AEG 64500G-M Operating instructions

UPS OPERATING INSTRUCTIONS
PROTECT 1.
PROTECT 1.100
PROTECT 1.150
PROTECT 1.200
Thank you for deciding to purchase the PROTECT 1. UPS
from AEG Power Solutions.
The following safety instructions are an important part of
the operating instructions are will protect you against
problems from operating errors and possible dangers.
Please read these instructions carefully prior to
commissioning!
2
1
Notes on these Operating
Instructions
Duty to provide information
These operating instructions will help you to install and
operate the Uninterruptible Power Supply (UPS), PROTECT
1.100, PROTECT 1.150 or PROTECT 1.200 as well as the
corresponding external battery units PROTECT 1.100 BP or
PROTECT 1.BP20, all referred to as PROTECT 1 in the
following, safely and correctly. These operating instructions
contain important information for avoiding dangers.
Please read these instructions carefully prior to
commissioning!
These operating instructions are an integral part of
PROTECT 1.
The owner of this unit is obliged to communicate the full
content of these operating instructions to all personnel
transporting or starting the PROTECT 1 or performing
maintenance or any other work on the unit.
Validity
These operating instructions comply with the current technical
specifications of PROTECT 1. at the time of publication. The
contents do not constitute a subject matter of the contract, but
serve for information purposes only.
Warranty and liability
We reserve the right to alter any specifications given in these
operating instructions, especially with regard to technical data
and operation.
Claims in connection with supplied goods must be submitted
within eight days of receiving the goods, along with the
packing slip. Subsequent claims cannot be considered.
The warranty does not apply for damage caused by noncompliance with these instructions (such damage also
includes damage to the warranty seal). AEG will accept no
3
liability for consequential damage. AEG will rescind all
obligations such as warranty agreements, service contracts,
etc. entered into by AEG or its representatives without prior
notice in the event of maintenance and repair work being
carried out with anything other than original AEG parts or
spare parts purchased from AEG.
Handling
PROTECT 1. is designed and constructed so that all
necessary steps for start-up and operation can be performed
without any internal manipulation of the unit. Maintenance and
repair work may only be performed by trained and qualified
personnel.
Illustrations are provided to clarify and facilitate certain steps.
If danger to personnel and the unit cannot be ruled out in the
case of certain work, it is highlighted accordingly by
pictographs explained in the safety regulations of chapter 3.
Hotline
If you still have questions after having read these operating
instructions, please contact your dealer or our hotline:
Tel:
+49 (0)180 5 234 787
Fax:
+49 (0)180 5 234 789
Internet: www.aegpartnernet.com
Copyright
No part of these operating instructions may be transmitted,
reproduced and/or copied by any electronic or mechanical
means without the express prior written permission of AEG.
© Copyright AEG 2009. All rights reserved.
