Uninterruptible Power Supply UPS Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA AEG Power Supply Systems GmbH Department: PSS TED Name: Schenuit/Bögge Revision: 02 Date: 09.05.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Notes on these Operating Instructions Duty to provide information These operating instructions must be read carefully by all persons working with or on the UPS prior to installation and initial start-up. These operating instructions are a composite part of the UPS.
Protect 5.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Table of Contents Notes on these Operating Instructions ...........................................2 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Safety Regulations.................................................................6 Important Instructions and Explanations ..................................6 Accident Prevention Regulations .............................................6 Danger during Maintenance and Repair Work.........................7 Fire Protection.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 8 8.1 8.1.1 8.2 8.3 8.4 Operation ..............................................................................32 Disconnecting the UPS (Individual Unit) ................................32 Restarting after Disconnection (Individual Unit) .....................33 Shutting Down the UPS .........................................................33 Emergency Shutdown ............................................................34 UPS Fuses ...........................
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 1 Safety Regulations 1.1 Important Instructions and Explanations The instructions for operation and maintenance, as well as the following safety regulations must be complied with to ensure the safety of personnel as well as the continued availability of the unit. All personnel installing/dismantling, starting up, operating or servicing the units must be familiar with and observe these safety regulations.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 1.3 Danger during Maintenance and Repair Work CAUTION: The voltage applied to the UPS can be fatal. Prior to start-up and/or maintenance work always disconnect the UPS from the power supply and secure the unit against reclosing. The capacitors must be discharged. Free-standing and movable components can protrude into the work area and cause injuries.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 1.6 Safety Awareness The personnel defined in chapter 1.5 are responsible for safety. They must also ensure that only suitably qualified persons are permitted access to the UPS or the safety area. The following points must be observed: All such working procedures are prohibited which are detrimental to the safety of persons and the operation of the UPS in any way. The UPS may only be operated in perfect working condition.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 1.8 Liability No liability is accepted if the UPS is used for applications not intended by the manufacturer. Any measures necessary for the prevention of injury or damage to equipment are the responsibility of the owner or user. In the event of any claims in connection with the UPS, please contact us immediately quoting: • Type designation • Works number • Reason for claim • Period of use • Ambient conditions • Operating mode 1.9 Directives The Protect 5.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 2 Technical Data Please refer to the enclosed technical data sheet for optional and unit-specific setting values. Type kVA 10 20 30 40 60 80 100 120 3 x 480 V ± 15 % Rated connection voltages Voltage range in V Frequency on rectifier input in Hz 45 - 66 Current consumption at max.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 3 General Information One application of Protect 5. 31/xxx systems is to ensure an uninterruptible power supply to computers, IT systems, process control systems and their periphery in production and administration systems. The Protect 5. 31/xxx range covers a power range of 10 kVA to 80 kVA. Figure 1 1 2 3.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The information exchange between the individual modules is carried out using the CAN bus (Controller Area Network). This CAN bus has high interference immunity and is frequently used for industrial applications.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The rectifier (REC) supplies the inverter and the battery with DC voltage. The inverter (INV) converts this DC voltage into a 1-phase AC voltage. In the event of a mains fault (such as a power failure), the power supply to the load is maintained from the battery without any interruption.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 4 Transport, Storage and Installation 4.1 Packing The UPS units are packed at the works to withstand both rail and road transport. The housing is fixed to the transport pallet using four bolts. The unit is packed in plastic film to prevent any damage to the surface paint and protect the unit against moisture. i NOTE: To prevent damage only remove the protective film from the UPS immediately prior to installation.