Users and Installation Guide UPS 40160 kVA, 400V 50/60 Hz output

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 22. 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. To advance to the Main menu and Mimic screen, press any Control Panel pushbutton once. After approximately 30 minutes on inactivity, the display screen darkens. To restore the screen, press any pushbutton once.

6.1 Identication of the display areas

The LCD screen on the Control Panel provides an operator interface with the UPS system.

You can use the LCD screen and the pushbuttons to: Look at a log of UPS events (alarms, notices, and commands) Monitor UPS operation Set UPS parameters Control UPS operation

Figure 23. Display areas of the LCD screen.

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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. The information area contains data about UPS status and operations. Select a menu option to display the desired information. The menu bar lists the titles of the available screens. To select a screen, press the pushbutton underneath the desired screen. Navigation pushbutton switches. Function changes depending on the screen displayed. Use to select menu screens or scroll through available screens. Designated function is indicated on the LCD screen above the respective pushbutton.

B C D

6.2 Main Menu

The UPS Main menu bar allows you to display data in the information area to help you monitor and control UPS operation. The following menus and options are available: EVENTS METERS CONTROLS SETUP Displays the list of Active System Events and a historical log of system events. Displays performance meters for the system or critical load. Displays the System Controls screen. Allows you to set the display contrast, set the date and time for the time stamp, congure the UPS serial communication ports and view the rmware version numbers. De-energizes the critical load and powers down the UPS. Returns to Main menu and Mimic screen from the Events, Meters, Controls, or System Setup screens. Returns to the main System Setup Level screen from a setup sub-menu.

LOAD OFF

6.2.1 Event Screens

Press the EVENTS pushbutton on the Main Menu bar or History Menu bar to display a listing of all system events that are currently active. The most recent event is listed rst. As events clear, they are removed from the Active System Events listing. To scroll through the events, press the UP or DOWN pushbuttons on the menu bar.

Figure 24. Active Events screen.

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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.e the most recent events, appears when you display the screen, and you must scroll upward to view older event listings. To scroll through the events, press the UP or DOWN pushbuttons on the menu bar. To return to the Active Events screen, press the EVENTS pushbutton on the menu bar.

6.2.2 Meter Screens

Press the METERS pushbutton on the Main Menu bar to display the Unit Meter screens. To scroll through the meter screens, press the UP or DOWN pushbuttons on the menu bar. The current UPS readings are displayed in the information area of the screen. The Input screen shows input voltage (phase-to-phase), output current (each phase), and frequency, of the incoming utility source, followed by the kVA, kW, and power factor measurements. The Bypass screen shows the bypass input voltage (phase-to-neutral), output current (each phase), and frequency, of the incoming utility source, followed by the kVA, kW, and power factor measurements.
The Battery screen displays the battery voltage (Vdc), the battery current (Idc), battery life, and the minutes of battery time remaining. When battery life decreases to less than 20 %, Check Battery is displayed.

The Output screen shows output voltage (phase-to-neutral), output current (each phase), and frequency, being supplied by the UPS, followed by the kVA, kW, and power factor measurements.

Figure 25 Input, bypass, battery and output meter screens.

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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. In addition, the screen displays the current status of the UPS and indicates whether the UPS is in Maintenance Bypass or Bypass, and the state of the Power Module (PM) and battery charger. Use the RIGHT or LEFT pushbuttons on the menu bar to toggle the menu bar functions between System Controls Screens 1 and 2.

Figure 26. System Controls screens 1 and 2.

The CHGR pushbutton switch, on the System Controls screen, toggles the charger function On and Off. The PM pushbutton switch toggles the Power Module function On and Off.

6.2.4 Setup screen

Press the SETUP pushbutton on the Main Menu bar to display the System Setup Level 0 Screen. This screen can be used to set the screen contrast, show the rmware versions installed, identify the unit type, and enter a password to access Level 1 functions. No password is necessary to access Level 0 functions. Use the UP or DOWN pushbuttons to highlight the setup function screen desired, then press the SELECT pushbutton to display the function screen. A password is required to access the Level 1 functions. To enter the password, select ENTER PASSWORD from the System Setup Level 0 menu to display the Enter Password screen. Use the LEFT or RIGHT pushbuttons to select the password character position. Use the UP or DOWN pushbuttons to change the password character. The default password is L1. Once the password is entered, press the DONE pushbutton.