4
Table of Contents
1
2
Notes on these Operating Instructions .............................3
General Information ..........................................................7
2.1 Technology ................................................................7
2.2 System Description....................................................8
2.3 Technical Data.........................................................11
3 Safety Regulations ..........................................................15
3.1 Important Instructions and Explanations .................15
3.2 Accident Prevention Regulations.............................15
3.3 Qualified Personnel .................................................16
3.4 Safety Instructions for PROTECT 1. .......................16
3.5 CE Certificate...........................................................20
4 Set-up..............................................................................20
4.1 Unpacking and Inspection .......................................21
4.2 Transport to Installation Site....................................22
4.3 Set-Up......................................................................23
4.4 Overview: Connections, Operating / Display
Elements..................................................................24
4.4.1 Front view...........................................................24
4.4.2 Display ...............................................................25
4.4.3 Rear view (connections): ...................................26
5 Electrical Connection ......................................................28
5.1 Safety of Personnel .................................................29
5.2 Mains Connection (General)....................................29
5.3 Checklist for Cable Connections .............................29
5.3.1 Connection Cross-Sections and Fuse Protection ... 30
5.4
Mains Connection.............................................................. 31
5.4.1 Preparation for the three-phase mains connection. 31
5.4.2 Connection of the Three-Phase Input Mains
Voltage ...............................................................31
5.4.3 Preparation of the Output Cabling .....................32
5.4.4 Connection of the Loads ....................................33
5.5 Connection of External Battery Modules .................33
5.5.1 Connection of the Battery Cubicle
PROTECT 1.100 BP ..........................................34
5.5.2 Connection of the Battery Cubicle
PROTECT 1.BP20 .............................................35
5.6 Mechanical Blocking of PROTECT 1. .....................36
5
6
Start-Up...........................................................................37
6.1 Operating Modes .....................................................38
6.1.1 Normal Operation...............................................38
6.1.2 Battery Operation / Autonomous Operation.......39
6.1.3 Bypass Operation ..............................................40
6.1.4 Manual Bypass ..................................................41
6.1.5 Unit overload ......................................................42
7 Interfaces and Communication .......................................43
7.1 Computer Interface RS232......................................43
7.2 Communication Slot ................................................43
7.3 Shutdown and UPS Management Software............43
8 Displays and Troubleshooting.........................................45
8.1.1 Signalling............................................................45
8.1.2 Overview Table of LED Displays / Acoustic
Warning Signals .................................................47
8.2 Faults .......................................................................49
8.2.1 Error Messages..................................................49
9 Parallel Operation ...........................................................51
9.1 Principle of Operation ..............................................51
9.2 Set-up / Connection of Parallel Operation Board ....52
9.3 Operation of the UPS in a parallel system ..............53
9.3.1 Start-Up..............................................................53
9.3.2 Changes to the parallel system..........................56
10 Maintenance....................................................................57
10.1 Charging the Battery................................................57
10.2 Checks.....................................................................57
10.2.1 Visual Check ......................................................57
10.2.2 Checking the Battery..........................................58
10.2.3 Fan Check..........................................................58
11 Storage, Dismantling and Disposal.................................59
11.1 Storage ....................................................................59
11.2 Dismantling ..............................................................59
11.3 Disposal ...................................................................59
12 List of Terms ...................................................................60
12.1 Technical terminology..............................................60
6
2
General Information
2.1
Technology
i
PROTECT 1. is an Uninterruptible Power
Supply (UPS) for essential loads such as small
data centres, servers, network components,
telecommunications equipment and similar
units. It consists of:
♦ Mains filter with overvoltage protection (appliance
protection / class D) and mains energy backfeed
protection
♦ Rectifier section with PFC logic
(power factor correction unit)
♦ Separate battery charger with
switch mode power supply technology
♦ IGBT inverter for continuous supply of connected loads
with sinusoidal AC voltage
♦ Automatic electronic bypass (SBS)
as additional, passive redundancy
SBS = Static Bypass Switch
♦ Manual bypass for maintenance and
service purposes (with automatic
SBS activation upon actuation)
♦ Control unit
on the basis of digital signal processor technology
7
2.2
System Description
The UPS is connected between the public utility mains and
the loads to be protected.
The power section of the rectifier converts the mains voltage to
DC voltage for supplying the inverter. The circuit technology
used (PFC) enables sinusoidal current consumption and
therefore operation with little system disturbance. A separate,
second rectifier (charging REC set up using switch mode power
supply technology) is responsible for charging or trickle-charging
the battery connected in the intermediate circuit. The
configuration of this charging REC means the harmonic content
of the charging current for the battery is almost zero, which
increases the service life of the battery even more. The inverter
is responsible for converting the DC voltage into a sinusoidal
output voltage. A microprocessor-driven control based on a
pulse-width modulation (PWM) guarantees, in conjunction with
digital signal processor technology and extremely fast pulsating
8
IGBT power semiconductors of the inverter, a voltage system of
the highest quality and availability on the secured busbar.