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The length of the ropes is calculated so that an angle of 45° is given between the rope and the top edge of the cabinet (DIN 580). The minimum load capacity of each rope must be ≥ 0.5 times the weight of the cabinet (DIN 580). The weight of each UPS can be found in Table 1, Chapter 2. One rope must be used for each transport eyelet.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Preparation: Leave the UPS on the transport pallet. Transport with lowlift truck Transport with forklift truck Figure 6 Transport with lowlift and forklift truck ATTENTION: Observe the centre of gravity of the unit! The lifting arms must be - sufficiently long and - sufficiently far apart. Transport the unit as follows: • Insert the lifting arms between the transport pallet and the UPS. • Carefully lift the UPS and transport it to its intended location.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA ATTENTION: The waste heat of the UPS must be dissipated! The ventilation of the battery compartments must be carried out in accordance with DIN/VDE 0510, Part 2. The following general rule is applicable for ventilation requirements (for lead-acid batteries): Q = 0.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 4.6 Storage UPS units may only be stored for a maximum period of six months in the original packaging in dry, ventilated rooms with a permanent roof. The permissible ambient temperature range is between -35 °C and +70 °C with a relative humidity of ≤ 85%. If the unit is stored for longer than six months, conventional desiccants must be added and the UPS units must be sealed in airtight plastic film.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.1.2 Operation with Faulty Mains Supply SBS Secured busbar Mains circuit Q29 _ ~ _ Loads ~ Q29 Q29 option Figure 9 Power circuit with a faulty mains supply The mains does not sufficiently maintain the supply of the rectifier of the UPS system. In this case, power is supplied to the inverter from the charged battery without interruption. The power supply to the loads is therefore also ensured in the event of a mains failure.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.1.3 Operation with a Faulty Inverter Secured busbar SBS Mains circuit Q29 _ ~ _ Loads ~ Q29 Q29 option Figure 10 Power circuit with a faulty inverter If an inverter is defective, power is supplied to the loads by the SBS circuit. The SBS is an electronic switching device between the load and the mains. The synchronisation unit in the SBS ensures that the frequency and phases of the inverter voltage are synchronised with the mains. 5.1.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.2 Function of the Circuit Breakers Load interrupter switch Q1: The rectifier is switched over to the REC circuit using load interrupter switch Q1 (Figure 2). The open-circuit shunt release of Q1 reacts in the event of a fault (e.g. short circuit) so that the rectifier is isolated from the REC circuit.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.3 Static Bypass Switch (SBS) SBS circuit Loads SBS trigger circuit SBS interface SBS control unit Figure 12 Functional principle of the SBS control unit The SBS control unit monitors the voltages of the load circuit and the SBS incoming mains and, in the event of an overload or inverter fault, initiates switchover of the load to the SBS circuit without interruption (providing the SBS circuit is in the permitted tolerance range).
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA ATTENTION: If the SBS is blocked, there is no switchover to the SBS circuit! This means that if the INV fails or is switched off by the operator, the load circuit is no longer connected to the power supply. The loads must then be manually reconnected by switching the INV back on or activating the SBS (switch Q28 off and back on). 5.4 Charging the Battery The battery is charged according to DIN 41772 in accordance with a CVCC curve.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Test of the battery charging circuit: This brief test checks the connected battery by lowering the voltage and carrying out a current analysis. Line interruptions or defective fuses in the battery circuit are also detected. With a battery present, the test takes approx. 1 second. It is carried out automatically each week by the rectifier control unit. 5.6.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.6.2 Capacity Test The capacity test allows the availability of the battery to be tested using the currently available inverter load. In this process, the regulator lowers the DC voltage setpoint to approx. 1.9 V/cell. Generally, the battery backs up the DC voltage and supplies the entire current to the inverter. This simulates a rectifier circuit failure. In the event of a battery fault, the inverter continues to be supplied by the rectifier.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 6 Connection CAUTION: Prior to commencing work, ensure that the connection cables are disconnected from the power supply and that it is not possible to activate the power supply. i NOTE: In order to avoid deformation of the supporting rail and to protect the base of the connection terminal against torsional forces, it is advisable to hold the cable in position when tightening the clamping screw (refer to Figure 14/15).
