Installation and user manual

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INTRODUCTION Pag. 2 di 47

The Uninterruptible Power Supply provides critical loads with continuous computer grade power. Reliability and performance are the key design considerations. The UPS design also maximizes isolation of the load from disturbances and interruptions, minimizes maintenance and repair time with its slide out modular system, and provides monitoring of significant system operating characteristics. Proper installation and operation of the UPS are equally important factors in system reliability. This manual provides complete information on installation, operating and preventative maintenance of the UPS and Battery Cabinet. Illustrations showing the function of all operator controls, instruments, alarms and indicating lights are also given. The UPS series is available in different power ratings from 10 to 400KVA.

Should assistance be required, call your supplier with the following details for fast assistance:

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INDEX
INTRODUCTION ...................................................................................................1 WARNING ............................................................................................................6 EMERGENCY PROCEDURES ...................................................................................7 1 2 IDENTIFYING PACKAGED U.P.S. .......................................................................8
1.1 VERIFYING THE GOODS ............................................................................................................................. 8

HANDLIND, STORING AND POSITIONING .........................................................9

2.1 HANDLING ...................................................................................................................................................... 9 2.2 U.P.S. STORAGE............................................................................................................................................. 9 2.2.1 WITHOUT BATTERIES ........................................................................................................................... 9 2.2.2 WITH INTERNAL BATTERIES OR BATTERY CABINETS ................................................................ 9 2.3 POSITIONING ............................................................................................................................................... 10 2.3.1 CHOOSING THE ROOM ........................................................................................................................ 10

GENERAL DESCRIPTION.................................................................................11
3.1 OPERATING PRINCIPAL ........................................................................................................................... 11 3.2 DESCRIPTION AND PARTS ....................................................................................................................... 11 3.3 PART LAYOUT.............................................................................................................................................. 12 3.3.1 BREAKERS ............................................................................................................................................. 15 3.3.2 FUSES ...................................................................................................................................................... 15 3.3.3 TERMINAL CONNECTORS .................................................................................................................. 16
1. 2. 3.3.3.1 ......................................................................................................................................................... POWER UP TO 200 KVA 16 3.3.3.2 ...........................................................................................................................................................POWER OVER 200 KVA 16

3.4 CONNECTING THE U.P.S. TO THE MAINS SUPPLY ............................................................................ 17 3.4.1 COMPATIBILITY WITH THE POWER SUPPLY................................................................................. 17
3. 4. 5. 3.4.1.1 ................................................................................................................................................... INDIRECT POWER SUPPLY 17 3.4.1.2 ............................................................................................................................................................... INPUT WIRE SIZING 17 3.4.1.3 ......................................................................................................................PROTECTION OF THE U.P.S. OUTPUT LINE 18

3.4.2 CONNECTING THE SYSTEM ............................................................................................................... 18 3.5 CONNECTING THE BATTERIES TO THE U.P.S. ......................................................................................... 19 3.5.1 CONNECTION TO A 120cm HEIGHT BATTERY CABINET .................................................................... 19 3.5.2 CONNECTION TO A 180cm HEIGHT BATTERY CABINET .................................................................... 19 3.5.3 CONNECTING INTERNAL BATTERIES .................................................................................................... 20

STARTING-UP AND SHUTTING DOWN THE MACHINE .....................................21

4.1 STARTING-UP THE MACHINE ................................................................................................................. 21 4.2 SHUTTING DOWN ....................................................................................................................................... 22 4.2.1 EMERGENCY POWER OFF SWITCH ( optional)................................................................................. 22

ACTIVATING THE MANUAL BY-PASS..............................................................23

5.1 5.2 ACTIVATING THE BY-PASS KEEPING THE U.P.S SWITCHED ON.................................................. 23 ACTIVATING THE BY-PASS SHUTTING DOWN THE U.P.S ............................................................... 24

CHECK TOOLS ..............................................................................................24

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6.1 THE CONTROL PANEL AND ITS FUNCTIONS...................................................................................... 24 6.1.1 MONITORING......................................................................................................................................... 26 6.1.2 DIAGNOSTIC TOOLS ............................................................................................................................ 26
6. 7. 6.1.2.1 .............................................................................................................................................. EVENT AND HISTORY MENUS 26 6.1.2.2 .........................................................................................................................................................................BATTERY TEST 27

6.1.3
8. 9.

FUNCTIONING MODE CONFIGURATION......................................................................................... 28

6.1.3.1 ..................................................................................................................................................... BATTERY CHARGE MODE 28 6.1.3.2 ...........................................................................................................................................FORCING ON INVERTER MODE 28

6.2 RELAY BOARD ............................................................................................................................................. 32 6.3 P.C. INTERFACE........................................................................................................................................... 33 6.4 REMOTE PANEL (OPTIONAL)...................................................................................................................... 33 6.4.1 INSTALLATION OF REMOTE PANEL WITHOUT E.P.O. ................................................................. 34 6.4.2 INSTALLING THE REMOTE PANEL WITH E.P.O. ............................................................................ 36

BATTERIES....................................................................................................37
7.1 INTERNAL BATTERIES.............................................................................................................................. 38 7.2 EXTERNAL BATTERY CABINETS ........................................................................................................... 38 7.2.1 DESCRIPTION OF THE B2 BATTERY CABINET WITH BATTERIES FROM 7A/H....................... 39 7.2.2 DESCRIPTION OF THE B2 BATTERY CABINET WITH BATTERIES FROM 40A/H..................... 40 7.2.3 DESCRIPTION OF THE B3 BATTERY CABINET WITH BATTERIES FROM 65A/H..................... 41 7.2.4 DESCRIPTION OF THE B4 MODEL BATTERY CABINET FROM 65 UP TO 130 A/H ................... 42

TECHNICAL CHARTS .....................................................................................43

10.

WARNING The equipment manufacturer supplies this handbook to the companies that will actually use the equipment. Reprinting part or whole of this handbook is forbidden. All the information in this handbook is of exclusive right of the manufacturer. All rights are reserved. This handbook is to be used only inside the works in order to find all necessary information to prevent injuries and to install and use the U.P.S.

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WARNING PLEASE READ THIS TECHNICAL HANDBOOK VERY CAREFULLY BEFORE CARRYING OUT INSTALLATION PROCEDURES PLEASE KEEP THIS HANDBOOK IN A WELL-KNOWN PLACE WITHIN REACH OF ALL UPS USERS

In this handbook you will find explanations on how to install, set-up, and use the uninterrupted static power supply. All technicians and users who are about to use these UPS must have previously read this handbook. Technicians trained by AEC Manufacturing only must carry out installation and maintenance.

Inside this machine there are continuously working fans, therefore do not insert any type of object in the ventilation grids. Please use protective rubber gloves when working on damaged batteries. Never remove the doors and protection covers while the equipment is operative.

When working on the UPS you must remove any metallic objects you may be wearing, such as rings, watches, pens and any other type of object which could provoke a short circuit when operating inside the machine. There are dangerous voltages in the uninterruptible static power supply even when its turned off with all the switches switched off and with the access covers removed! There is a dangerous voltage at the ends of the batteries even when the switches are disconnected. Please operate very carefully on the batteries; a short circuit can cause great damage to people or things.

Do not smoke and do not use a naked flame when working on the equipment. If the uninterruptible power supply system or the room where this is installed should catch fire never use water to put out the flames.

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CAUTION!
EMERGENCY PROCEDURES
If there is an emergency it is possible to disconnect the power supply charge by switching off all the switches on the control panel. On the machines that are equipped you may press the E.P.O. button.

PEOPLE HIT BY ELECTRICAL DISCHARGE

Ask immediately for the help of a qualified and trained person.
When a rather high voltage and high intensity electric hit a body current this can provoke burns. The burns appear in and around the areas where the current enters and exits the body. Even if only small burns are visible on the skin, the tissues beneath could be seriously damaged. In any case, and however serious the burn may be, NEVER TOUCH the injured person with bare hands until you are sure that the electricity has been cut off.

SYMPTOMS AND SIGNS Redness, edema, skin burns or skins carbonisation in the areas where the electricity entered and exited the body. The person may loose consciousness. The person may stop breathing or his/her heart may stop beating. Shock symptoms. FIRST AID
Cut off the power supply and move the injured person away from the source of contact. Call immediately for an ambulance and, if necessary, for the help of a technician specialised in electrical equipment.

