Transcript
MIZAR 10÷15kVA ; ALCOR 20÷30kVA
®
POWERTRONIX UNINTERRUPTIBLE POWER SUPPLY
User Manual MIZAR 10÷15 kVA ALCOR 20÷30 kVA
Document : DT0418 English Revision 00
Date 20-09-2007
Issued by P.Valle / D.Andryka
Approved by ANDREA G.
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User Manual DT0418-E00
Page 1 of 37
MIZAR 10÷15kVA ; ALCOR 20÷30kVA 1.
GENERAL OVERVIEW .................................................................................................................................................3 1.1. UPS GENERAL DESCRIPTION .......................................................................................................................................3 1.1.1. UPS APPLICATIONS OF THE UPS........................................................................................................................3 1.1.2. POWER AND AUTONOMY....................................................................................................................................3 1.1.3. SAFETY AND EASE OF USE.................................................................................................................................3 1.2. CONFIGURATION AND OPTIONAL EQUIPMENT.............................................................................................................4 1.2.1. BASE CONFIGURATION.......................................................................................................................................4 1.2.2. BATTERY CABINET ..............................................................................................................................................4 1.2.3. TRANSFORMER CABINET....................................................................................................................................4 1.2.4. REMOTE COMMUNICATION CARD ......................................................................................................................5 1.2.5. UPS MANAGEMENT SOFTWARE .........................................................................................................................5 REMOTE PANEL ...................................................................................................................................................................5 1.2.6. REMOTE E.P.O. PUSH-BUTTON PANEL...............................................................................................................6 1.3. OPERATING PRINCIPLE.................................................................................................................................................7 1.3.1. UPS BLOCK DIAGRAM .........................................................................................................................................7 1.3.2. INPUT STAGE, POWER MODULE AND OUTPUT STAGE......................................................................................7 1.3.3. LOGIC AND AUXILIARY CIRCUITS .......................................................................................................................8 1.3.4. BATTERIES ..........................................................................................................................................................8 1.3.5. MANUAL BY-PASS ...............................................................................................................................................8 1.3.6. FRONT PANEL .....................................................................................................................................................8
2.
INSTALLATION INSTRUCTIONS ...........................................................................................................................................9 2.1. GENERAL INFORMATION...............................................................................................................................................9 2.2. RECEPTION AND IDENTIFICATION ................................................................................................................................9 2.3. STORAGE ......................................................................................................................................................................9 2.4. UPS POSITIONING .......................................................................................................................................................10 2.5. ROOM SPECIFICATIONS..............................................................................................................................................12 2.6. LAYOUT AND CONNECTION TO THE MAINS ................................................................................................................13 2.7. UPS AUXILIARY CONNECTIONS ..................................................................................................................................19 2.7.1. REMOTE COMMUNICATION BOARD..................................................................................................................20 REMOTE.......................................................................................................................................................................21 2.7.2. PANEL (Optional) ................................................................................................................................................21 2.7.3. UPS MANAGEMENT SOFTWARE .......................................................................................................................22 2.7.4. REMOTE E.P.O. BUTTON ...................................................................................................................................22 EARTH CONNECTION ....................................................................................................................................................22
3
CONTROL PANEL........................................................................................................................................................23 3.1. INTRODUCTION.................................................................................................................................................23 LCD CONTROL PANEL ............................................................................................................................................................24 3.1.1. MENU 1. UPS STATUS AND ALARMS ..........................................................................................................26 3.1.2. UPS IN FAULT CONDITIONS........................................................................................................................27 3.1.3. MENU 2: MEASUREMENTS ..........................................................................................................................28 3.1.4. MENU 3. UPS COMMANDS.................................................................................................................................28 3.1.5. MENU 4: PANEL SETUP ................................................................................................................................29 3.1.6. MENU 5: EVENTS RECORDER MANAGEMENT.........................................................................................29 3.1.7. MENU 6: SERVICE MODE.............................................................................................................................29
4.
INSTRUCTIONS FOR USING THE UPS ...............................................................................................................................30 4.1. INTRODUCTION ..............................................................................................................................................................30 4.2. ROTARY POWER SWITCH............................................................................................................................................30 4.3. MANAGING THE UPS BATTERY ...................................................................................................................................34 4.3.1. BATTERY TEST PROGRAMMING.......................................................................................................................34
5.
MACHINE FAULTS ......................................................................................................................................................35 5.1. 5.2. 5.3.
6.
GENERAL ALARMS ......................................................................................................................................................35 FIRE .............................................................................................................................................................................36 FAULTS RELATED TO THE NATURE OF THE LOAD......................................................................................................36
SCHEDULED MAINTENANCE.............................................................................................................................................37 6.1.
ANNUAL MAINTENANCE (OR EVERY SIX MONTH IN CASE OF UPS HIGH CRITICAL MISSION) ....................................37 POWERTRONIX SpA reserves the right to modify this document without any notice
User Manual DT0418-E00
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA 1. GENERAL OVERVIEW 1.1.
