door open. 2. Remove the door by opening a screw from the bottom hinge. 3. Place the door to its correct position. 4.
6. Route input and output cables through wire way to the terminals of the cabinet. 7. System output cables (L1, L2, L3, and N) should be connected to copper bars either top or bottom of the cabinet. 8. System input cables (L1, L2, L3, and N) should be connected next to the fuses: S11, S21, S31. 9. PE cables should be connected to terminal X1 at the bottom of the cabinet. 10. Place the metal plates to correct positions and fix the switches S11-S31 to their correct position. 11.
9.3 XSlot Hot Sync card The parallel interface wiring requires the Hot Sync CAN bridge card. Terminal J3 Name Description 1 Alarm 2 Alarm Rtn Programmable UPS alarm. Activated by a remote dry contact closure. 3 Alarm Relay NC Normally-closed contact opens when UPS is on bypass. 4 Alarm Relay Com Bypass contact return. 5 Alarm Relay NO Normally-open contact closes when UPS is on bypass.
Note! The Hot Sync CAN Bridge card has build-in termination resistor enabled by jumper J7. The default jumper setting without termination resistor is J7: Pin 2-3. Place the the jumper J7 to correct setting: the first and last UPS modules should have the CAN bus termination resistor enabled (Jumper J7: Pin 1-3). In addition to the CAB bus cable a back-up pull-chain cable is needed for bypass operation. Figure 42. Communication wiring for parallel UPS system.
Building Alarm Pull Chain Wiring Terminations From UPS 1 To UPS 2 To UPS 3 (If installed) To UPS 4 (If installed) TB2-1 (BA 2) TB2-1 (BA 2)) TB2-1 (BA 2) TB2-1 (BA 2) TB2-2 (Rtn) TB2-2 (Rtn) TB2-2 (Rtn) TB2-2 (Rtn) Bypass Relay Pull Chain Wiring Terminations All UPSs From To TB2-1 (BA 2) TB2-3 (Byp) TB2-2 (BA 2 Rtn) TB2-4 (Byp Rtn) Figure 43. Bypass control (pull-chain) wiring for parallel UPS system.
10 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.
11 Dimensional drawings Figure 44. UPS cabinet dimensions. (40-80 kVA) Figure 45. UPS cabinet top and bottom dimensions.
Figure 46. UPS cabinet dimensions (100-160 kVA) Figure 47.
Figure 48. Large battery cabinet dimensions. Figure 49. Large battery cabinet top and bottom dimensions.
Figure 50. Small battery cabinet dimensions and empty space for batteries Figure 51.
Figure 52.
12 Technical data 12.1 Standards UPS 40 kVA 60,80 kVA 100, 120 kVA Safety IEC/EN 62040-1-1, EN 60950 EMC IEC/EN 62040-2, UPS for restricted sales distribution Product IEC/EN 62040-3 160 kVA 12.2 Environmental specification UPS 40 kVA 60,80 kVA 100, 120 kVA Amb. Temperature IEC/EN 62040-1-1, EN 60950 Relative humidity 0 to 95%, no condensation allowed Storage –25°C to +60°C, excluding batteriesIEC/EN 62040-3 Altitude 1500 m above sea level Vibration max 0.
12.5 System DC circuit UPS 40 kVA 60,80 kVA Battery monitoring Advanced Battery Management (ABM™) Battery type VRLA 12 Volts Battery qty 40 pcs. Nominal voltage 480 Volts (240 cells) Float voltage 2.30 VPC Cut off voltage 1.70 VPC with 2 min countdown timer; 1.56 VPC absolute value Battery charging 10 A 20 A 100, 120 kVA 30 A 160 kVA 40 A 12.
13 Warranty 13.1 Standard 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.