PEOPLE WHO HAVE COME INTO CONTACT WITH CORROSIVE LIQUIDS

Ask immediately for qualified expert help. All batteries installed in this system are completely dry and no corrosive liquids leak out of their cases if the batteries are in perfect condition. If the storage batteries get damaged in any way, this could provoke the leakage of the electrolyte or a short circuit of the internal cells; the electrolyte is corrosive and causes burns. SYMPTOMS AND SIGNS A piercing sensation on the skin The skin will appear reddened sometimes with small blisters and exfoliation. FIRST AID Place the injured area under a strong jet of cold running water for at least 10 minutes so as to avoid further damage to the tissues. N.B. Make sure that the water can flow away freely as the substance that caused the burn contaminates it. While swilling the injured area be careful not to splash yourself with contaminated water. Call for an ambulance immediately. . If the electrolyte comes into contact with eyes you must intervene immediately by washing them with running water until expert medical help arrives. If the battery electrolyte is swallowed it is advisable to make the injured person drink plenty of milk or water.

IN ALL CASES ASK FOR EXPERT MEDICAL HELP

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IDENTIFYING PACKAGED U.P.S.

On receiving the goods you should verify the contents. On the front of the package you will find the sticker which will allow you to identify the contents. In the picture you can see the identity sticker which is placed on the packaging of the equipment:

1 2 4 6
Picture 1

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

3 5 7

Specifies the U.P.S. model Specifies voltage and frequency input admittance Specifies voltage and frequency output admittance Specifies the number of batteries which may be inside the machine Specifies internal battery capacity Specifies the serial number of the product Specifies weight

In the picture you can see the identity sticker placed on the packaging of the battery:

1 2 4
Picture 2 1.1 VERIFYING THE GOODS

1. 2. 3. 4. 5.

Specifies the battery cabinet model Specifies the number of batteries contained Specifies battery capacity Specifies the serial number of the product Specifies weight

3 5

After making sure that the goods are those required, please check that the equipment has not been damaged. In order to do this you must verify the integrity of the packaging. After having removed the packaging check that the metal panels have not been damaged during transport. If the goods are not compliant in any way please put them back in their original packaging and send them back to the manufacturer.

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2 2.1 1. 2. 3.

HANDLIND, STORING AND POSITIONING HANDLING Remove the screws which fasten the machine to the pallet (Picture 3) Remove the wooden pallet by using a lift truck and carefully place it on the floor (Picture 4) For floor handling you will only need a transpallet with a suitable loading capacity: see charts 4a/b

Picture 3 Picture 4

2.2

U.P.S. STORAGE

2.2.1 WITHOUT BATTERIES If you need to store the UPS this must be protected from dust and dirt (even if it is well packaged). It must not be exposed to the inclemency of the weather and the room shouldnt be too humid (humidity below 90% non-condensing), nor should the UPS be exposed to sources of heat; room temperature should be between +1 e +40C. 2.2.2 WITH INTERNAL BATTERIES OR BATTERY CABINETS If you need to store the UPS containing batteries or a complete battery cabinet, you should respect all the conditions mentioned in the previous paragraph. You should also remember that battery discharge over time, even when not in use, therefore it is necessary to recharge them every 4 months.

In any case, you must follow the manufacturers indications to store the batteries. Non-compliance with these indications can cause an efficiency decrease and a shorter life of the storage batteries.

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2.3

POSITIONING

Installation space varies according to the size of the U.P.S (see charts 8a/b/c) and to the battery cabinet which may be incorporated (chart 17). A distance margin from the walls of the room where the U.P.S. is positioned is also necessary for air circulation and ordinary/extraordinary maintenance. Please refer to chart 5 for minimum margin distances. All models with a power up to, and including, 30 KVA can carry a buffer battery inside; therefore you must leave a margin on the right-hand side whereas the left side can be positioned against the wall. All models with a 60KVA power or over need a distance margin of at least 40cm either side or at least a metre from the ceiling. U.P.S from 10 to 50 KVA 25-30 cm U.P.S. from 60 to 400 KVA 40 cm

40 cm (Only with internal batteries) Picture 5

40 cm

40 cm

2.3.1 CHOOSING THE ROOM

Element Room access Room size Floor load Ventilation Requirements All the doors which the equipment has to go through in order to reach the chosen room have to be large enough to allow the passage of the U.P.S (charts 8a/b/c) and its handling equipment. We advise you to forbid access to the place where the U.P.S. and its battery cabinets are placed to all non authorized users. Room space must be suitable to allow installation of the equipment and periodical and extraordinary maintenance. When choosing the rooms please remember that the equipment must not be exposed to the inclemency of the weather, to corrosive substances, to excessive humidity (humidity below 90% non-condensing) or to very high sources of heat. The environment should not be very dusty. Please be very careful if you decide to carry out any building work after setting up the machine. According to the data in charts 8a/b/c you must check that the floors of the chosen rooms can support the equipments weight. The U.P.S. operative temperature is specified in chart 15. Room temperature should be preferably between 15 and 25C Ventilators expel the heat dissipated by the U.P.S. into the air, therefore the room structure must be suitable to guarantee sufficient aeration to eliminate the heat produced by the U.P.S. If room temperature does not comply with the recommended parameters or if air circulation in the room is not adequate, you must supply the room with a ventilation system or, if this should not be sufficient, install an air conditioning system. The rooms where the U.P.S. is installed must be equipped according to fire and safety regulations.

Safety rules

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3 3.1

GENERAL DESCRIPTION OPERATING PRINCIPAL

The U.P.S. is a continuous double conversion system with an output transformer. It works by carrying out a continuous double conversion of the main supply, guaranteeing a constant stablized supply of both voltage and frequency, maintaining charge and control of the batteries (On-line functioning). In order to guarantee continuous supply when the voltage of the electric system are no longer correct, power is drawn from the batteries. The system is supplied complete with an automatic static commutator that connects the output to the back-up power supply, or if there are special alarms such as the E.P.O. (Emergency Power Off) it shuts down completely output voltage. 3.2 DESCRIPTION AND PARTS

During normal functioning (picture 6) the system takes power from the mains by means of the input terminal (1). The voltage goes through the disconnecting switch and the fuse board in order to reach the rectifier module (2), exiting which is a continuous controlled voltage available to charge or maintain battery efficiency and to the inverter input (3). This step is to generate a three-phase voltage, stabilized and synchronized with the back-up voltage. The static commutator (4) selects the power source to power the load, usually on inverter (3). If there is an increase of output current or with specific alarms, the device (4) will commutate to the emergency supply (7) maintaining output continuity. If transferring takes place, output continuity is allowed by the synchronism of the voltages generated with the emergency voltage. If asynchronous commutation should take place there will be a power dip for maximum 20 ms.

(7) (1) (2) (3) (4) (5)

(6) Picture 6
When the power supply is not in the set parameters, the equipment maintains output voltage by taking power from the batteries (picture 7). The system is provided with a current control that keeps the current inside set parameters in the event of current overloaded.

Picture 7

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3.3

PART LAYOUT

It is important to be familiar with the parts that are necessary during the connection procedures before connecting the equipment. In order to access the parts which will be described you must remove the second access, which is the metal panel used to protect the inside parts of the U.P.S. and also to protect the user from accidental contacts with live parts. U.P.S. from 10 KVA to 50 KVA A KEY

A = Display board B = Relay board C = Interface connector D = Terminal E = Breakers F = Fuse cards F E = Earthing

B C

Picture 8 U.P.S. from 60 to 100 KVA

A F

D C

Picture 9 Pag. 12 di 47

U.P.S. from 120 and 200 KVA A

FFFFFFFF

D E C

Picture 10

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Picture 11 U.P.S. from 300 and 400 KVA

Battery switch

Battery connection Battery fuses

Rectifier fuses

Mains switch Reserve switch Spare fuses Output switch

Main entry

Back-up entry

Output Relay board

RS 232

Neutral bar

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3.3.1 BREAKERS
The U.P.S. has a system of breakers, which allows the user to carry out the necessary operations in order to use and carry out maintenance on the equipment and to shut down the power supply if there is an emergency. A sticker placed on the second access specifies the name of each switch near the switch itself. The by-pass switch contains a protection device so, as it cannot be disconnected inadvertently. The user can remove this protection device if he/she decides to carry out a manual by-pass. (Chapter 5). 1. 2. 3. 4. 5. MAINS SWITCH RESERVE SWITCH MANUAL BY-PASS OUTPUT SWITCH BATTERY SWITCH Break the mains supply, as specified in point 1 (picture 6) Break the secondary power supply, as specified in point 7 (picture 6) Short-circuits the secondary input with the output Break the loading power supply. Break, according to the model, one or both battery polarities.