UPS GENERAL DESCRIPTION
These UPS families have the compact construction, with the outer metal frame and the electronic circuits and power components inside. All user accessible elements are placed on the back side, while the control panel – on the front side. The top and side covers can be removed, giving an access to the internal part of the UPS for the service or maintenance purposes. The front side of all units contains the user interface panel useful for monitoring, maintenance and control. The terminal block for the electrical connection to the mains, reserve, load, external batteries, and the main rotary switch, are located on the back side of the unit. The internal batteries are placed in the lower part of the UPS, with an access from front side. 1.1.1. UPS APPLICATIONS The new UPS family was designed to provide stabilized and filtered power, especially for supplying sophisticated and sensitive electronic devices (i.e. for data processing systems). Alcor and Mizar UPSes can be used to supply electronic systems of medical centers, police stations, motorway tunnels, broadcasting stations, banks, technical and administrative offices, requiring the power source free from voltage and frequency variations. 1.1.2. POWER AND AUTONOMY Thanks to its modular design, the UPSes are available in two series with rated power from 10kVA to 15kVA (Mizar) and from 20kVA to 30kVA (Alcor). These two families have different power sections, while batteries and cabinet remain the same. Both UPSes can utilize the internal battery block of 60 pcs. of 5, 7.2 or 9Ah batteries. An external battery modules can be used to increase the UPS autonomy. 1.1.3. SAFETY AND SIMPLICITY OF USE All the UPS elements available for user daily maintenance are insulated and disconnected from hazardous voltages. Control of the overload and excessive temperatures guarantees the immediate and most suitable intervention in the case when one of these conditions occurs during operation. The operator can view the UPS status on the front panel and perform shut down or switching operations easily (see chap. 3 page 19). The unit is provided with the E.P.O. (Emergency Power Off). This function is activated by pressing the button located on the front panel. A remote E.P.O (optional) switch can be connected to UPS to provide remote emergency power off action. The UPS state can be easily monitored with the personal computer and an interacting program (optional) or through the remote panel (optional), especially when the UPS is installed in unmonitored areas. See chap. 1.2.5 - 1.2.6.
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
1. GENERAL OVERVIEW 1.2. 1.2.1.
CONFIGURATION AND OPTIONAL EQUIPMENT BASE CONFIGURATION
The UPS is available in the following configurations: Input Three-phase Input Three-phase Input Single-phase Input 1.2.2.
Output Three-phase Output Single-phase Output Single-phase Output
Power Mizar / Alcor 10÷15 kVA / 20÷30 kVA 10÷15 kVA / 20÷30 kVA 10÷15 kVA / 20÷30 kVA
BATTERY CABINET
When the autonomy time provided with the basic configuration is not sufficient, additional optional battery cabinet can be connected to the UPS. The batteries cabinet can contain up to 2 battery blocks of 4.5 – 5 – 7.2 – 9 Ah. 1.2.3.
TRANSFORMER CABINET
If a galvanic isolating transformer is required, it can be positioned inside UPS cabinet in the place of the internal batteries - in this case an external battery cabinet is essential. The standard transformer is three-phase/three-phase (or single-phase/single-phase or three-phase/singlephase) with 1:1 ratio, but it can be supplied with a different transformation ratio upon customer request.
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
1. GENERAL OVERVIEW 1.2.4.
REMOTE COMMUNICATION CARD M1
Remote communication board (the code CS0098), gives possibility of monitoring and communicating with UPS. Monitoring can be implemented with the PC and dedicated software or through a remote panel. There are also voltage free contacts available on the terminal board M1(more info at page 20) 1.2.5.
CN1
CN3
UPS MANAGEMENT SOFTWARE
The “UPS MANAGEMENT” Generex communication software allows interaction between UPS and PC or the network based on Windows, Win-NT, Novell, OS2, Dec, and Linux operating systems. The software is used to monitor and control parameters of one or more UPSes supplying the network (more info at page 22)
1.2.6.
REMOTE PANEL
The remote panel is used for remote viewing of the UPS state, it shows the status of the main UPS blocks with LED indicators and the sound signalization in the case of alarm conditions (more info at page 21)
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA 1.2.7.
REMOTE E.P.O. PUSH - BUTTON
The remote E.P.O push-button provides the safe, remote way to fast and full disable the unit running in the event of an emergency (more info at page 22)
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
1. GENERAL OVERVIEW
1.3.
OPERATING PRINCIPLE
The UPS described here is an on-line dual conversion type UPS with automatic by-pass in compliance with European standard EN62040-1-2. This UPS performs a dual conversion of the incoming voltage continuously and without interruption. The absence of direct connection between mains and the load provides blocking all voltage and frequency disturbances. The dual conversion guarantees that the output energy is always well regulated and has correct voltage and frequency values, ideal for the operation of professional applications. When the input voltage exceeds the allowed range or - more frequently - is not present, the load is supplied by converted energy from the batteries. The system is supplied with an automatic by-pass. In the event of a UPS fault or overload, the by-pass connects immediately the load directly to the mains through a reserve line, making possible normal load operation without interruption. See fig. 1.3.1 1.3.1.
UPS BLOCK DIAGRAM
MANUAL BY-PASS
MANUAL BY-PASS
I3
ROTARY SWITCH
RESERVE LINE
I2
RESERVE LINE
ROTARY SWITCH
I1
MAINS INPUT
ROTARY SWITCH
I4
= =
ROTARY SWITCH
RECTIFIER – BATTERY CHARGER
INVERTER
I1
OUTPUT LOAD
STATIC SWITCH
ROTARY SWITCH
BATTERY
1.3.2.
INPUT STAGE, POWER MODULE AND OUTPUT STAGE
From the input bars the mains are connected via the MAINS INPUT l1 switch to the power module. The rectifier regulates the DC voltage to a reference value, charging continuously the battery. Then the DC voltage supplies the inverter, which feeds the load with regulated sinusoidal voltage (phase and amplitude controlled). In normal operating conditions, the static switch (providing energy to the load) selects the inverter as the voltage source; in the case of fault or overload, the UPS output is redirected to the reserve line. This operation allows providing the energy to the load. When the cause of the alarm disappears, the static switch automatically selects the inverter to feed the load again.