Figure 27. System Setup Level 0, enter password, and System Setup Level 1 screens.

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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. Use the UP or DOWN pushbuttons to highlight the COM port to be set up, then press the SELECT pushbutton. To return to the System Setup screen, press the RETURN pushbutton. The COM Setup screen is used to change and save the settings for the serial communication ports. The COM port number selected from the Serial Port Setup screen will be displayed. If the changes are not wanted, the ABORT pushbutton may be used to return to the Serial Port Setup screen. Use the UP or DOWN pushbuttons to highlight the setting to be changed. Use the SELECT pushbutton to toggle through the values for the setting to make the change. Press SAVE or ABORT. Once the action is completed, the Serial Port Setup screen appears.

Figure 28. Serial Port Setup Screen at System Setup Level 1.

The Level 1 screen will timeout after 60 minutes, or can be logged out at any time by selecting the LOG OUT function from the menu screen.

6.2.5 Load Off Screen

The Load Off screen appears when the LOAD OFF pushbutton is selected from the Main Menu bar or System Controls Menu bar. This screen allows the LOAD OFF process to be aborted if the LOAD OFF pushbutton was pressed accidentally.

Figure 29. Load off screen.

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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 30. Mimic screen and Main Menu.

6.4 Status Indicators

The four symbols on the left side of the control panel are status indicators. They are coloured light emitting diode (LED) lamps, and they work in conjunction with the alarm horn to let you know the operating status of the UPS. Normal This green indicator is illuminated when the UPS is operating in Normal mode. The Power Module is supplying power to the critical load. The indicator ashes when the system needs attention. The LCD screen shows all active notices. Some notices may be accompanied by an audible horn. To silence the horn, press any Control Panel pushbutton once. The indicator may be ashing while other indicators are illuminated. The indicator continues to ash until acknowledged by pressing any Control Panel pushbutton once. Battery This yellow indicator is illuminated when the UPS is operating in Battery mode. Because Battery mode is a normal condition of the UPS, the Normal indicator also remains illuminated. This yellow indicator is illuminated when the UPS is operating in Bypass mode. The critical load is supported by the bypass source. The Normal indicator is not illuminated when the system is in Bypass mode. This red indicator is illuminated when a situation requires immediate attention. The LCD screen shows the highest priority active alarms. All alarms are accompanied by an audible horn. To silence the horn, press any Control Panel pushbutton once. The Alarm indicator may be illuminated along with other indicators. The indicator ashes until acknowledged by pressing any Control Panel pushbutton once.

Bypass

Alarm

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7
7.1
1. 2. 3. 4. 5. 6.

Operating instructions
Starting the UPS in Normal Mode
Close the UPS input feeder circuit breaker. Close UPS Bypass input feeder circuit breaker. Observe UPS Control Panel display screen becoming active as an indication of logic power. Press the CONTROLS pushbutton on the Main menu bar. The System Controls screen appears. On the System Controls screen, the Power Module (PM) status should indicate SHUTDOWN. Press the NORMAL pushbutton on the System Controls menu bar. If Auto Bypass is enabled, the critical load is immediately supplied by the bypass source, in Bypass mode, until the inverter turns on and the UPS transfers to Normal mode. The status indicator on the UPS Control Panel indicates the UPS is in Bypass mode. If Auto Bypass is not enabled, the UPS output remains off until the UPS transfers to Normal mode.

The following procedures provide instructions for operating the UPS system.

To start the UPS system, perform the following procedure:

7.

Observe the following messages appear sequentially on the Power Module (PM) status line: DC STARTING INVERTER STARTING READY ONLINE The rectier and inverter turn on. When the inverter reaches full voltage, UPS output contactor K3 closes and the static switch turns off supplying power to the critical load in Normal mode. It takes approximately 1 minute for the UPS to achieve Normal mode.