3.3.2 FUSES
The U.P.S. includes (where is foreseen) a system with two fuse groups, both counting three fuses each which are able to disconnect electrical power input (points 1 and 7 picture 6), when the electrical power is not within the set parameters. The type of fuse, which is used, guarantee quick intervention and therefore are a guarantee also for optimum protection of the internal devices. Furthermore, there is also a fuse on the line, which connects the U.P.S. to the batteries (point 6 picture 6), both for internal and external batteries. A B C

Picture 12 Board A, (picture 12), to the users left, protects the state of the rectifier input, board B (picture 12) (where is foreseen), to the users right, protects the reserve line. Whereas the single-fuse board C protects the battery line. 3.3.2.1 REPLACING THE FUSES CAUTION! : ALL CONNECTING PROCEDURES DESCRIBED IN THIS CHAPTER MUST BE CARRIED OUT BY AUTHORIZED ELECTRICIANS OR BY QUALIFIED TECHNICIANS. CAUTION! : BEFORE REPLACING THE FUSES YOU MUST CARRY OUT THE MANUAL BY-PASS PROCEDURE WITH THE U.P.S. DISCONNECTED (CHAPTER 5)

A nut screw fastens each fuse. When replacing a fuse you must unscrew the two knurled nuts corresponding to the fuse, which must be replaced, remove the washers, replace the fuse and put back the washers and the knurled nut in this order. IMPORTANT spare fuses are supplied together with the U.P.S. If they have to be purchased please make sure that they are extra-fast fuses for the current specified in charts 9a and 9b so as to guarantee total protection.

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3.3.3 TERMINAL CONNECTORS

3.3.3.1

POWER UP TO 200 KVA

In all the models the terminal board is on the front of the U.P.S. protected by the second access.

It can be perpendicular or horizontal according to the model. In any case, please refer to the alphanumeric specifications on the terminal board. The jumpers are arranged as in the picture (highlighted in grey), and are used to short-circuit the main input and the reserve input. According to the type of installation, you can remove them to connect the system to an auxiliary power source (back-up supply, generator).

U1

V1

W1

N1

U2

V2

W2

N2

D(-)

C(+)

Picture 13 = Foreseen only in some models U, V, W = Main input U1, V1, W1, N1 = Reserve input (where is foreseen) U2, V2, W2, N2 = Output D(-),C(+) = Battery pole input. D(-) negative pole, C(+) positive pole.

3.3.3.2

POWER OVER 200 KVA

In the high power systems instead of using terminal boards for power connections a group of copper bars with perforated ends are used. Therefore with the help of cable terminals, knurled screws and nuts a suitable connection for the current values in circulation. As for the connection references please refer to the alphanumeric specifications on the copper bars which respect the same specifications present on the terminal boards in equipment up to 200KVA.

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3.4

CONNECTING THE U.P.S. TO THE MAINS SUPPLY CAUTION! : ALL CONNECTING PROCEDURES DESCRIBED IN THIS CHAPTER MUST BE CARRIED OUT BY AUTHORIZED ELECTRICIANS OR BY QUALIFIED TECHNICIANS.

CAUTION! : THE U.P.S. WITHOUT IT.

NEED A NEUTRAL WIRE. THE SYSTEM CANNOT WORK

3.4.1 COMPATIBILITY WITH THE POWER SUPPLY

The parallel connection to the public mains is normally allowed, as the U.P.S. is comparable to a passive charge. The mains supply must supply a higher power than the U.P.S rated power as it has to take into account several factors, such as: 1. 2. 3. 4. Power absorbed by the output charge on the uninterruptible power supply System efficiency (see chart 15) Power needed to charge the batteries Input harmonic distortion

If you know the amount of power needed by the connected electrical equipment and you can evaluate the probable expansion margins it is possible to make a first rough estimate of the power required. As for the power absorbed by the batteries while charging, you can easily work out the power required by multiplying 436 times 1/10 of the total battery capacity (E.g.: For a 40A/h battery space, the power needed to charge the battery will be: 436 X (40 / 10) = 1,744 kW). As for input harmonic distortion please remember that for the power supply the uninterruptible power supply is to be considered as a non-linear load, which generates harmonic frequency currents multiples of the (50/60 Hz). In function of the line impedance these create a harmonic voltage distortion. This latter value (total harmonic voltage distortion) must not exceed the specific environment reference parameters. There are several ways of reducing this parameter: by increasing the power supply, the section of power supplies cables or by choosing an interruptible power supply with specific features (twelvephase input, with filter).

3.4.1.1

INDIRECT POWER SUPPLY

TRANSFORMER If you are using a system input isolation transformer this will reduce distortion effects and stop its diffusion in the system. Therefore, apart from decreasing harmonic disturbance you can also probably avoid oversizing the power supply line. GENERATOR Particular attention must be paid when sizing a possible input power unit; this has high output impedance, which is defined on the rating plate as subtransient reactance of the alternator. This parameter makes a negligible harmonic current distortion become a seriously disturbing element for the correct functioning of the U.P.S.

3.4.1.2

INPUT WIRE SIZING

When choosing the wire you must bear in mind a technical, economical and safety evaluation. Technically speaking, the main factors that affect wire sizing are voltage, current, overcurrent, temperature and how the wires are laid. However, it is always a good rule to size the wires so as the voltage drop on each wire is below 3% of the applied voltage. Particularly important is the sizing of the neutral wire especially when the U.P.S. is used to power unbalanced loads or loads with strong harmonic distortion. Taking into account these last remarks, the enlargement factor must be decided according to the size of the phase wire (usually 1,5-2 times).

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3.4.1.3

PROTECTION OF THE U.P.S. OUTPUT LINE

The main electric distribution systems to which the U.P.S. can be connected are the TN-S and TT systems (pictures 14 and 15). If you do not have this type of equipment please talk to a specialized technician. The protection devices, which can be applied to the U.P.S. output line, are against overcurrent and are differential. As for their size, please bear in mind that if there is a power shortage the U.P.S. works on its own (disconnected from the main line), with a current restriction equal to 150% of the rated current, therefore in order to protect against overcurrent you must choose a device that is activated within this threshold. As for differential protections you must use type A differentials (for alternate current and for switches with continuous components), which are low sensitivity (0,30,5-1 A).

L1 L2 L3 N PEN

TN-S

N PE

L1 L2 L3 N

TT

U.P.S The TN-S system has the neutral grounded in a specific point to which the systems earth is also connected with a separate protection wire.

U.P.S The TT system has the neutral grounded in a specific point and the systems earth is connected to an earth which is independent from the neutral. This is the most used device at distribution level. Picture 15

Picture 14

3.4.2 CONNECTING THE SYSTEM

To connect the U.P.S. you must carry out the following procedures: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Open the front door, the key is attached to one of the supporting feet Shutdown all breakers. Verify the integrity of the by-pass breaker lock out Make sure there is no voltage on the mains supply Unscrew the second access panel setscrews and remove the panel Connect the earthling wire for the mains to the earth bar of the T2000 Connect the general mains to the U, V and W terminals of the U.P.S. ( in cyclic sense) If the back-up supply mains are available disconnect the jumpers from terminals U1 and U, V1 and V, W1 and W, then connect the back-up supply to the U1, V1 and W1 terminals Connect the supply mains neutral wire to the N1 terminal Connect the mains that power the connected electric equipment to U2, V2 e W2 terminals at the U.P.S. output Connect the mains neutral wire that powers the connected electric equipment to the N2 terminal at the U.P.S. output If you need to connect external battery compartments please proceed to the following paragraph. Replace the second access panel and fasten its screws. Lock the front door with its key Reassemble the side grids on the supporting base

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3.5 CONNECTING THE BATTERIES TO THE U.P.S.