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1. GENERAL OVERVIEW
MIZAR 10÷15kVA ; ALCOR 20÷30kVA
1.3.3. LOGIC AND AUXILIARY CIRCUITS The control logic occupies the separate board (0SDE0150) and represents the “intelligence” of the UPS. It manages operations of the step-up converter, inverter and by-pass, based on feedback signals taken from the power module. The control logic also manages the other three boards, i.e. the battery charger, auxiliary power supply and signal interface. The battery charger handles recharging of the outside batteries connected to the UPS. The signal interface receives the signals from the control logic and converts them into the protocol required by the front panel of the UPS and also the relays board. Going backwards, the selected commands from the front panel (automatic by-pass forcing) and/or relay board (EPO) are sent from the signal interface to the control logic which interprets them and performs desired operation – like switch on/off inverter or shuts off the UPS. The auxiliary power supply supplies all the boards and electronic components in the UPS. 1.3.4. BATTERIES The battery set provides energy to the system when the input mains is out of the allowed range or not present; in all other cases batteries are constantly recharged by the charger module. In this way the batteries are always ready for use when required. 1.3.5. MANUAL BY-PASS The manual by-pass is useful in the situation, when it is necessary to disable the UPS and keep the load supplied by the mains (e.g.: UPS stopped, fault, etc.). This circuit is active in the first position of rotary switch, located on the rear part of the UPS. This operation can be done at any time and doesn’t involve any interruptions of the supply voltage if only the reserve line voltage is within the range. 1.3.6. FRONT PANEL The UPS can be managed via the front panel. Using the panel it is possible to execute the commands, display states and measurements and reset the alarm circuits. The panel is equipped with an LCD screen used to display the operating status of the UPS, the load and all types of measurement (see chap. 3)
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION
2.
INSTALLATION INSTRUCTIONS
2.1.
GENERAL INFORMATION
This chapter describes the system installation procedures and lists the following subjects: • • • • • • • 2.2.
Reception and identification Storage UPS positioning Room specifications Arrangement and connection to mains UPS Auxiliary connections Earth connection RECEPTION AND IDENTIFICATION
After removing the packing, visually inspect (inside and outside) the UPS and battery module (if included) to check for any damage that could occur during shipping. If there is any damage, inform the shipper or retailer immediately. Check the supplied material against the packing slip. The machine has an adhesive identification plate indicating the type, power and serial number; it is located on the rear side of the unit (Fig.2.2) Fig. 2 . 2
CONFIG. UPS
2.3. STORAGE If the system is not going to be installed immediately it must be stored in an environment with adequate protection against excessive humidity and sources of extreme heat (from +5 to +40°C, humidity less than 95% without condensation). If the battery module is supplied, also make sure that no more than 6 months pass between one battery recharge and the next. Once this period of time has elapsed, temporarily hook the UPS up to the mains and run it for the time needed to recharge the batteries.
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA 2. INSTALLATION 2.4.
UPS POSITIONING
All dimensions are in millimeters.
The same cabinet is used for both series (MIZAR and ALCOR). The mechanical parameters are described in the following tables: POWER (kVA) 10 15
DIMENSIONS WxDxH (mm)
MIZAR WEIGHT (Kg) w/o batteries
390x900x900
WEIGHT (Kg) with batteries
70
220
Tab. 2.4a POWER (kVA) 20 25 30
ALCOR DIMENSIONS WEIGHT (Kg) WxDxH (mm) w/o batteries 390x900x900
WEIGHT (Kg) with batteries
80
230
Tab. 2.4b The weight difference is in the case the batteries are mounted or not in the same UPS cabinet. For handling you need to remember that the machine, unless special arrangements are made, is shipped and thus handled with the batteries inside, thus you need to refer to the higher weight of the version used. All the connections are located in the rear panel and can be reached just removing the cover as shown in Fig. 2.4
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION Fig. 2.4 shows the cover and the external connections.
2
1 3
4
METAL COVER
Fig. 2.4 1. 2. 3. 4.
Rotary switch Air cooling grid Communication cards slot (Relay & SNMP) Metal cover
Looking at the back, the cables input is located in the lower side, that it is accessible removing the metal cover (Fig.2.4) For the cables connection according to the UPS configuration refer to fig.2.6c/d/e at pages 17-18.
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION 2.5.
ROOM SPECIFICATIONS
The room where the UPS is installed must be clean; it must have pollution class 2 (CEI) and must be able to dissipate the heat produced by the machine, as shown in table 2.5a. Table 2.5a Rated P (kVA) Diss. P (W) 15 750 30 1440 For correct battery ventilation, the room must be able to ensure an exchange of air equal or greater than what is shown in table 2.5b. Table 2.5b Air exchange only for battery hydrogen 4.5 Ah batteries 7Ah batteries 9 Ah batteries (60 blocks) (60 blocks) (60 blocks) 0.2m3/sh
0.2m3/h
0.2m3/h
Remember that the average life of the batteries is closely correlated with the operating temperature; a temperature of around 20°C is normally recommended. (when the temperature rises above 20°, for each 10° higher the battery life drops by 50%)
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION 2.6.