In the event of mains faults (such as e.g. current failures), the
voltage continues to be supplied from the inverter to the load
without any interruption. From this point onwards, the inverter
draws its power from the battery instead of the rectifier. Since no
switching operations are necessary, there is no interruption in
the supply to the load.
The automatic electronic bypass serves to increase the reliability
of the supply further, especially in the case of individual systems.
It switches the public mains directly through to the load without
any interruption, e.g. when there is an inverter malfunction. As a
result, the automatic bypass represents an extra passive
redundancy for the load.
An integrated, manually operated bypass unit ensures an
uninterrupted supply to the connected loads in the case of
maintenance and/or service work. The internal electronic part
(with the exception of the metal-clad manual bypass) can be
disconnected via the mains input miniature circuit breakers.
The greatest possible supply reliability of connected loads is
attained by the parallel connection of up to max. three
PROTECT 1. UPS systems. The n+x technology thus
guarantees maximum reliability through up to double active
redundancy on the one hand as well as on the other hand the
possibility of increased power with simple redundancy or even
only higher UPS power without any redundancy. The relationship
between the available output power and the degree of active
redundancy can be seen in the following overview:
Parallel system with PROTECT 1.100
Number of UPS units
Available power
Active
redundancy
degree
1
2
3
0
10 kVA
20 kVA
30 kVA
1
---
10 kVA
20 kVA
2
---
---
10 kVA
9
Parallel system with PROTECT 1.150
Number of UPS units
Available power
Active
redundancy
degree
1
2
3
0
15 kVA
30 kVA
45 kVA
1
---
15 kVA
30 kVA
2
---
---
15 kVA
Parallel system with PROTECT 1.200
Number of UPS units
Available power
Active
redundancy
degree
1
2
3
0
20 kVA
40 kVA
60 kVA
1
---
20 kVA
40 kVA
2
---
---
20 kVA
10
2.3
Technical Data
Type rating
PROTECT 1.100
10000 VA (cos ϕ = 0.7 ind.)
7000 W
PROTECT 1.150
15000 VA (cos ϕ = 0.7 ind.)
10500 W
PROTECT 1.200
20000 VA (cos ϕ = 0.7 ind.)
14000 W
UPS input
3ph~ / N / PE
Rated connection voltage
Voltage range without
battery operation
400 V/ 230 VAC
304 VAC – 478 VAC ± 3 %
(rectifier)
176 VAC – 261 VAC VAC ± 3 %
(bypass)
Frequency
50 Hz / 60 Hz
(autom. detection)
Frequency tolerance range
± 4 Hz
Current consumption at full load (max.)
PROTECT 1.100
13 A (3ph~) / 46 A (bypass)
PROTECT 1.150
19 A (3ph~) / 68 A (bypass)
PROTECT 1.200
25 A (3ph~) / 91 A (bypass)
System disturbance factor
λ
0.95
UPS output
Nominal voltage output
Nominal frequency
Type of voltage
Crest factor
220 / 230 / 240 VAC ± 1%
(configuration via
“CompuWatch” software )
50 Hz / 60 Hz ± 0.1%
(dependent on mains frequency)
Sine, distortion
2% THD (linear load)
6% THD (non-linear load)
3:1
11
Overload behaviour
with mains supply
Overload behaviour with
battery operation
Short-circuit behaviour
Up to 105% continuous;
> 105% – < 130% for 10 min.
130% for 1 s
Following this, automatic,
uninterrupted switchover to
integrated bypass (SBS).
Switch-off after 1 min if overload
continues to be present. (Switch
back if overload decreases = load
< 90%)
Up to 105% continuous;
> 105% for 10 s
2.5 x IN for 100 ms
Battery
Standby times with external standard battery units
Standby times (full load / half load) [min.]