CAUTION! : ALL CONNECTING PROCEDURES DESCRIBED IN THIS PARAGRAPH MUST BE CARRIED OUT BY AUTHORIZED ELECTRICIANS OR BY QUALIFIED TECHNICIANS.

CAUTION! : FOR SECURITY REASONS THE BATTERIES ARE TRANSPORTED WITH SOME OF THE JUMPERS DISCONNECTED, THEREFORE PLEASE REMEMBER TO RE-CONNECT THEM. SEE CHAPTER 7

3.5.1 CONNECTION TO A 120cm HEIGHT BATTERY CABINET

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Make sure that the U.P.S. is switched off and that all switches are off Unscrew the setscrew from the second access panel of the U.P.S. and remove it Unscrew the setscrew from the battery cabinet roof and remove it Make sure there is no voltage on the U.P.S. battery terminals Connect the earthling wire to the earth bar of the U.P.S Connect the earthling wire to the earth bar of the U.P.S Connect the two wires, supplied to connect the external battery cabinet, to the C and D terminals of the U.P.S. (C= positive, D= negative) Connect the wires from the U.P.S. to the C and D terminals of the battery cabinet N.B. Check and control all the connections of the jumpers inside the batteries of the battery cabinet (chapter 7) Make sure that the corresponding battery breaker placed on the U.P.S is off, then shut down the battery switch on the cabinet Using a multimeter verify the correct polarity on the U.P.S. battery terminals Close the second access of the U.P.S. by fastening its screws Close the battery cabinet roof by fastening its screws Reassemble the side grids on the supporting base

3.5.2 CONNECTION TO A 180cm HEIGHT BATTERY CABINET

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Make sure that the U.P.S. is switched off and that all switches are off Unscrew the setscrew from the second access panel of the U.P.S. and remove it Open the front access door of the battery cabinet with its key Make sure there is no voltage on the U.P.S. battery terminals Connect the earthling wire to the earth bar of the U.P.S Connect the earthling wire to the earth bar of the U.P.S Connect the two wires, supplied to connect the external battery cabinet, to the C and D terminals of the U.P.S. (C= positive, D= negative Connect the wires from the U.P.S. to the C and D terminals of the battery cabinet N.B. Check and control all the connections of the jumpers inside the batteries of the battery cabinet (chapter 7) Make sure that the corresponding battery breaker placed on the U.P.S is off, then shut down the battery switch on the cabinet Using a multimeter verify the correct polarity on the U.P.S. battery terminals Close the second access of the U.P.S. by fastening its screws Reassemble the side grids on the supporting base

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3.5.3 CONNECTING INTERNAL BATTERIES

1. 2. 3. 4. 5. Make sure that the U.P.S. is switched off and that all switches are off Unscrew the setscrew from the right-hand side panel of the U.P.S. and remove it N.B. Check and control all the connections of the jumpers inside the batteries of the battery cabinet (chapter 7) Close the side panel by fastening its screws Reassemble the side grids on the supporting base CAUTION! : THE U.P.S. AUTONOMY DEPENDS ON THE STATE OF THE BATTERIES; A CORRECT AND PROGRAMMED MAINTENANCE IS FUNDAMENTAL TO AVOID A BAD CONDITION OF THE BATTERIES FROM HAMPERING U.P.S. FUNCTIONING WHEN NECESSARY.

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4 4.1

STARTING-UP AND SHUTTING DOWN THE MACHINE STARTING-UP THE MACHINE

CAUTION! : IF THE BATTERY BREAKER IS CLOSED, BEFORE STARTING UP T2000, THIS CAN CAUSE U.P.S DAMAGE.

In order to start-up follow the procedures 4.1.1 or 4.1.2 for U.P.S with independent riserve line:

4.1.1 U.P.S without independent reserve line

1. 2. 3. 4. Make sure that the wires are correctly connected respecting the cyclic sense of the phases U,V,W Make sure that the Manual By-pass switch is turned off and blocked by its blocking device Give power to the mains Close the Mains switch breaker, the display will turn on and the message UPS STOPPED will appear, all the synoptic leds (picture 17) will be red except leds H and B which remain green; wait till led A (picture 17) start flashing, if this does not happen the supply voltage is not adequate or the cyclic sense of the phases is incorrect, therefore you must disconnect the equipment, verify the connections and start this procedure again from the beginning. Close the Output switch breakers, led G (picture 17) will turn green Press the button for about two seconds, on the display the message switch on procedure started will appear, if the steps of procedure have been followed correctly led C (picture 17) and led E will become green and the message UPS in alarm mode will appear Once you have carried out the turning on procedure and leds C and E are green, it is possible to close the Battery switch breaker and led D will be green. If installation has been correctly carried out and the turning on procedure done successfully, the message UPS in normal operation operation will appear and all the synoptic leds will be green Go to paragraph 4.1.3

5. 6. 7. 8. 9.

4.1.2 U.P.S with independent reserve line (only where is foreseen)

1. 2. 3. 4. Make sure that the wires are correctly connected respecting the cyclic sense of the phases U,V,W Make sure that the Manual By-pass switch is turned off and blocked by its blocking device Give power to the mains Close the Reserve switch breaker, the display will turn on and the message UPS STOPPED will appear, all the synoptic leds (picture 17) will be red except led H which remain green; wait till led A (picture 17) start flashing, if this does not happen the supply voltage is not adequate or the cyclic sense of the phases is incorrect, therefore you must disconnect the equipment, verify the connections and start this procedure again from the beginning. Close the Mains switch and Output switch breakers, leds G and B (picture 17) will turn green button for about two seconds, on the display the message switch on procedure started will appear, if the steps of procedure have Press the been followed correctly led C (picture 17) and led E will become green and the message UPS in alarm mode will appear Once you have carried out the turning on procedure and leds C and E are green, it is possible to close the Battery switch breaker and led D will be green. If installation has been correctly carried out and the turning on procedure done successfully, the message UPS in normal operation operation will appear and all the synoptic leds will be green Go to paragraph 4.1.3

5. 6. 7. 8. 9.

4.1.3 First time starting-up

If the turning on procedure has been carried out for the first time we advise you to continue this procedure to verify the real efficiency and to get familiar with the system 1. 2. Select the language you wish to use by following the indications in the menu (diagram 1a/b) Carry out the battery test (see 6.1.2.2) and verify the outcome Pag. 21 di 47

3. 4.

Carry out the complete by-pass procedure with the U.P.S. switched on (paragraph 5.1) and all operations to restore the by-pass Carry out a power shortage test by turning off the Mains switch and make sure that the U.P.S. goes into alarm mode and that led D starts flashing and led F stays green (picture 1and 7) then turn on the Mains switch and check that normal functioning has been restored. SHUTTING DOWN CAUTION! : THE FOLLOWING PROCEDURE WILL DISCONNECT THE LOAD!

4.2

In order to turn off you must: 1. 2. 3. 4. 5. Press for about 5 seconds the button. On the display the message TURN OFF UPS will appear and leds C,E and F (picture 17) will be red and the message UPS STOPPED will appear on display Open Output switch and led G will be red Open Battery switch and led D will be red Open Reserve switch and led A will be red Open Mains switch and the U.P.S. will be off completely

4.2.1 EMERGENCY POWER OFF SWITCH ( optional)

The Emergency Power Off switch (E.P.O.) allows, after pre-setting the function, U.P.S. shutdown totally or partially in emergencies. Standard setting only has the totally turned off feature. If you want to modify this set up please ask for a specialized technician to do. It is installed on the machine or on the remote control panel. Specialised technicians can carry out After-sales installation only. The switch on board the machine is on the right-hand side of the control panel; for the switch on the remote control panel, please see picture 19. Partial shutdown results in deactivating the static and the inverter, which in consequence will turn off all the electric equipment connected to the systems output, whereas the rectifier and battery will continue receiving charge current. Total shutdown deactivates all functions (including the rectifier). During the emergency the message WARNING emergency shutdown will appear on the control panel. There are two ways to restore normal functioning: RESTORING FROM PARTIAL SHUTDOWN: Press switch off button for about three

seconds then press the switch on button for about five seconds and wait till the end of the shutdown procedure. RESTORING FROM TOTAL SHUTDOWN: for about five Press the switch on button seconds and wait till the end of the shutdown procedure.