8. 9.

Close battery breaker any time after INVERTER SYNCING or CLOSE BATTERY appears on the display screen. The UPS is now operating in the Normal mode and the NORMAL status indicator is illuminated.

7.2

Starting the UPS in Bypass Mode

If the Inverter Output of the UPS is not available and the critical load needs to be energised, perform the following procedure: 1. Close the UPS input feeder circuit breaker.

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2. 3. 4. 5. 6. 7.

Close UPS Bypass input feeder circuit breaker. Observe UPS Control Panel display screen becoming active as an indication of logic power. Press the CONTROLS pushbutton on the Main menu bar. The System Controls screen appears. On the System Controls screen, the Power Module (PM) status should indicate SHUTDOWN. Press the BYPASS pushbutton on the System Controls menu bar. The critical load is immediately supplied by the bypass source, in Bypass mode. The UPS is now operating in the bypass mode and the BYPASS status indicator is illuminated.

7.3

Starting the Power Module

To start the Power Module without transferring the critical load to normal, perform the following procedure: 1. 2. 3. 4. 5. 6. 7. 8. Close the UPS input feeder circuit breaker. Close UPS Bypass input feeder circuit breaker. Observe UPS Control Panel display screen becoming active as an indication of logic power. Press the CONTROLS pushbutton on the Main menu bar. The System Controls screen appears. On the System Controls screen, the Power Module (PM) status should indicate SHUTDOWN. Press the pushbutton to display System Controls Screen 2. Press the PM ON pushbutton on the System Controls menu bar. Observe the following messages appear sequentially on the Power Module (PM) status line: DC STARTING INVERTER STARTING INVERTER SYNCING READY The rectier and inverter turn on. When the inverter reaches full voltage, the UPS is ready to transfer to the Normal mode and supply the critical load.

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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. 2. Press the CONTROLS pushbutton on the Main menu bar. The System Control screen appears. 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. If the bypass source is not available, the power processor remains on and an alarm sounds. The UPS is now operating in the bypass mode and the BYPASS status indicator is illuminated. The Power Module (PM) status indicates READY. System is now on bypass and UPS power processor remains on.

3.

Warning!
Power is present inside the UPS cabinets.

7.5
1. 2.

Transfer from Bypass to Normal Mode

Press the CONTROLS pushbutton on the Main menu bar. The System Control screen appears. Press the NORMAL pushbutton on the System Controls menu bar. The UPS switches to Normal mode. If the power processor is not available, the system remains on bypass and an alarm sounds. The UPS is now operating in the Normal mode and the NORMAL status indicator is illuminated. The Power Module (PM) status indicates ONLINE.

To transfer the critical load to normal mode, perform the following procedure:

3.

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7.6 Transfer from Normal to Bypass Mode with UPS Shutdown

1. 2. 3. 4. Transfer critical load to bypass by performing procedure in paragraph 7.4. Press the CONTROLS pushbutton on the Main menu bar. The System Control screen appears. Press the pushbutton to display System Controls Screen 2. Press the PM OFF pushbutton on the System Controls menu bar. The Power Module (PM) status indicates SHUTDOWN. The input and output contactors open, the battery breaker or disconnect is tripped, and the Power Module is turned off. The bypass source supplies the critical load.

Warning!
Power is present inside the UPS cabinets.

7.7

UPS and Critical Load Shutdown

To perform maintenance or service on the critical load, shut down power to the load by performing the following procedure: 1. 2. Turn off all equipment that is being powered by the UPS. Perform LOAD OFF procedure contained in paragraph 7.9. The input, output, and bypass backfeed contactors open, the battery breaker or disconnect is tripped, and the Power Module is turned off.

Warning!
Power is present inside the UPS cabinets, until the upstream input feeder circuit breaker is opened. 3. Open the UPS input and bypass (if dual feed) feeder circuit breakers.

7.8
1. 2. 3.

Charger Control
Press the CONTROLS pushbutton on the Main menu bar. The System Control screen appears. Press the pushbutton to display System Controls Screen 2. Press the CHARGER ON or CHARGER OFF pushbutton on the System Controls menu bar to toggle the charger on or off.