LAYOUT AND CONNECTION TO THE MAINS
For connection to the mains a layout solution like the one shown in diagram 2.6 is recommended. The circuit breakers B-C-D are magnetothermic type without differential protection, or if this is required, with a triggering current greater than 0.3A, delayed and suitable for load with DC current (type A). Switch A is used as external BY-PASS. Block diagram 2.6 DISTRIBUTION PANEL D
A UPS I1 BY-PASS
B
RESERVE LINE I1-Rotary Switch RESERVE
I1-Rotary switch
Config.: 3 in – 3 out
OUTPUT
C RESERVE LINE
I1-Rotary switch
MAINS INPUT MAINS
= =
LOAD
I1-Rotary switch BATTERY
INTERNAL BATTERY
DISTRIBUTION PANEL D
A UPS I1- Rotary switch BY-PASS
B
RESERVE LINE I1- Rotary switch RESERVE INPUT
Config.: 3 in – 1 out
I1- Rotary switch
OUTPUT
C RESERVE LINE
I1- Rotary switch
MAINS INPUT MAINS
= =
LOAD
I1- Rotary switch BATTERY
INTERNAL BATTERY
DISTRIBUTION PANEL D
A UPS I1- Rotary switch BY-PASS
B
RESERVE LINE I1- Rotary switch RESERVE INPUT
I1- Rotary switch
Config.: 1 in – 1 out
OUTPUT
C RESERVE LINE
I1- Rotary switch
MAINS INPUT MAINS
= =
LOAD
I1- Rotary switch BATTERY
INTERNAL BATTERY
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION
The control parts and all the power connections of the UPS in question need to be able to permanently support the current shown in tab. 2.6 (three-phase/three-phase) or in tab. 2.7 (three-phase/single-phase) or in tab.2.8 (single-phase/single-phase) UPS power (kVA) 10 15 20 25 30
Mains input Imax (A) 20 20 50 50 50
Reserve input Imax (A) 15.2 22.8 30.3 38 45.5
User outputs Imax (A) 15.2 22.8 30.3 38 45.5
Battery discharge current (A) 13.4 20 27 33.4 40 Table 2.6
UPS power (kVA) 10 15 20 25 30
Mains input Imax (A) 20 20 50 50 50
Reserve input Imax (A) 46 68 91 114 137
User outputs Imax (A) 46 68 91 114 137
Battery discharge current (A) 13.4 20 27 33.4 40 Table 2.7
UPS power (kVA) 10 15 20 25 30
Mains input Imax (A) 60 60 150 150 150
Reserve input Imax (A) 46 68 91 114 137
User outputs Imax (A) 46 68 91 114 137
Battery discharge current (A) 13.4 20 27 33.4 40 Table 2.8
WARNING !! IN ADDITION TO THE CIRCUIT BREAKER AND PROTECTION IT IS ADVISABLE TO SET UP AN APPROPRIATE CHANGE-OVER CONTACT ON THE INPUT SIDE OUTSIDE THE UPS TO PROTECT AGAINST VOLTAGE RETURNS (OPTION ALREADY PRESENT IN THE MIZAR SERIES), AS INDICATED IN TABLE 2.6/2.7/2.8 AND THE FOLLOWING DRAWING:
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION
If necessary for the Alcor series 20-25-30kVA, a system against voltage return needs to be created in the UPS distribution panel as shown in diagram 2.6b (option already present in the Mizar series). A: general mains circuit breaker / switch C: automatic switch or at least a fuse for the mains B: automatic switch or at least a fuse for the reserve network K3: protection contactor against return voltage K1-K2: additional relays on the change-over contact coil supply UPS DISTRIBUTION PANEL A
B K3
L1
L1-RESERVE
L2
L2-RESERVE
L3
L3-RESERVE
NEUT
NEUTRAL
K1
K2
C L1-MAINS L2-MAINS L3-MAINS NEUTRAL
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION
WARNING !! BEFORE CONNECTING THE UPS MAKE SURE THE LINES THAT CONNECT THE UPS MAINS AND RESERVE INPUTS TO THE DISTRIBUTION PANEL ARE OPEN AND DISCONNECTED MAKE SURE THAT THE BATTERY PANEL SWITCH IS OPEN. PUT WARNING SIGNS ON THE DISTRIBUTION PANEL AND BATTERY PANEL TO PREVENT ACCIDENTAL ACTIONS.
REAR PANEL
GND
L1
L2 L3 N MAINS INPUT
N
L3 L2 L1 RESERVE LINE
+
N BATTERY
L1
L2 L3 N UPS OUTPUT
GND
Figure 2.6c
Figure 2.6c: UPS terminal block in three phase/three phase configuration.
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION
REAR PANEL
N Removable jumper
GND
+ MAINS INPUT
RESERVE LINE
N BATTERY
N
GND
UPS OUTPUT
Figure 2.6d
Figure 2.6d: UPS terminal block in single phase/single phase configuration
REAR PANEL
GND L1 L2 L3 N MAINS INPUT
RESERVE LINE
+
-
N
GND UPS OUTPUT
N
Figure 2.6e
Figure 2.6e: UPS terminal block in three phase/single phase configuration
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA If not required, the UPS is supplied with mains and reserve line in parallel (Fig.2.6c). It is possible to separate them by removing the connecting bars. Before connecting the UPS it is necessary to: - make sure that the mains voltage and frequency match those indicated on the adhesive plate located on the rear side of the UPS (input voltage, operating frequency, etc.); - make sure that the earth connection of the system fully complies with the requirements of IEC standards or local laws. After that install four pole circuit breakers upstream and downstream from the UPS with the following specifications: - rating equal or greater than what is indicated on the label on the UPS rear (kVA); - specifications in compliance with IEC standards or local laws for “Curve C” circuit breakers.