Pag. 22 di 47

ACTIVATING THE MANUAL BY-PASS CAUTION! : IF YOU CARRY OUT THIS PROCEDURE INCORRECTLY YOU COULD DAMAGE THE U.P.S. THE MANUFACTURER DECLINES ALL RESPONSABILITIES FOR DAMAGE DUE TO INCORRECT MANOUEVRING.

CAUTION! : DURING THE ENTIRE PERIOD OF FUNCTIONING IN BY-PASS MODE, THE ELECTRIC EQUIPMENT CONNECTED TO THE OUTPUT OF THE DEVICE WILL BE SUBJECT TO THE FLUCTUATIONS MAINS VOLTAGE.

This manual operation transfers the load directly to the mains during maintenance or if the equipment breakdown.

Picture 16 5.1 1. 2. 3. 4. ACTIVATING THE BY-PASS KEEPING THE U.P.S SWITCHED ON Verify that led A is green (fig.17) Press keys F6 and F2 at the same time, using the scroll keys select On reserve and confirm your choice by pressing F6; make sure that led F (picture 17) become yellow Turn on the Manual by-pass breaker Turn off the Output switch breaker

RESTORING NORMAL FUNCTIONING FROM THE PREVIOUS CONDITION: 1. 2. 3. 4. Make sure the led F (picture 17) is yellow Turn on the Output switch breaker Turn off the Manual by-pass breaker Press keys F6 and F2, at the same time and wait until led F turns green

Pag. 23 di 47

5.2 ACTIVATING THE BY-PASS SHUTTING DOWN THE U.P.S 1. Verify that led A is green (Fig.17). 2. 3. 4. 5. 6. 7. button for about 5 seconds; the message Turn off U.P.S will appear on the display and leds C,E Press the and F (picture 17) will turn red and the message UPS stopped will appear on the display Turn on the by-pass switch breaker and led D will be red Turn off the Output switch breaker and led G will be red Turn off the Reserve switch breaker (where is foreseen) Turn off the Mains switch breaker Turn off the Battery switch breaker

RESTORING NORMAL FUNCTIONING FROM THE PREVIOUS CONDITION: 1. Turn on the Reserve switch breaker (where is foreseen), the message UPS Stopped will appear on the display, all the synoptic leds (picture 17) will be red except led H remain green; wait till led A (picture 17) starts flashing, if this does not happen the supply voltage is not adequate or the cyclic sense of the phases is incorrect, therefore you must disconnect the equipment, verify the connections and start this procedure again from the beginning. Turn on the Main switch e Output switch breakers, led B and led G (picture 17) will be green Turn off the Manual by-pass breaker. Press the button for about 2 seconds; the message Switch on procedure started will appear on the display, if the procedure has been carried out correctly led C (picture 17) and led E will be green and the message UPS in alarm mode will appear Once you have carried out the turning on procedure and that led C and E are green, it is possible to close the Battery switch breaker and led D will be green CHECK TOOLS

2. 3. 4. 5. 6

The user can communicate with the U.P.S. in the following ways: Using the control panel on the front of the control board Using relay interface Using a Personal Computer connected to the U.P.S. Using the remote control panel (Optional) You can connect all these check tools described above to the same machine without creating interference or incompatibility among the components. The use of photocouplers on all interfaces (except for relay interface) guarantees galvanic separation of the interfaces remote controlled from the U.P.S. assuring all connected equipment total protection from disturbance and interference. 6.1 THE CONTROL PANEL AND ITS FUNCTIONS 1. 2. 3. 4.

F1

F2

F3

F4

F5

F6

F7

F8

Picture 17 Led A Associated element Back-up mains supply Colour green red Pag. 24 di 47 Meaning Back-up mains OK Breaker is off (where is foreseen) Incorrect input voltage

flashing B Rectifier mains supply green red flashing green C Rectifier red green red flashing green red flashing green yellow red green red flashing H Chart 1 Panel check functions can be split into three main categories: 1. 2. 3. Monitoring Diagnostic tools Functioning mode configuration By-pass green red

Incorrect frequency Not synchronised Rectifier mains OK Rectifier mains alarmed Incorrect cyclical sense Rectifier OK Rectifier alarmed Rectifier off battery OK Battery alarmed Battery discharging inverter OK Inverter alarmed inverter off inverter current over 125% Static commutator on inverter Static commutator on back-up Static commutator off or blocked Output voltage OK Incorrect output voltage Opened breaker Output current over the nominal value Manual by-pass open Manual by-pass closed

Battery

Inverter

Static commutator

Output voltage

In the interface system we refer to elements. For element we mean a group of components which concur to the same function. ELEMENTS SYSTEM RECTIFIER BATTERY INVERTER BACK-UP BREAKERS Chart 2 DESCRIPTION Includes the U.P.S. as a whole Includes devices for conversion from alternating to direct voltage Includes the device for energy storage Includes devices for conversion from alternating to direct voltage This is the emergency mains supply Includes all the breakers in the U.P.S.

Pag. 25 di 47

6.1.1 MONITORING
Monitoring allows checking that all specific functions are within the set limits ELEMENTS U.P.S. System AVAILABLE MEASUREMENTS Phase-phase output voltage Phase-neutral output voltage Output current Inside temperature Load percentage Phase-phase output voltage Link DC voltage Link DC current Frequency Input Voltage Link DC voltage Link DC current Voltage Current Voltage Frequency

Inverter

Rectifier Battery Back-up Chart 3

6.1.2 DIAGNOSTIC TOOLS

The diagnostic tools allow checking the U.P.S. functioning state, by checking for the presence of alarms in progress or already activated and Battery State. The available diagnostic tools are: 1. Event menu 2. History menu 3. Battery test

6.1.2.1

EVENT AND HISTORY MENUS

The EVENT menu allows viewing of all the alarms in progress, whereas the HISTORICAL menu allows viewing alarms which were active but which have already been restored. They are used when the alarm of the machine goes off to locate the origin and the cause of the alarm and also to establish how serious the problem is. Both have an error code and a short message. The historical menu also shows the date and the time the alarm went off. 1. 2. 3. The error code is the code which identifies the type of error shown by the system La display message shows the message that can be seen in the EVENT or HISTORICAL menu, that is, a brief explanation of the reason for the alarm The seriousness defines how serious the problem is: Anomaly: If the alarm is caused by a temporary event User: If incorrect or intentional manoeuvring by the user causes the alarm Failure: If the alarm is caused by a system failure that can be restored only by the user Pag. 26 di 47

SISTEM Error code SY1 SY2 SY3 SY4 SY5 SY6 SY7

Display message Inverter w/o load Load on back-up Error out voltage High Temperature Pretemp. alarm Error direct voltage. Mains error Display message High Temperature Cyclic sense error. Rectifier Error Boost charge Voltage Error Display message Inverter off Desaturation IGBT Voltage Error Inv. Not synchronised Frequency error Current > 125% Current > 150% High current Display message Cyclic sense error. Voltage Error Frequency error Display message Rectifier Error Back-up error Output error By-Pass Battery error User mode

Description Inverter without load Load on mains Error in output voltage Temperature block Critical temperature DC Link voltage error Power supply in alarm Description High Temperature Cyclic sense error. Rectifier alarmed Boost charge activity Error in mains voltage Description Inverter off Desaturation IGBT Error in inverter voltage Error in frequency synchronism Frequency error Output Current > 125% Output Current > 150% Output Current outside parameters Description Cyclic sense error. Voltage Error Frequency error Description Rectifier breaker Back-up breaker Output breaker Manual By-pass Battery breaker Jumper in the relay board

Seriousness Anomaly Anomaly User /failure Anomaly Anomaly Anomaly Anomaly Seriousness Anomaly User Failure User Anomaly Seriousness User / Anomaly failure / User Anomaly / failure Anomaly Anomaly Anomaly Anomaly Anomaly Seriousness User Anomaly Anomaly Seriousness User User User User User User