To turn the battery charger on or off, perform the following procedure:

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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. The Load Off screen appears, providing a choice to proceed with the shutdown or to abort the shutdown.

Note!
All power to the critical load is lost when the LOAD OFF is selected in the following step. You should use this feature only when you want to de-energise the critical load. 2. To shut down the UPS, press LOAD OFF from the Load Off screen menu bar, and hold for three seconds. To abort the shutdown, press CANCEL. When LOAD OFF is selected and held for three seconds, the input, output, and bypass backfeed contactors open, the battery breaker or disconnect is tripped, and the Power Module is turned off.

Note!
Do not attempt to restart the system after Load Off until the cause of the shutdown has been identied and cleared. 3. To restart the UPS after pressing the LOAD OFF pushbutton, follow the procedure, in paragraphs 7.1 or 7.2.

7.10 Using the REMOTE EMERGENCY POWER OFF Switch

An UPS Emergency Power Off is initiated by Remote Emergency Power OFF (REPO) pushbutton switch. In an emergency, you can use this switch to control the UPS output. The REPO switch deenergises the critical load and powers down the UPS immediately, without asking for verication. The UPS, including Bypass, remains off until restarted. To Use the REPO Switch:

Note!
All power to the critical load is lost when the REPO switch is activated in the following step. You should use this feature only when you want to de-energise the critical load. The following instructions are for the Powerware supplied REPO switch. If a customer supplied REPO switch is used it may not activate in the same manner. If this is the case, refer to the operating instructions provided with the switch.

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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 verication.

Note!
Do not attempt to restart the system after Load Off until the cause of the shutdown has been identied 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.

7.11 Using Mechanical Bypass Switch (40-80 kVA)

The operation of the integral MBS is allowed for a trained person only who is familiar with the UPS behaviour and functions. The full UPS wiring diagram with a MBS switch is presented in the installation part of the manual.

Note!
The integral MBS consist of four switches (S1, S2, S3, S4) and failure to understand the correct sequence may drop the critical load.

Figure 31. The normal positions of the three MBS switches.

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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. 3. 4. 5. 6. 7. 8.

Perform transfer from normal mode to bypass mode as described in paragraph 7.4. Remember to verify the transfer before proceeding the next step. Turn ON the S3 switch to bypass UPS. Turn OFF the S4 switch to disconnect UPS output: Perform LOAD OFF procedure contained in paragraph 7.9. Turn OFF the S1 switch to disconnect UPS rectier input. Turn OFF the S2 switch to disconnect UPS bypass input: UPS is now in the mechanical bypass mode, see below:

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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. 3. 4. 5. 6. 7. 8.

Turn ON S1 switch to connect rectier input to UPS. Turn ON S2 switch to connect bypass input to UPS: Perform UPS start-up procedure (bypass mode) contained in paragraph 7.2. Turn ON S4 switch to connect UPS output to load. Turn OFF S3 switch to disconnect bypass output. Perform transfer from bypass to normal mode as described in paragraph 7.5. Remember to verify the transfer before proceeding the next step. UPS is now in Normal mode, see below:

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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. Regular routine checks of operation and system parameters will enable your system to function efciently for many trouble-free years.

8.2 Important Safety Instructions

Remember that your UPS system is designed to supply power EVEN WHEN DISCONNECTED FROM THE UTILITY POWER. The UPS module interiors are unsafe until the DC power source is disconnected and the electrolytic capacitors are discharged. After disconnecting the utility power and the DC power, authorised service personnel should wait at least ve minutes for capacitor bleed off before attempting internal access to the UPS module.