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION 2.7.
UPS AUXILIARY CONNECTIONS
The communication boards are mounted in the rear UPS section. The standard equipment is composed of the remote communication board (CS0098) and set-up for the SNMP board. Access for the connections to these devices is located on the rear part of the UPS (fig.2.7a)
Remote communication board (CS0098) SNMP board
Fig. 2.7a
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION 2.7.1.
REMOTE COMMUNICATION BOARD
Remote communication board is used to allow connection between the UPS and external devices. The board has a series of voltage free contact terminals (M1) which can be connected to a dedicated synoptic panel (chap. 2.7.2), acoustic or visual warning devices or remote signaling systems. One or more remote EPO buttons (chap. 2-7-4) can be connected via the other two contacts (CN1). Lastly, it is possible to connect the system to a PC via a DB9 (CN3) connector and use the specific software (chap. 2.7.3)
Fig. 2.7.1a
Battery Low
Mains not present
Load on reserve
Inverter Run
Fig. 2.7.1b
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION 2.7.2.
REMOTE PANEL (Optional)
Remote panel is connected to the UPS via the terminal board M1 located on the remote communication board (CS0098)(connection diagram fig. 2.7.2a). This device is used for remote monitoring of the main UPS blocks, the status of the main blocks is represented through LED, and there is also an acoustic alarm, which can be shut off with key 5. LED description 1) Green ON UPS LED If it’s on, the UPS is operating correctly If it’s off, indicates that one or more inverter section alarms are present (acoustic alarm enabled) 2)Yellow ON BATTERY LED If it’s on, the UPS is operating on battery (acoustic alarm enabled) 3) Red LOW BATTERY LED If it’s on, indicates imminent end of battery discharge (acoustic alarm enabled) 4) Yellow ON BYPASS LED If it’s on, indicates load supplied from reserve (acoustic alarm enabled) 5) ALARM SILENCE key Used to switch off the acoustic alarm
Fig. 2.7.2b
6) Green LED If it’s on, indicates correct power supply connected to the panel
M1 DB9 5 9 4 8 3 7 2 6 1
2 1
K1 3
4 5 12V-12A
Male Connector
12 11 10 9 8 7 6 5 4 3 2 1
UPS Remote Panel M1 1 2 3 4 5 6 7 8
Battery LOW Ups ON On By-Pass Mains Status Common
CS0098 Relay Board EXT SUPPLY
CS0098 Relay Board 1 12 9 4 2-5-8-11
UPS REMOTE PANEL 1 2 3 4 5
NOTE: ON CS0098 COMMON TAGBLOCKS (2-5-8-11) MUST BE CONNECTED TOGETHER
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
2. INSTALLATION
2.7.3.
UPS MANAGEMENT SOFTWARE
This software is used to monitor the conditions of the UPS via a PC connected to the system by the supplied cable. For more information on the installation and use of the software see the user manual which came with it. 2.7.4.
REMOTE E.P.O. BUTTON
Particular attention must be paid to the external connection of buttons or actuators for the EPO function (emergency stop). This connection is composed of a series or normally-closed switches (Fig.2.7.4) which open the series if commanded, generating the stop of the UPS with the consequent and irreversible interruption of voltage to the load. The series of external EPO buttons must be connected to the CN1 terminal board of the relay board CS0098. If there are no external EPO contacts to the system jumper JP1 must be enabled. (circle in fig.2.7.1a) For safety reasons, without an external EPO button, CN1 is normally shortened with a wire jumper.
Fig. 2.7.4
EARTH CONNECTION The earth input cable must be connected to the earth terminal of the UPS and must be always the first cable to be connected. It is advisable to insert an appropriate antioxidant between the earth bar and lug to keep the accurate contact over time. All of the cabinets and accessories must be earthed in accordance with local regulations. WARNING !! INADEQUATE EARTH CONNECTION MAY CAUSE A RISK OF ELECTRIC SHOCKS TO PERSONNEL OR OF FIRE
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA
3. Control Panel
3 CONTROL PANEL 3.1.
INTRODUCTION
The control panel is located on the upper front part of the UPS, and it’s used for easily check the general status of the UPS and batteries and related alarms. The panel contains an LCD screen (which indicates the operating status, measurements and alarms of the UPS) and the red EPO button located at the left of the display. The display panel shows text messages and operating parameters on an LCD screen with 4 lines and 20 characters per line. The screens are organized in 6 multi-level menus, which can be selected using the membrane buttons under the LCD display.