RECTIFIER
Error code RC1 RC2 RC3 RC4 RC5

INVERTER
Error code IV1 IV2 IV3 IV5 IV6 IV7 IV8 IV9

BACK-UP
Error code RS1 RS2 RS3

BREAKERS
Error code SZ1 SZ2 SZ3 SZ4 SZ5 OP1 Chart 4

6.1.2.2

BATTERY TEST

CAUTION! : CARRY OUT THE BATTERY TEST ONLY WHEN THE MACHINE IS IN NORMAL MODE OPERATION

The battery test allows the user to check battery connection quality and fuse condition. To carry out the test press the F6 and the F3 keys together then press F6 to confirm, as specified in diagram 1. The test lasts for a minute, during which the U.P.S. takes the necessary energy to maintain its load from the battery. At the end of the test the result will appear under the form of Good Battery or Bad battery. Pag. 27 di 47

CAUTION! : PLEASE NOTE THAT SPECIALIZED TECHNICIANS MUST CARRY OUT THE PROCEDURES DESCRIBED BELOW ONLY

In the second case, that is to say Bad batteries, you must check the fuses on the connecting line between the U.P.S and the battery cabinet. To do so you must measure the direct voltage on the battery fuse ends which are placed in the U.P.S and in the battery cabinet (see chapters 3.3 e 7.2) with a multimeter. If the fuses are not damaged, voltage measurement is next to zero. If the fuse check is positive, it means that the connected batteries are no longer suitable to maintain the load if there is a power shortage.

6.1.3 FUNCTIONING MODE CONFIGURATION

This product gives you the possibility of configuring the functioning mode in order to modify its use.

6.1.3.1

BATTERY CHARGE MODE

Press the F6 key and the starting key as specified in diagram 1a/b. These keys activate the starting procedure which consists of the starting of the rectifier only (picture 6 point 2). This makes it possible to charge the batteries through the terminal contacts C and D. This function is very useful if the U.P.S. is not used for a long time and therefore needs complete battery charge.

6.1.3.2

FORCING ON INVERTER MODE

To activate this function press the F6 key and the F2 key together as specified in diagram 1a/b. This will mean that the system output will constantly be connected to the inverter, thus excluding the emergency mains supply. While the system is starting up it provides output energy only when the voltage level has reached set parameters. With this type of forcing it is possible to start up the U.P.S. without the emergency mains supply.

Pag. 28 di 47

6.1.4 STRUCTURE MENU

Pag. 29 di 47

Any Menu

Key function specification

Menu: Buzzer Active Disactive

Phase-phase output voltage Phase-neutral out voltage Output current Load percentage Inside temperature Phase-phase output voltage Direct voltage Direct current Direct voltage Direct current Phase-phase output voltage Direct voltage Direct current Frequency Phase-neutral out voltage Frequency

Menu: Measurements

Main menu

U.P.S system Rectifier Battery Inverter Back-up

Menu: Events System Rectifier Battery Inverter Back-up

As described in 6.2.2.1.there is a description for each selected item

Software version Date and time

Diagram 1a

Pag. 30 di 47

Menu: static forcing

on inverter not forced on back-

Menu: Parameters

Battery test

Carries out the battery test

Main menu

Menu: historical

System Rectifier Battery Inverter Back-up

As described in 6.2.2.1.there is a description for each selected item

Menu: settings Language Clock To set date F2 key moves the

Menu: Language English Deutsch Italiano Espanol Mexican English English

pointer and the arrows set the value. After setting values press .

U.P.S Off

System start-up in battery charging mode

Diagram 1b

Pag. 31 di 47

6.2

RELAY BOARD

The relay board is a user interface system, which allows viewing of the U.P.S. State through eight diverters, one standard and seven optional, which are controlled. These contacts are used especially to start up the acoustic and visual alarm systems when specific events occur. The types of relays, which are used, allow connecting functioning electric equipment up to 250V alternating, with a 10A maximum absorption. For each relay we can associate an alarm or we keep the standard setting. In case of particular requirement for relay programming, to aks our engineers. The position of this board varies according to the model, but in any case once you have removed the second access it is always visible and accessible to the user.

CN1 CN2

CN3

Led

Jumper 1

H Terminal 24

Picture 18 CONTACT NUMBER 2 5 8 11 14 17 20 23 AVAILABLE CONTACTS 1 N.C. 3 N.A. 4 N.C. 6 N.A. 7 N.C. 9 N.A. 10 N.C. 12 N.A. 13 N.C. 15 N.A. 16 N.C. 18 N.A. 19 N.C. 21 N.A. 22 N.C. 24 N.A. ALARM CONFIGURATION TABLE
Output current > 150% Output current > 125%

RELAY A B C D E F G H Chart 5

RELATED STATE (STANDARD) RECTIFIER STARTED(OPTIONAL) INVERTER STARTED(OPTIONAL) LOAD ON RESERVE LINE(OPTIONAL) LOAD ON INVERTER(OPTIONAL) PRE-ALARM TEMPERATURE(OPTIONAL) TEMPERATURE ALARM OR DESATURATION(OPTIONAL) LOW BATTERY VOLTAGE(OPTIONAL) OUTPUT CURRENT > 125%(OPTIONAL)

Load on reserve Load on inverter

Reserve frequency KO Frequency alarm Reserve voltage KO Sincro alarm Wrong reserve phase seq. Zero phase alarm V Inverter bad Main voltage KO IGBT Desaturation Boost charge Inverter on Rectifier ON Rec. Phase seq. Wrong Summary alarm VDC < 350V High temp. Rectifier Iout > Rating current Relay board jumper Power supply alarm Battery switch DC Link fault By-pass switch Pre Temp. Alarm Output switch High Temp. Alarm Reserve switch Voltage out KO Main switch

(N.C.= Normally closed N.O.= Normally open)

The states associated to the relay are standard, but a specialised technician according to necessity can modify them. You can verify the state of the relays with the leds (picture 18) which are placed above each relay. Pag. 32 di 47

6.3 P.C. INTERFACE . The U.P.S is supplied with a communication interface, which allows signal exchanging with external equipment. The interface output is a serial port, which transmits to the RS232 system. The communication protocol is compatible with Generex and Megatech U.P.S. management software. Furthermore, other types of interfaces are available by using adapters, such as: SNMP communication port to connect the U.P.S. to the mains USB communication port to connect Plug & Play to a PC RS485 serial communication port (half-duplex or full-duplex) Through integrating with server and enterprise management platforms SNMP (Simple Network Managing Protocol), or even via web, you can control remote management. Inserting the U.P.S. in LAN/WAN, with the usual Ethernet connection (available as optional interface through the RS232 port), it is possible to treat it like any other network element with its own IP address with which all the other pieces of equipment on the network can have advanced communication. 6.4 REMOTE PANEL (optional)

The remote panel is an extension of the synoptic supervision (picture 17 plus chart 1); this is particularly useful when you need to monitor machine functioning in a remote place. Furthermore, it is possible to supply it with an E.P.O. switch (chapter 4.2.1). This device is composed of two main parts, one interface board inside the machine and an actual synoptic which should be installed in a place of your choice to carry out monitoring at a maximum distance of 25 meters. The synoptic is in a wall box with a bottom cable passage. Please remember that the remote panel needs a 220-240V/50-60Hz power supply, which is to be taken only from the U.P.S. output. A specialized technician is recommended to install these devices.

E.P.O. Switch (optional)

Cable passage

Picture 19

Please refer to picture 6 for the meaning of the state of the leds.

Pag. 33 di 47

6.4.1 INSTALLATION OF REMOTE PANEL WITHOUT E.P.O.

To install this board please follows the procedures below: Make sure that the U.P.S. is off and that all the switches are off (if the U.P.S. is already operative please proceed to by-pass setting chapter 5) Unscrew the set screws from the second access panel of the U.P.S. and remove it. Check if there is an interface board (picture 20); (present only if requested before purchase). Its position varies according to the different models but it is always viewable and accessible by the user.