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 6.2 Connection of the Mains, Load and Battery Cables X1 U V X2 W L- X3 L+ U X4 N U N PE PE Figure 14 Connection panel of the Protect 5. 31/10-40 kVA X1 X2 X3 U V W L- L+ U N X4 U N Figure 15 Connection panel of the Protect 5.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The cables are connected as follows: • Open the control cabinet door. • Remove the connection cover from the terminals. • Insert the cables to be connected into the UPS from below or from the rear. Cables coming from above are routed down next to the UPS. • Secure the cables to the respective copper rails by securing the cable lugs (refer to Figure 14 and 15) using a spanner. • Secure the protective earth conductors (PE) to the designated unit frames.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 6.4 Connection Cross Sections and Fuse Protection Layout of cross sections in acc. with DIN 0298, Part 4, Table 3 Laying type B1/B2 1 Rectifiers, input Rectifier fusing in A X1 2 Cross section in mm²/pole *1 min. max 3 SBS circuit input SBS fusing in A X4 4 Cross section in mm²/pole *1 min. max 5 Load output Load output fusing in A X3 max. 6 Cross section in mm²/pole min. max.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 7 Start-Up The start-up procedure is the same for the various UPS versions from 10 kVA to 80 kVA. Prior to start-up, ensure that the preset unit specifications match the battery specifications. For parallel systems, see description of "Parallel Operation"! i NOTE: The start-up instructions of the battery manufacturer must be complied with. Any necessary parameter modifications must be made by our service personnel or via the DOU.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 7.2 Starting up the UPS (Individual Unit) Step Action DOU LED Display 1 Q1 and battery isolator (external) to the "OFF" position. 2* Q29 (internal option) to position "2" service mode. 3 Switch on mains voltage for rectifier and SBS circuits. Wait Red/yellow/green Self-test until the self-test finishes. continuously 4* Q29 (internal option) to position "1" inverter operation. 5 The loads are supplied by the SBS.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 8 Operation 8.1 Disconnecting the UPS (Individual Unit) ATTENTION: Only switch off the UPS in an absolute emergency by switching off the rectifier circuit and SBS circuit in their distribution! In addition, the inverter must be switched off using the remote OFF contact. The external battery isolator must be opened to completely disconnect the unit from the power supply. To restart the system, proceed as described in Chapter 7.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 8.1.1 Restarting after Disconnection (Individual Unit) Proceed as described in the following table to restart the UPS after it has been disconnected from the power supply. Step Action DOU LED Display 1 Q1 and battery isolator (external) set to "OFF" position. 2* Q29 (internal option) set to "3" manual bypass (load supply via manual bypass). 3 Connect the mains voltage for the rectifier circuit and SBS circuit.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA To restart the UPS after shutdown, proceed as described in Chapter 7. 8.3 Emergency Shutdown Emergency shutdown is available as an option and mainly serves to disconnect the loads from the power supply via an external contact. The exact design of the emergency shutdown depends on customer requirements. i 8.4 NOTE: For more information, please refer to the relevant operating instructions.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9 Graphical Display and Operation Unit 9.1 General Information The graphical display and operation unit (DOU) is integrated in the front of the UPS housing. It serves to signal and display UPS unit data and to control and parameterise the UPS system. The DOU consists of a display unit with 3 LEDs, a graphical LCD and an operating panel with 5 keys. The global unit status can be read from the 3 LEDs.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9.1.2 Keyboard Operation You can use the ENTER key to open and close submenus and to acknowledge control functions and parameters. The 4 display keys are assigned to different functions. The current key functions are represented as symbols which can be found in a small framed area on the right-hand side of the LCD. In the “operating display” and in the “system”, you can switch the converters on and off using the general keys.
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Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9.2 Start-Up Following the power-up reset, the DOU performs a self-test. Data is loaded from the power converters after the test has been completed successfully. The LEDs light up sequentially during this phase. A start screen appears on the LCD, and a status bar indicates the duration of the start-up process. When you start up the DOU for the first time (commissioning), you must select the menu language using the general keys "<" and ">".