Figure 3.1a
Two LEDs are present on the left side of the display, a green one called “NORMAL” and a red one called “ALARM”. The actions of the LED are summarized in table 3.1a. POWERTRONIX SpA reserves the right to modify this document without any notice
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3. Control Panel
STATUS
UPS OK
Alarm present
Alarm stopped
GREEN LED
On
Off
On
RED LED
Off
On
flashing Table 3.1a
LCD CONTROL PANEL
Figure 3.2
ESC PUSH BUTTON To switch off the buzzer
MENU’ PUSH BUTTON To return to the previous menu or to enter into main menu from the alarm display
BACK PUSH BUTTON NEXT PUSH BUTTON To scroll among the menu and the sub menu. Pressing them both at the same gives ENTER command
During normal UPS operation the control panel uses a series of messages to display the operating status of the single component blocks of the system, thus the operator is informed in real time (also with sound signal) of any faults occurred in the system. Table 3.2 summarizes the list of available menus. MENU UPS STATUS AND ALARMS
N° 1
MEASUREMENTS UPS COMMANDS PANEL SETUP EVENTS RECORDER MANAGEMENT SERVICE MODE
2 3 4 5 6
NOTES This is default content of the LCD screen. System returns to this level automatically when no keys are used for 3 min. Used to display the values of all the measurements Inverter on / off, static switch, battery test Settings for date / time / battery test / language Displays the log of events and related alarms Reserved for technical assistance service Table 3.2
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3. Control Panel
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It is possible to scroll among the listed 6 menu in table 3.2 using the NEXT(>) or BACK(<) keys. By pressing the NEXT(>) and BACK(<) keys simultaneously, you select ENTER (< >) and by confirming the selection go to the next menu level. To return to the previous menu level press the MENU key Each alarm indication on the display is followed by a sound signal which can be switched off by pressing ESC (see figure 3.2) If the operator does not perform any actions for 3 minutes, the “1. UPS STATUS AND ALARMS” menu is automatically displayed.
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MIZAR 10÷15kVA ; ALCOR 20÷30kVA 3.1.1. MENU 1: UPS STATUS AND ALARMS This menu is characterized by the first line of the message which can be UPS OPERATING (if the UPS is operating normally) or UPS ALARM (if the UPS has an alarm condition). The meanings of the displayed messages are given below: UPS IN NORMAL OPERATING CONDITIONS MESSAGE MAINS OK / NOT AVAILABLE
MEANING The input mains line is on and the voltage is / is not in the specified range RESERVE MAINS OK / NOT AVAILABLE The input by-pass supply line is on and the voltage is / is not in the specified range BATTERY FLOAT CHARGE The battery voltage is within the specified limits INVERTER ON The inverter is on and operating normally INVERTER – RESERVE SYNCHRONIZED / NOT Indicates the normal synchronization status SYNCHRONIZED between the inverter and by-pass line LOAD ON INVERTER The load is supplied by the inverter LOAD ON RESERVE The load is supplied by the by-pass line. This may be a temporary condition which lasts 20 seconds after short overload UPS MASTER Controls the other UPSes in parallel system UPS SLAVE Controlled by another UPS in parallel system Table 3.2.1
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3. Control Panel 3.1.2. UPS IN FAULT CONDITIONS
If the UPS experiences the fault, the normal status message will be replaced with the alarm one. An alarm message will differ depending on the type of fault which occurred. Activated sound signal can be switched off by pressing the ESC key. The ENTER (< >) key can be used to display the list of indications which let the operator to understand the meaning of the alarm. The keys can be used to scroll through all the active alarms. When the alarm cause disappears, the LCD will return to the default message. ALARM CAUSE
UPS ALARM
< BACK or NEXT> The possible alarms and associated with them help messages are listed below. ALARM MESSAGE INVERTER OFF INVERTER OVERLOAD STATIC SWITCH LOCKED BATTERY TEST FAILURE BATTERY PREALARM MAINS NOT AVAILABLE RESERVE NOT AVAILABLE UPS EMERGENCY POWER OFF PARALLEL DATA EXCHANGE FAILURE
MEANING The load is no longer supplied by the inverter and subject to any mains failures The inverter is off due to an overload and the load is supplied by the reserve network After 3 unsuccessful automatic switching attempts from the reserve to inverter, the UPS blocks the static switch in the reserve network position Displayed whenever the periodic test on the battery fails for any reason At the battery voltage of around 640V the UPS warns the user of a low battery voltage At 600V discharging ends and the UPS goes off The mains is not proper for the UPS specifications, it might be out of the range allowed by the system, or simply not present The reserve is not proper for the UPS specifications, it might be out of the range allowed by the system, or with incorrect cyclic direction, or not present Displayed whenever the E.P.O. button is pressed, for any reason This alarm occurs when there is not data exchange between UPSes in parallel, for any reason. It may be due to a missing or incorrect connection of one or more parallel fibers
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3. Control Panel 3.1.3. MENU 2: MEASUREMENTS
To access this screen press ENTER on position “2. Measurements” on the main menu. The operator can now check the value of the following electrical measurements by using the arrows < or >: V in phase – neutral = reserve line Y-voltage V in phase/phase = reserve line voltage between lines Input current = UPS input three phase currents V out phase/neutral Output current = Battery V,I = Frequency =
= UPS output Y-voltage output current at load battery voltage and current UPS output frequency
Temperature Temperature
temperature of the power module, input stage, output stage and cabinet temperature of the external battery cabinet in order to regulate the battery voltage according to measured
= =
If no operation is performed for 3 minutes, the “1. UPS STATUS AND ALARMS” menu is displayed. 3.1.4. MENU 3: UPS COMMANDS Using this menu it is possible to have operating control to the UPS MESSAGE 3.1 INVERTER ON 3.2 INVERTER OFF 3.3 SWITCH LOAD TO INVERTER 3.4 SWITCH LOAD TO RESERVE 3.5 START BATTERY TEST
MEANING With this message, by pressing ENTER the user can switch the inverter permanently on or off It is necessary to switch on the inverter when starting and after the stop due to the permanent overload. With this message, by pressing ENTER the load will be switched from the reserve line to the inverter. With this message, by pressing ENTER the load will be switched from the inverter to the reserve line. With this message, by pressing ENTER an automatic battery test will be started. The test lasts about 30 seconds.