14

B Picture 20

If there is a board please go directly to point 8 otherwise continue with the following procedures. Insert the four supports for the printed circuit in the holes as specified (picture 21)

Picture 21 Fasten the board as specified in picture 20 (named PCB2000 A14Rxx), to the supports you have just inserted Create a connection with the supplied flat-cable between connector A (picture 20) and connector CN3 on the relay board (picture 18), respecting polarity, that is to say, the coloured wire level with the sign on the board (picture 22)

Pag. 34 di 47

PCB2000 A14R00

Picture 22

Position the remote panel in the place chosen for monitoring Proceed to connect power supply (220-240V/50-60Hz) to the M3 connector of the PCB2000 A16Rxx board (picture 23), remembering to leave the central terminal free Carry out connection between interface connector indicated with the letter B (picture 20) and the M1 connector in picture 23. Bear in mind that the connection must be carried out symmetrically (pin1-pin14, pin2-pin13, . . ., pin13-pin2, pin14-pin1) Close the U.P.S second access by fastening the screws Continue the starting procedure (chapter 4) (if already operative restore functioning from U.P.S by-pass following the instructions in paragraph 5)

PCB2000 A16 Rxx

M2 Picture 23

M1

14

Pag. 35 di 47

M3

6.4.2 INSTALLING THE REMOTE PANEL WITH E.P.O.

CAUTION! : FOLLOW THE INSTRUCTIONS VERY CAREFULLY. ANY MISTAKE WILL CAUSE AN OUTPUT VOLTAGE DROP.

To carry out the installation of a remote panel with E.P.O., you must first carry out all installation procedures for the normal remote panel, as in paragraph 6.4.1 then check the actual efficiency of the remote panel by checking that the leds respect the colours on the control panel. After doing so please carry out the following instructions: Make sure that the U.P.S. is off and that all the switches are off (if the U.P.S. is already operative please proceed to by-pass setting chapter 5) Unscrew the set screws from the second access panel of the U.P.S. and remove it. Using cutting nippers cut the jumper as shown on the relay board (picture 18) Turn on the Reserve switch disconnecting switch, the message UPS Off will appear on the display and all the synoptic leds (picture 5.1) will turn red except for led H which will be green; wait till led A (picture 17) starts flashing Turn on the Main switch disconnecting switch, led B(picture 17) will turn green Press the button for about two seconds, the message Starting up procedure started, and if the procedure has been carried out correctly led C (picture 17) and led E will turn green in sequence and the message UPS alarmed will appear on the display Press keys F6+F3 with the arrows F7-F8 select Level of EPO, press F6 to confirm, select Stop completed and press F6.Press F3 to go back to the main menu Press the E.P.O. switch on the remote panel and check that the emergency button actually works (leds C, E, F picture 17) chapter 6.1 must turn red and the message (Emergency EPO block) will appear Reset the switch Continue the starting procedure (chapter 4) (if already operative restore functioning from U.P.S by-pass following the instructions in paragraph 5)

Pag. 36 di 47

BATTERIES

The system guarantees uninterruptible power by using buffer batteries directly connected to the AC/DC conversion output. A periodical check of the Battery State will prevent unpleasant mishaps that may occur if there is a power shortage, such as short autonomy or in extreme cases even non-intervention of the system with consequent load loss. If storing battery cabinets or U.P.S. containing batteries please remember to recharge them every four months (chapter 6.1.3.1), in order to guarantee the best maintenance possible. For transport safety the batteries inside the cabinet are disconnected in some points to discontinue circuit continuity, therefore you must restore these connections when installing the batteries. As already mentioned system autonomy depends on the type of battery used and, above all, on their capacity. Battery capacity is expressed in ampere/hour, from this parameter you can work out system autonomy. This expresses the amount of current delivered in a given time interval, discharging a storage battery at a given condition (discharge current), until it reaches a set voltage. For example, a 50 Ah capacity can deliver 2,5 A for 20 hours. Excessively hot temperatures, over 40C, can drastically reduce battery life, due to plate corrosion caused by an increase of acid aggressiveness. However, the system has a device, which can reduce working voltage according to the temperature, thus improving battery life.

Picture 24 The discharge characteristic varies according to the make and model but it may be compared to the graph above. The buffer system used is composed of a string of 32 batteries connected in series. The capacity of each single string corresponds to the capacity of a battery, whereas for parallel series it results in the sum of all the strings. In this manner it is possible to increase system autonomy.

Pag. 37 di 47

7.1

INTERNAL BATTERIES

The internal batteries are arranged on pullout drawers with 8 batteries each. The size of the drawer allows housing of 7 A/h capacity batteries. Therefore total capacity may be 7 (4 drawers) or 14 A/h (8 drawers). To access the battery compartment remove the side door by unscrewing the four fastening screws in the corners. Now you can restore the jumpers as shown in the picture.

Jumper to be restored

Picture 25 7.2 EXTERNAL BATTERY CABINETS

In order to have a wide range of autonomy the U.P.S. has a series of cabinets with variable sizes and capacities (chart 7), which range from (with single cabinet) 7 Ah up to 200Ah. Each cabinet has a series of breakers, one fuse, the jumpers to restore connections (for battery safety, the batteries will be disconnected for transporte then get connected later), the cabinet key and the terminal board. The connecting terminal board has two terminals for each pole, in this manner it is possible to put several batteries in parallel (up to a maximum of six)(picture 26). + . U.P.S + + + + + + -

Battery cabinet 1

Battery cabinet 2

Battery cabinet 6

Picture 26 The cabinet code indicates the type of cabinet and also the number of batteries housed in it. With these last two parameters you can establish total available capacity (A/h). For instance, if you have a cabinet containing 96 7 A/h batteries, knowing that the string is composed of 32 batteries, if you divide 96/32= 3, you get the total number of strings, which multiplied by the capacity of each single string gives total capacity: 3 (strings) X 7 (A/h) = 21 A/h total capacity. T2K BX XXX XXX

Type

The X gives the number for size identification

The Xs give the number for battery capacity

The Xs give the number for the amount of batteries

Chart 6

Pag. 38 di 47

Cabinet model

Available autonomy in A/h

Sizes Width Depth Height

B2 Special solution, 2 battery in one cabinet

28

600

800

120

Chart 7

7.2.1 DESCRIPTION OF THE B2 BATTERY CABINET

The B2 battery cabinet, apart from having similar aesthetic mechanical characteristics to the U.P.S., also maintains the same size parameters as the models up to 50KVA. It has four drawers who can include a string of batteries each, in this manner it is possible to have four different total capacities according to the number of drawers used. The internal wiring is for the maximum number of batteries, which may be placed inside, therefore it is prepared for possible expansion. The area assigned to connections and protection devices is situated under the roof. To access this area you must remove the four fastening screws in the corners of the roof. Apart from the materials listed in picture 27, there are also the battery jumpers. Polystyrene strips are inserted around the batteries for transport protection and they must be removed when installing. To connect to the U.P.S. we suggest using the specific cable passage. The use of both cable passages will occur when you are connecting battery cabinets in parallel.

Battery UPS !

Battery UPS 2

Jumper to be restored

Pag. 39 di 47

7.2.2 DESCRIPTION OF THE B2 BATTERY CABINET WITH BATTERIES FROM 40A/H

The B2 battery cabinet, apart from having similar aesthetic mechanical characteristics to the U.P.S., also maintains the same size parameters as the models up to 50KVA. The area assigned to connections and protection devices is situated under the roof. To access this area you must remove the four fastening screws in the corners of the roof. Apart from the materials listed in picture 28, there are also the battery jumpers. To connect to the U.P.S. we suggest using the specific cable passage. The use of both cable passages will occur when you are connecting battery cabinets in parallel.

CABLE PASSAGE FUSE

DISCONNECTING SWITCH TERMINAL BOARD

BATTERY SHELF SEEN FROM ABOVE

JUMPERS TO BE RE-CONNECTED

Picture 28

Pag. 40 di 47

7.2.3 DESCRIPTION OF THE B3 BATTERY CABINET WITH BATTERIES FROM 65A/H

The B3 battery cabinet, apart from having similar aesthetic mechanical characteristics to the U.P.S., also maintains the same size parameters as the models from 60 to 100KVA. The area assigned to connections and protection devices is situated under the roof. To access this area you must remove the four fastening screws in the corners of the roof. Apart from the materials listed in picture 29, there are also the battery jumpers. To connect to the U.P.S. we suggest using the specific cable passage. The use of both cable passages will occur when you are connecting battery cabinets in parallel.