PROTECT
1.100
PROTECT
1.150
PROTECT
1.200
1 x PROTECT 1.100 BP
16 / 42
---
---
5h
2 x PROTECT 1.100 BP
42 / 97
---
---
7h
---
10h
Coupled
battery cubicles
Recharging time
to 90% capacity
3 x PROTECT 1.100 BP
60 / 134
---
1 x PROTECT 1. BP 20
19 / 47
10 / 29
6 / 19
2 x PROTECT 1. BP 20
47 / 103
29 / 68
19 / 47
9h
3 x PROTECT 1. BP 20
78 / 77
47 / 103
34 / 62
13h
4 x PROTECT 1. BP 20
103 / 243
68 / 153
47 / 103
18h
5 x PROTECT 1. BP 20
138 / 312
85 / 202
63 / 138
24h
5h
Nominal DC voltage (intermediate circuit): 240 VDC
Trickle charge voltage: 274 VDC ± 1%
Battery charging current (max.): 4.2 ADC
Type
Sealed, maintenance-free
PROTECT 1.100 BP
2x20 blocks 12V 9Ah,
e.g. CSB HR 1234WF2
PROTECT 1.BP20
1x20 blocks 12V 20Ah,
e.g. Panasonic LC-X1220P
12
Communication
Interfaces
Shutdown software on CD
RS232
Sub-D (9-pin)
Additionally: Communication slot
for expansions (e.g. AS/400 /
USB / remote signal indicator /
SNMP, …)
“CompuWatch” for all common
operating systems, e.g.
Windows, Linux, Mac, Unix,
FreeBSD, Novell, Sun
General data
Classification
Full load efficiency
( AC-AC / DC-AC )
Inherent noise (1m distance)
PROTECT 1.100
PROTECT 1.150
PROTECT 1.200
Cooling type
Operating temperature range
Storage temperature range
Relative humidity
Site altitude
VFI SS 111 acc. to IEC 62040–3
Sustained transformer
technology
> 90% / > 88%
< 55 dB(A)
< 60 dB(A)
< 60 dB(A)
Forced air cooling through
variable-speed fans
0°C to +40°C
Recommended: +15°C to +25°C
(due to battery system)
0°C to +40°C
< 95% (without condensation)
Up to 1000 m at nominal output
Use more than 1000 m above
sea level results in the following
reduction in output power:
Height(m)
1000
1500
2000
2500 3000
Output power
100%
95%
90%
85%
13
80%
Housing colour:
Weight:
PROTECT 1. 100
PROTECT 1. 150
PROTECT 1. 200
PROTECT 1. 100 BP
PROTECT 1. BP20
Dimensions W x H x D:
PROTECT 1.100/1.150/1.200
PROTECT 1.100 BP
PROTECT 1. BP 20
Blackline
39 kg
55 kg
55 kg
135 kg
170 kg
260 mm x 717 mm x 670 mm
260 mm x 717 mm x 670 mm
260 mm x 717 mm x 810 mm
Directives
The PROTECT 1. meets the product standard EN 50091.
The CE mark on the unit confirms compliance with the EC
outline directives for 73/23 EEC – Low voltage and for 89/336
EEC – Electromagnetic compatibility if the installation
instructions described in the operating instructions are
observed.
For 73/23 EEC low-voltage
directive reference number
EN 62040-1-1 : 2003
For 89/336 EMC directive
reference number
EN 50091-2 : 1995
EN 61000-3-2 : 1995
EN 61000-3-3 : 1995
i
Warning:
This is a product for industrial and commercial
use in the second environment – to prevent
malfunctions, restrictions on the installation or
additional measures may be required.
14
3
Safety Regulations
3.1
Important Instructions and Explanations
The instructions for operation and maintenance, as well as
the following safety regulations must be complied with to
ensure the safety of personnel as well as the continued
availability of the unit. All personnel installing/dismantling,
starting up, operating or servicing the units must be familiar
with and observe these safety regulations. Only trained and
qualified personnel may perform the work described, using
tools, equipment, test equipment and materials intended for
the purpose and in perfect working condition.