If no operation is performed for 3 minutes, the “1. UPS STATUS AND ALARMS” menu is displayed.
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3. Control Panel
3.1.5. MENU 4: PANEL SETUP MESSAGE 4.1 DATE SETTING
4.3 BATTERY TEST SETTING
MEANING Used to set up the actual date, using the arrows to increase / decrease the numbers Used to set up the actual time, using the arrows to increase / decrease the numbers Used to set the periodic battery test, selecting the day of the week, the number of weeks between the tests and the time of day to start the test
4.4 PANEL LANGUAGE SETTING
Used to select the display language between Italian, English, Spanish, Polish, Czech, Portuguese
4.5 ALARMS SETUP
It allows the user to select the possibility to hide or show a recorded alarm until the ESC button is pushed
4.2 TIME SETTING
If no operation is performed for 3 minutes, the “1. UPS STATUS AND ALARMS” menu is displayed.
3.1.6. MENU 5: EVENTS RECORDER MANAGEMENT In this menu the user can see last 1024 events / alarms in chronological order. The event log display can be opened by selecting 5. EVENT LOG in the main menu and then choosing DISPLAY LOG command. The screen will show the date and time of the last event that occurred. It is possible to scroll the list using the buttons In all positions on the event list, pressing MENU causes the return of the display to the MAIN MENU. To delete all the events select DELETE EVENTS from the submenu and then press . If no operation is performed for 3 minutes, the “1. UPS STATUS AND ALARMS” menu is displayed.
3.1.7. MENU 6: SERVICE MODE Entering into this menu the user can change UPS rated data, reset the EPO, identify the software and hardware version, etc. This menu is password protected to prevent unauthorized access. If no operation is performed for 3 minutes, the “1. UPS STATUS AND ALARMS” menu is displayed.
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4. Instructions for use
4. INSTRUCTIONS FOR USING THE UPS 4.1. INTRODUCTION This chapter describes how to correctly use the system. The UPS may be in one of the following operating conditions: • Normal operation - The load is supplied by the UPS. The UPS is in normal operation and uses mains to supply energy to the load and charge the batteries. This mode guarantees complete uninterrupted power passed to the load. Operation with internal automatic by-pass – The load is supplied by the mains In the event of an inverter fault and/or overload, the power to the load is provided by the reserve line. This mode does not guarantee complete uninterrupted power passed to the load. • Operation with maintenance manual by-pass enabled – The UPS is disabled. The load is connected directly to the mains through the maintenance or emergency manual by-pass line. This mode does not guarantee complete uninterrupted power passed to the load. • Battery operation - The load is supplied by the UPS. The UPS is in normal operation and uses the battery to supply energy to the load because the mains voltage is out of the allowed range. This mode guarantees complete uninterrupted power passed to the load.
4.2. ROTARY POWER SWITCH The rotary power switch, located on the UPS rear side, allows the user to safely switch on /off the machine, without any possible mistakes.
To completely isolate the machine from hazardous voltages it is necessary to also open the battery switch, which is not present on the UPS. Also remember about the presence of potentially loaded capacitors inside the converter It means thet you must wait for at least 10 min. before accessing the internal parts of the machine.
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4. Instructions for use Follow the below steps to correctly switch on the UPS:
Rotary switch: Position BY-PASS Description Loads UPS status LCD info Notes What to do?
Manual BY-Pass is on Loads powered by the reserve line through the manual BY-PASS UPS completely off, control logic is off No info available on LCD It is possible to supply the loads by the reserve line through the manual BY-PASS to check the cables connection After checking the correct cables connection, proceed to the next step
Rotary switch: Position Description Loads UPS status LCD info
Notes What to do?
l♫
Manual BY-PASS on, reserve line connected and pre-charge the DC bus from the battery Loads supplied by the reserve line through the manual BY-PASS UPS control logic supplied by reserve line (if present) and/or battery (if present) LCDÆ UPS status Green Led Æ OFF Red Led Æ ON Buzzer Æ ON It is possible to check UPS alarm and status looking at LCD menu. The sound can be shut down pushing the ESC key on the control panel Wait for 10sec before proceeding
Rotary switch: Position STEP1 Description Loads UPS status LCD info Notes What to do?
Manual BY-PASS on, reserve line connected and DC bus pre-charge completed and mains connected Loads supplied by the reserve line through the manual BY-PASS Reserve line and mains connected, input stage active and battery in charge (810VDC) LCDÆ UPS status Green Led Æ OFF Red Led Æ ON It is possible to check UPS alarm and status looking at LCD menu. Proceed to the next step
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4. INSTRUCTIONS FOR USE
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Rotary switch: Position STEP2 Description Loads UPS status LCD info Notes What to do?
Used only during the powering off Loads supplied by the reserve line through the manual BY-PASS As the previous step As the previous step As the previous step Proceed to the next step
Rotary switch: Position STEP3 Description Loads UPS status LCD info Notes What to do?
Manual BY-PASS opened, reserve line connected and DC bus pre-charge completed and mains connected Loads supplied by the reserve line through the static switch UPS supplied by reserve line and mains (if present) and/or battery (if present), input stage activated and battery in charge (810VDC) LCDÆ UPS status Green Led Æ OFF Red Led Æ ON It is possible to check UPS alarm and status looking at LCD menu. Proceed to the next step
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4. INSTRUCTIONS FOR USE
Rotary switch: Position UPS Description Loads UPS status LCD info Notes What to do?