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9.3.2 Main Menu Current cursor position Operating display Settings Information Service Thu 01-Jan-04 Fig. 18 Blocking Fault history 00:00 Main menu After start-up, the “main menu” represents the highest menu level, which means that you can open further submenus from here, and you can always return to this level. The “main menu” has the typical menu structure. Additional submenus are displayed on the left-hand side.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The operating display consists of 3 parts: On the left-hand side, the unit status is shown in a pictogram. The individual components of the unit are represented here as symbols. The respective symbol flashes in the event of messages or faults in a component. In addition, the current power circuit is indicated via a bar diagram. The centre part displays the most important measured values of the unit in a digital as well as an analogue format.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9.3.5 Blocking You can call up the “Blocking” menu from the “main menu”. After you have entered the current password, you can “block operation” of the control systems (switching on/off and fault acknowledgement). The password must be entered digit by digit and then acknowledged using the ENTER key. The password set ex works is: 1201. In menus where switching operations are normally possible, blocking is indicated by a key. 9.3.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Menus for changing the operating statuses: • In the “Rectifier operating mode” menu, you can change the charge status of the rectifier (charger). The current charge status is displayed. • In the “Battery test” menu, you can initiate different battery tests, depending on the test implemented. The status and measured values of the battery are displayed during the test. See Appendix, Battery Tests.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 10 Annex 10.1 Battery Handling using the Graphical DOU 10.1.1 Charging the Battery The battery is charged according to DIN 41772 in accordance with a CVCC curve. This ensures that the battery is charged in the shortest possible time and also prevents overcharging. Battery charging is electronically controlled and monitored. Operating faults are registered, causing the charging process to be interrupted.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 10.1.2 Battery Data Depending on the system configuration, different battery parameters can be set in the "SERVICE / BATTERY VALUES" menu. The parameters for the individual battery tests are also set in this menu. Please refer to the data sheets of the battery manufacturer for the individual values to be set.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Protect-5: The standby time is determined by calculating the balance of the battery currents.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 10.1.4 Possible Battery Tests Test of the battery charging circuit: This brief test checks the connected battery by lowering the voltage and carrying out a current analysis. Line interruptions or defective fuses in the battery circuit are also detected. With a battery present, the test takes approx. 1 second. It is carried out automatically each week by the rectifier control unit.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 11 Interfaces 11.1 Remote Signalling The remote signalling PCB consists of a remote signalling master board A12 and an expansion board A13, the contacts of which are connected to terminal block X12.
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Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 12 Maintenance and Repairs 12.1 Diagnostic Functions The comprehensive diagnostic functions implemented in the UPS not only increase its operational reliability considerably, but also reduce the time required for maintenance work and troubleshooting to a minimum. The UPS is equipped with the following diagnostic functions, some of which are optional: Self-diagnosis: This is activated when the system is switched on.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 12.2.1 Fault Table Faults that occur are displayed on the DOU in plain text. Some faults can be located and eliminated quickly using the following table. Fault Q1 triggered. Possible cause Earth fault or short circuit on the battery side. REC does not work. Q1 not in "ON" position. F20 to F22 defective F31 to F33 defective. Fault in the SBS circuit. SBS does not work. INV does not work. No load voltage. Faulty connection to battery. Fan does not work.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 12.2.2 Removing and Installing the Fan CAUTION: The fan can only be removed and installed by trained and qualified personnel when the UPS is switched on. Always observe the safety regulations! Figure 22 Installing and removing the fan (sample model 60 kVA) Figure 23 Fan distribution (example model 60 kVA) – (top view from front) The defective fan is removed as follows (see Figure 23): • Remove the corresponding fuse in acc. with Table 7.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA visual checks and functional tests of the unit to maintain its high availability and operational reliability and also to check the battery charge. It is only possible for the UPS to reach its high degree of availability of approx. 99.99% if any unit fault is eliminated within 24 hours. This must be ensured by providing the necessary service work (e.g. through maintenance contracts).
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA • Activate the manual bypass via Q29 in accordance with Chapter 8 Disconnect the UPS in accordance with Chapter 8 and check the following functions when restarting the system: • LEDs of the DOU • Correct start-up of the rectifier and the inverter • Functioning of the SBS control • Check the output voltages of the rectifier and the inverter as well as of the SBS and the battery charging voltage. 12.3.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 13 Spare Parts and Customer Service Despite using non-wearing components, we recommend stocking the spare parts listed in Table 10. This will help to ensure permanent operational availability of your UPS.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 14 Annex Optional equipment is available for the Protect 5.
Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Figure 25 shows all the PCBs included in the scope of supply. These are mounted on the control unit pivot plate behind a cover which can be opened by loosening the fixing bolts. When closing this pivot plate, ensure that no cables are pinched.