Important instructions are emphasized by the words
“Caution”, “Attention”, “Note” and indented text.
Caution
This symbol identifies all working and operational
procedures requiring absolute compliance to
avoid any danger to persons.
Attention
This symbol identifies all working and operational
procedures requiring absolute compliance to
prevent any damage, irreparable or otherwise, to
the unit and its components.
i
3.2
Note
This symbol identifies technical requirements and
additional information requiring the operator's
attention.
Accident Prevention Regulations
Compliance with the accident prevention regulations valid in
the respective country of use and the general safety
regulations in accordance with IEC 364 is mandatory. The
following safety rules must be observed prior to performing
any work on the PROTECT 1.:
♦ Disconnect the unit from the power supply
♦ Secure the unit against being switched back on
15
♦ Verify that the unit is disconnected from the power
supply
♦ Earth and short-circuit the unit
♦ Provide protection by covers or barriers for any
neighbouring live parts
3.3
Qualified Personnel
The PROTECT 1. may only be transported, installed,
connected and serviced by qualified personnel who are
familiar with the pertinent safety and installation regulations.
All work performed must be inspected by responsible expert
personnel.
The qualified personnel must be authorised by the
responsible safety officer of the installation to perform the
work required.
Qualified personnel is defined as personnel
♦ having completed training and gained experience in the
respective field,
♦ familiar with the pertinent standards, rules and
regulations and accident prevention regulations,
♦ having received instruction on the mode of operation
and operating conditions of the PROTECT 1.,
♦ capable of recognising and preventing dangers.
Regulations and definitions for qualified personnel can be
found in DIN 57105/VDE 0105 Part 1.
3.4
Safety Instructions for PROTECT 1.
The UPS is live, and the voltage can be
dangerous. The unit may only be installed and
if necessary opened by trained and qualified
personnel. Repairs may only be carried out by
qualified customer service staff!
The output can be live, even when the UPS is not
connected to the mains supply!
16
For health and safety reasons, the unit must be
earthed correctly!
The PROTECT 1. may only be operated with or connected to
a three-phase power system with protective grounding using
a mains connection cable with PE conductor that has been
tested according to German standards (VDE).
Risk of burning!
The battery has powerful short-circuit currents.
Incorrect connection or isolation faults can lead to
melting of the plug connections, sparking potential
and severe burns!
The unit has a warning signal that sounds when
the battery voltage of PROTECT 1. is exhausted
or when the UPS is not working in its normal
mode (see also chapter 8 "Signalling”, page 47
and the following).
Observe the following safety instructions to
ensure permanent operational safety of and safe
work with the UPS and the battery modules
(special accessories):
♦ Do not dismantle the UPS!
(The UPS does not contain any parts that require
regular maintenance. Bear in mind that the warranty
will be invalidated if the unit is opened!)
♦ Do not install the unit in direct sunshine or in close
proximity of heaters!
♦ The unit is designed to be installed inside in heated
rooms. Never install the housing in the vicinity of water
or in an excessively damp environment!
♦ Condensation may occur if the UPS is brought from a
cold environment into the room where it is to be
installed. The UPS must be absolutely dry prior to startup. As a result, leave it to acclimate for at least two
hours.
♦ Never connect the mains input and the UPS output!
17
♦ Ensure that no fluids or foreign bodies can penetrate
the housing!
♦ Do not block the air vents of the unit! Make sure, for
example, that children do not insert any objects in the
ventilation openings!
♦ Do not connect household appliances such as
hairdryers to the UPS! Also take care when working
with motor loads. It is essential to avoid back-feeding
the inverter, e.g. if the load is intermittently operated in
regenerative mode.
Danger! Electric shocks!
Even after the mains voltage has been
disconnected, the components within the UPS
remain connected to the battery and can thus
cause electric shocks. It is therefore imperative
to disconnect the battery circuit before carrying
out any maintenance or repair work!