Manual BY-PASS opened, reserve line connected and DC bus pre-charge completed and mains connected Loads supplied by the reserve line through the static switch UPS supplied by reserve line and mains (if present) and/or battery (if present), input stage activated and battery in charge (810VDC) LCDÆ UPS status Green Led Æ OFF Red Led Æ ON It is possible to switch on the inverter from the LCD selecting the menu “3. UPS COMMANDS”, then pressing ENTER on the submenu “INVERTER ON” Wait for 20sec (loads supplied by the inverter and no more by the reserve line), check: LCDÆ UPS status Green Led Æ ON Red LED Æ flashing (refer to menu 4.5 pag.xx)
To complete the UPS power off, turn off the inverter and rotate the rotary switch to BY-PASS position. Wait for 10minutes for the complete discharge of all the internal capacitors. No hazardous voltages are now present inside the UPS, but on the cables connection board..
WARNING In BY-PASS position, although the UPS is off, the load is still supplied by the reserve line
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4. INSTRUCTIONS FOR USE
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4.3. MANAGING THE UPS BATTERY In addition to the battery voltage and current measurements, displayed in menu “2. MEASUREMENTS”, it is also possible to test the battery efficiency without any interruption to the load. In case of battery failure, the message “BATTERY TEST FAILED” will be displayed on the LCD. In this situation call the technical assistance centre. 4.3.1. BATTERY TEST PROGRAMMING The battery test can be executed at any time by selecting the menu “3. UPS COMMANDS” and pressing ENTER on “BATTERY TEST” command. The test lasts about 30 seconds. It is also possible to schedule a periodic battery test following the instructions below: 1. Select the “4. PANEL SETUP” menu and press ENTER 2. Select the “BATTERY TEST SETTING” and press ENTER. Select, using the arrows, the day of the week to perform the test, the number of weeks between tests (from 1 to 99, 0 means no automatic test) and the time of the day to start the test. Press ENTER to confirm each choice.
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5. TROUBLESHOOTING
5. TROUBLESHOOTING 5.1. GENERAL ALARMS In the event of a UPS fault, the default screen will be replaced by one of the alarm messages shown in the table below: ALARM INVERTER OFF INVERTER OVERLOAD STATIC SWITCH LOCKED BATTERY TEST FAILURE BATTERY PREALARM MAINS NOT AVAILABLE RESERVE NOT AVAILABLE UPS EMERGENCY POWER OFF PARALLEL DATA EXCHANGE FAILURE
CAUSE Initial start-up Permanent overload Continuous overload on UPS output
ACTION Start the Inverter Check the output Check the output load and restart the inverter Check the output short circuit
High transient loads on UPS output Check the output load and restart 3 failed switching attempts on the inverter inverter Battery test not OK Check the battery Check the battery fuses Battery almost discharged, the Shut down connected non-critical inverter is about to go off load No mains input Check the mains line voltage The input phase rotation is not Check the line cyclic direction correct. No input voltage Check the reserve line voltage. The EPO control has been Choose the BYPASS position of activated the rotary switch and wait until the LCD is completely off and then restart the UPS The machine is disabled due to Call technical assistance absence of communication
When an UPS experiences the fault which cannot be resolved and it is not able to guarantee uninterrupted power to the load, perform an EMERGENCY BY-PASS and then leave the machine isolated and off. Call the technical assistance.
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5. TROUBLESHOOTING 5.2. THE FIRE
In the almost impossible case of fire, remember to only use CO2 or powder extinguishers. Always activate the emergency BY-PASS and completely shut off the machine, disconnecting the battery panel as well. 5.3. FAULTS RELATED TO THE NATURE OF THE LOAD Many times normal UPS reactions to the non-standard load or installation environment are incorrectly recognized by the users as the UPS faults. The most common situations are described below: • The UPS is left with load supplied by the reserve line even if the inverter section is operating correctly: this may occur on excessive absorbed peak current. It causes the major drop-down voltage, which – if is repetitive - leads to the switching load to the reserve line. The system, after three failed attempts to switch and return to the inverter, blocks the static switch on the reserve line to protect the inverter, therefore it is necessary to study the load current and eliminate the causes of the overcurrents. The repetitive peak current should not exceed 2.5 times the effective value. • The accuracy of the UPS output voltage is not optimal: this may depend on an excessively unbalanced and/or distorting load.
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6. Maintenance
6. SCHEDULED MAINTENANCE The UPS while its lifetime requires scheduled maintenance cycles to maintain operating reliability and efficiency. Scheduled maintenance must be performed by the company which provided the machine or company specialized and trained on the system by the seller.
6.1. ANNUAL MAINTENANCE (OR PERFORMED EVERY SIX MONTHS IN THE CASE OF UNITS IN CRITICAL APPLICATIONS) The following actions and tests are performed while the scheduled maintenance: • • • • • • • • • • • •
cleaning the machine cleaning the control logic and interface boards checking the tightening of all nuts and bolts and electrical connections (UPS and battery) testing the ventilation efficiency testing the inverter output wave form testing output voltage / frequency testing synchronization testing signals, alarms and EPO tripping display calibration with calibrated instrument operating test of manual switches and automatic devices operating test of switching circuits power failure test of UPS line, battery efficiency test and test of correct battery charger operation.
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