Warning!
Qualied service personnel should perform servicing and maintenance only. LETHAL VOLTAGE PRESENT. This unit should not be operated with the cabinet doors open or protective panels removed. Do not make any assumptions about the electrical state of any cabinet in the UPS system. Since each battery string is an energy source in itself, opening the Battery Circuit Breaker does not de-energise the voltage within the battery string. DO NOT ATTEMPT TO ACCESS ANY INTERNAL AREA OF THE BATTERY STRING YOURSELF. VOLTAGES ARE ALWAYS PRESENT IN THE BATTERY STRINGS. If you suspect that a battery string needs service, you should contact your service representative. If the string requires service, refer to the battery manufacturers operating manual for instructions on battery maintenance, or contact your service representative. Observe these precautions when working on or around batteries: 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. Disconnect the charging source prior to connecting or disconnecting terminals. Determine if the battery is inadvertently grounded. If it is, remove the source of the ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance. When replacing batteries, use the same number of sealed, lead-acid batteries. Proper disposal of batteries is required. Refer to your local codes for disposal requirements.

See chapter 10. Recycling the used UPS or batteries

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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. 2. 3. 4. Check the area surrounding the UPS system. Ensure the area is not cluttered, allowing free access to the unit. Ensure the air intakes (vents on the front doors) and exhaust opening (on top of the UPS cabinet sections) are not blocked. Ensure the operating environment is within the parameters specied in Product Specications. Ensure the UPS is in Normal mode (Normal status indicator is illuminated). If an alarm lamp is illuminated or the Normal status indicator is not illuminated, contact your service representative.

8.3.2 MONTHLY Maintenance

Perform the following steps monthly: 1. 2. Monitor system parameters from the Control Panel. Check the two air lters (located behind the front door) and replace as necessary. The lters size is 203 x 381 x 25 mm (10 16 1). To remove lter: a. Open front door latch and swing door open. b. Slide lter up and remove from cabinet. c. Slide new lter into brackets until seated on bottom brackets. d. Close door and secure with latch. Record the check results and any corrective actions in a suitable log.

3.

8.3.3 ANNUAL Maintenance

Only authorised service personnel familiar with maintenance and servicing of the UPS system should perform annual preventive maintenance. Contact your service representative for more information about service offerings.

8.3.4 BATTERY Maintenance

Contact your service representative for battery maintenance. Only authorised service personnel should perform Battery replacement and maintenance.

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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: 1. 2. 3. 4. 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]. Display Battery Log by pressing and holding [ESC], then press [B]. Display UPS log by pressing and holding [ESC], then press [D]. Select Transfer --> Capture Text ; Save le by giving the le name Start to download the UPS log -> ESC+D When the log is downloaded ->Transfer->Capture Text ->Stop You have now saved the log to le.

Saving to the le is done the following way in the HyperTerminal program:

Note!
The brackets ([ ]) in the following bullets indicate standard keyboard characters. To use a key combination, hold down the Escape key and press the indicated letter key.

8.4.1 Display UPS Control Panel

When this function is invoked, a facsimile of the UPS control panel is displayed on the terminal screen. All controls are functional and will control the UPS remotely. The only exception is the Load Off control that requires the operator to press and hold the local control for two seconds to shut down the UPS. To remotely control the UPS or view UPS information, use the escape key legend to control the function normally controlled by the control panel soft keys.

8.4.2 Event History Log

This key sequence prints the entire Event History Log of the UPS at the time the data is requested. The printout begins with the oldest alarm entry in the queue and ends with the most recent. Any alarms that occur while the Event History Log is printing are included in chronological order. The Event History Log lists up to 500 system events in chronological order with the most recent event listed last.

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In this mode, system events are continually logged through the serial port to the device connected to the port. 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.hh KYWD MESSAGE **** <CR> <LF> Where: Equals: MM Month (2 digits) YYYY Year (4 digits) DD Day (2 digits) HH Hour (2 digits) MM Minute (2 digits) SS Second (2 digits) hh Hundredths of Second (2 digits) KYWD Keyword (ALARM, NOTICE, COMMAND, or STATUS) **** System Diagnostic Information <CR> Carriage Return Character (ASCII 13) <LF> Line Feed (ASCII 10) An alarm message is prexed by the word CLEAR whenever an alarm is entered into the Event History Log with a cleared status. If a port is operating in Terminal mode and is connected to a computer, you can press [Esc] [H] to print the entire log with a rmware version header. Here is a sample Event History Log printout: 03/11/2004 14:13:12.954 NOTICE: Battery Voltage Low

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