If it is necessary to replace the battery or carry
out maintenance work, this must be done by or
under the supervision of a specialist familiar
with batteries and the necessary safety
precautions!
Only authorized persons are allowed in the
vicinity of the batteries!
When replacing the batteries, the following must be observed:
Only ever use identical, maintenance-free sealed lead
batteries with the same data as the original batteries.
Danger! Explosive!
Never throw batteries into open fire.
Never open or damage batteries. (Electrolyte
may leak out and damage skin and eyes. It may
be toxic!)
Batteries can cause electric shocks and high
short-circuit currents.
18
Therefore, take the following safety precautions when working
with batteries:
♦ Take off watches, rings and other metallic objects!
♦ Only use tools with insulated handles!
i
Avoid using multiple outlet adapters with a
central on/off switch as protection against
uncontrolled load switch-off as well as for
avoiding peak inrush currents.
Switch OFF the UPS using its main switch if you do not intend
to use it for some time. PROTECT 1. must be switched off
every evening if the electricity supply in your company is
switched off every night. Otherwise, the battery will be
discharged. Frequent and exhaustive discharging of the
battery leads to a shorter service life of the battery and should
therefore be avoided!
For personal safety reasons, never switch on
the main switch when the mains connector of
PROTECT 1. is disconnected!
19
3.5
CE Certificate
20
4
Set-up
4.1
Unpacking and Inspection
The unit has been completely checked and inspected.
Although the unit has been packed and shipped with the
usual care, transport damage cannot be completely excluded.
i
Any claims due to transport damage must
always be asserted against the transport
company!
Check the shipping container for damage on arrival. If
necessary, ask the transport company to check the goods
and make a record of the damage in the presence of the
transport company employee and report the damage to the
AEG representative or dealer within eight days of delivery.
Check that the delivery is complete:
♦ PROTECT 1. with 10000, 15000 or 20000 VA
♦ Cable clamping unit
♦ Special battery connection cable (PROTECT 1.100)
♦ 25-pin parallel operation cable
♦ RS232 communication cable
♦ Management software “CompuWatch” on CD
♦ Operating instructions
Delivery of external battery modules includes:
♦ External battery unit
♦ Battery connection cable
♦ Battery fuses and terminal connectors (PROTECT 1.
BP20)
Please contact our hotline (see page 4) in case of any
discrepancy.
The original packaging provides effective protection against
mechanical shocks and should be retained so the unit can be
transported safely later on.
21
Please keep plastic packaging bags away from babies and
children in order to safeguard against suffocation accidents.
Handle the components with care. Please take into account
the weight. It may be necessary to engage the help of a
second person.
4.2
Transport to Installation Site
The PROTECT 1. is equipped with transport rolls for easy
transport to the intended installation site. It is recommended
to install the UPS where:
♦ The connection work can be conveniently carried out;
♦ There is enough space for proper operation and, if
necessary, for periodic and extraordinary maintenance
work; in this regard, the connection cables should be
long enough to move the UPS (to open the UPS if
necessary) without having to switch it off.
♦ The use of an external manual bypass is recommended
♦ The UPS is protected against external atmospheric
influences;
♦ The humidity and the ambient temperature are within
the limits;
♦ The fire protection standards are observed.
The battery service life strongly depends on the ambient
temperature. Ambient temperatures between+ 15° and + 25°C
are optimum.
Attention!
Only transport the PROTECT 1. in an upright
position! Never tilt or cant it; avoid displacing
the centre of gravity!
Make sure that no magnetic storage media are stored and/or
operated close to PROTECT 1.
22
4.3
Set-Up
Note the following points when setting up the UPS system
and its external battery units (special accessories):
♦ The contact surface must be smooth and level. It must
also be sufficiently strong and sturdy to avoid vibration
and shocks.
♦ Make sure that the mounting is able to support the
weight, especially in conjunction with external battery
units (special accessories).