CABLE PASSAGE FUSES

DISCONNECTING SWITCH TERMINAL BOARD

Battery shelf seen from above

JUMPERS TO BE RE-CONNECTED

Chart 29

Pag. 41 di 47

7.2.4 DESCRIPTION OF THE B4 MODEL BATTERY CABINET FROM 65 UP TO 130 A/H

The battery disposition independent from the capacity In the 2nd, 3rd and 4th planes there are 8 battery elements, and in the 1st and the last one there are 4 battery elements In the 5th plane there is the battery breaker and the protection fuse, while in the 1st plane there are the short circuits for the intenal connections and the disposition for the ground connection.

VERTICAL VIEW FOR BATTERY PLANE

BATTERY PLANES

JUMPERS TO BE RE-CONNECTED

Chart 30

Pag. 42 di 47

TECHNICAL CHARTS MECHANICAL DATA Size kVA 10 15 20 30 40 50

Dimensions (mm) weight (Kg) Surface (mq) Load (Kg/mq) Protection degree Cable entrance Cooling Colour N of cabinets Chart 8c MECHANICAL DATA Size kVA Dimensions (mm) weight (Kg) Surface (mq) Load (Kg/mq) Protection degree Cable entrance Cooling Colour N of cabinets Chart 8c MECHANICAL DATA Size in kVA Dimensions (mm) weight (Kg) Surface (mq) Load (Kg/mq) Protection degree Cable entrance Cooling Colour N of cabinets Chart 8c

600x750x1200 250 260 270 280 290 310 0,42 556 578 600 622 645 918 IP 21 Bottom front Forced ventilation with 1 ventilators Forced ventilation with 2 ventilators Cabinet: RAL 7035 Panel and fittings: RAL 7010 1 1 1 1 1 1

60 580 967

80 800x750x1200 620 0,60 1050

100 660

120

150

1118 IP 21 Bottom front Forced ventilation with 3 ventilators Forced ventilation with 5 ventilators Cabinet: RAL 7035 Panel and fittings: RAL 7010 1 1 1 1

1400x750x1200 680 710 1,05 644 676

200 1400x750x1200 920 1,05 876

250 1600x1000x1800 1,6

300

400 2600x1000x1800 2900 2,6 1115

IP 21 Bottom front Right front Forced ventilation with 5 ventilators Forced ventilation with 10 ventilators Cabinet: RAL 7035 Panel and fittings: RAL 7010 1 1

Pag. 43 di 47

CABLE AND FUSE CHART SIZE Kva Rectifier input fuse (A) Reserve input fuse(A) Battery fuse(A) Main input cable(mm2) Reserve input cable(mm2) Output cable (mm2) Battery cable (mm2) Chart 9a 10 3x32 3x50 1x50 3x6 4x6 4x6 2x6 15 3x32 3x50 1x50 3x6 4x6 4x6 2x6 20 3x50 3x80 1x80 3x10 4x10 4x10 2x10 30 3x80 3x100 1x100 3x16 4x16 4x16 2x16 40 3x100 3x125 1x125 3x25 4x25 4x25 2x25 50 3x125 3x160 1x160 3x35 4x35 4x35 2x35 60 3x125 3x200 1x200 3x50 4x50 4x50 2x50

CABLE AND FUSE CHART SIZE Kva Rectifier input fuse (A) Reserve input fuse(A) Battery fuse(A) Main input cable(mm2) Reserve input cable(mm2) Output cable (mm2) Battery cable (mm2) Chart 9b 80 3x200 3x200 1x315 3x70 4x70 4x70 2x70 100 3x315 3x315 2x400 3x70 4x70 4x70 2x70 120 3x315 3x315 1x400 3x95 4x95 4x95 4x70 150 3x400 3x400 1x415 3x95 4x95 4x95 4x70 200 3x400 3x400 1x630 3x95 4x95 4x95 4x95 250 3x400 3x400 1x630 6x70 8x70 4x95 300 3x630 3x630 2x630 6x70 8x70 8x70
Copper bars

400 3x630 3x630 2x1250 9x70 12x70 12x70

RECTIFIER INPUT SIZE in Kva Rated voltage Input voltage tolerance Minimum input voltage without discharging the battery @ rated load Rated frequency Frequency tolerance Maximum power absorbed with the batteries when charging in KVA Maximum current absorbed with battery @400Vac @ rated Iout in A Cos @ 380Vac and rated Iout Input current distortion @ rated Iout Start up time Rpercentage efficiency with batteries in buffer charge Chart 10 Pag. 44 di 47 10 15 20 30 40 50 60 80 100 120 150 200 250 300 400 380/400/415 V 3F 400Vac -12%/+16% 415Vac -18%/+10% 340 Vac 50/60 Hz 5%
14,1 19,7 27 39,2 53 64,1 77,8 105 133 155 188 254 308 363 472

380Vac -10%/+18%

20,4

28,5

39

56,6

76,5

92,5

112

152

192

224

271

367

446

525

683

0,82 30 % 8% with THD filter 20 seconds

97,8 97,8 97,9 98,1 98,2 98,2 98,3 98,3 98,4 98,4 98,5 98,5 98,6 98,6 98,7

RECTIFIER OUTPUT SIZE in Kva Rated battery voltage Rated buffer charge Boost charge voltage Working dynamics Stability with dynamic variation of the input voltage and the output current Ripple in buffer charge Maximum output current (A) Maximum adjustable battery current Chart 11 10 15 20 30 40 50 60 80 100 120 150 200 250 300 400 384 V (192 EL/V or 32m/b 12V) 436 V regulable 442 V regulable 320-480 V 1% < 1%
25,3 5 35,6 5 48,4 8 70,5 10 95,4 15 115 15 140 20 190 30 240 40 280 40 340 40 459 60 558 60 657 60 855 60

INVERTER INPUT SIZE in Kva Rated voltage Working range Current @ rated Iuot @ Vdc 320 in ampere Working dynamics Stability with dynamic variation of the input voltage and the output current Ripple in buffer charge Chart 12 10 15 20 30 40 50 60 80 100 120 150 200 250 300 400 384 V 320/480 V
218 272 326 408 543 678 812
1084

27,7

41,4

55,1

82,4

110

137

164

320-480 V 1% < 2%

STATIC COMMUTATOR Size in Kva Rated voltage Rated frequency Frequency range Voltage tolerance Working range 50% overload 1000% Efficiency Mainswith inverter, synchrony inverter-mains without transfer time synchrony Chart 13 10 15 20 30 40 50 60 80 100 120 150 200 250 300 400 380/400/415 V 3F + N 50/60 Hz 304/488 V 30 minutes 100 ms 99,5 % 0 seconds 20 ms

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INVERTER OUTPUT SIZE in Kva Rated voltage Rated current @ cos 0,8 @ 400 V output 10 15 20 30 40 50 60 80 100 120 150 200 250 300 400 380/400/415 V 3F + N
116 145 173 217 289 361 434 578

14,5 21,7 28,9 43,4 57,8 72,3 86,7

50/60 Hz Rated frequency Wave type With linear charge THD With crest factor 3:1 Static stability with V variation in Dynamic stability with load variation from 0 to 100% Voltage restore time With mains synchrony Frequency stability From internal quartz Applicable crest factor (Ipk/Irms) 110 % Overloading at 125 % 25 C 150 % Balanced load Voltage symmetry 100% unbalanced load sinusoidal 1,5% 5% 1% 5% 10 ms 1% ; 1,5% ; 2,4% 0,001% 3.01 60 minutes 10 minutes 1 minute 1% 5% 120 1 120 3
91,2 91,4 91,6 91,8 92,1 92,2 92,3 92,5 92,6 92,7 92,8 92,9 93 93,1 93,1

Balanced load Phase angle 100% toleration unbalanced load Efficiency with a 100% load

Chart 14

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SYSTEM SIZE in Kva Efficiency AC/AC @ Cos 0,8 Vin 400V Vout 400V 100% Noise @ 1 meter in db(A) Working temperature Relative humidity @ 20C Power derating over 1000 meters above sea level MTBF KHR 10
88,4

15
88,6

20
88,7

30
89,2

40
89,6

50
89,7

60
89,9

80
90,1

100 120 150 200 250 300 400

90,3 90,4 90,6 90,7 90,9 91 91

55 0C 40C < 90% 5% every 1000 meters 200

Chart 15 I

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