♦ Set up the units so that adequate air circulation is
assured. There must be at least 200 mm clearance
behind the rear fans for ventilation purposes. Do not
block the intake openings on the front and, if present,
on the side of the unit. There must be a gap of at least
50 mm here.
♦ External battery units must be placed on the side of the
UPS system. To ensure the greatest possible
mechanical stability, do not place the external battery
unit(s) above or below the UPS system.
♦ Avoid extreme temperatures! We recommend an
ambient temperature from 15°C to 25°C in order to
maximize the service life of the batteries. Do not
expose the units to direct sunlight or operate them
close to other heat sources such as radiators.
♦ Protect the units against external effects (in particular
moisture and dust). In this regard, please also refer to
the instructions in chapter 3, page 15 in these operating
instructions.
If you transport the unit from a cold room into a warm one, or
if the room temperature suddenly drops, then condensation
may form inside the unit. To avoid any damage due to
condensation, let the unit acclimate for 2 hours before you
switch it on.
23
4.4
Overview: Connections, Operating / Display
Elements
4.4.1
Front view
PROTECT 1.100
PROTECT 1.150
PROTECT 1.100BP
PROTECT 1.BP20
24
PROTECT 1.200
4.4.2
Display
12
11
10
9
8
7
3
6
4
5
2
1.
2.
3.
4.
5.
6.
7 – 11.
7.
8.
9.
10.
11.
12.
1
OFF pushbutton
ON pushbutton / alarm off
Orange-coloured Bypass LED
Green Inverter LED
Orange-coloured Battery LED
Green Line LED
Bar graph LED (7-10 green, 11 orange-coloured)
for UPS capacity utilisation or remaining battery
capacity
LED load (0-35%)
battery capacity (96-100%)
LED load (36-55%) battery capacity (76-95%)
LED load (56-75%) battery capacity (51-75%)
LED load (76-95%) battery capacity (26-50%)
LED load (96-105%) battery capacity (0-25%)
Red Fault LED
A detailed explanation of the displays is found on page 45.
25
4.4.3
Rear view (connections):
PROTECT 1.100
8
7
6
13
5
11
2
3
11
10
9
4
1.1
1.2
1.3
1
N
L1
L2 L3 JP1 JP2 L
N
PROTECT 1.150 / 1.200
6
6
13
12
11
7
5
11
10
9
8
2
1
1.1
3
N
L1 L2 L3
26
1.3
4
+
-
L
N
1.2
JP1
JP2
Explanations:
1.
Connection terminal cover for mains/UPS input
(1.1) and output (1.3), additional pair of terminals
for setting individual or parallel operation (1.2);
Battery connection terminals
(PROTECT 1.150 / 1.200)
2.
Mains input miniature circuit breaker
3.
Manual bypass switch
4.
Socket for external battery module
(PROTECT 1.100) or connection terminals for
external battery (PROTECT 1.150/1.200)
5.
Connectors for parallel operation
6.
Fan (attention: Leave at least 10 cm clearance
behind fan for unobstructed airflow out!)
7.
Communication slot for optional expansion boards:
SNMP, AS/400, USB
8.
Communication interface RS232 (Sub-D9)
9.
Cable clamping unit (is mounted instead of the
cover from no. 1)
Strain relief clamps
PE/earthing terminals
Macrolon plate as additional insulation to prevent
short circuits when using uninsulated cable lugs
(PROTECT 1.150/1.200)
Cover of the cable clamping unit
10.
11.
12.
13.
27
5
Electrical Connection
Caution
Prior to commencing work, ensure that the
connection cables are de-energised and that it
is not possible to activate the power supply.
i
In order to avoid deformation of the supporting
rail and to protect the base of the connection
terminal against torsional forces, it is advisable
to hold the cable in position when tightening the
clamping screw.
The protective measure of earth connection serves to prevent
excessive touch voltage on freely accessible metal parts. The
PROTECT 1. is earthed by the provided earthing bolts (
/
PE). Prior to start-up, it must be ensured that the PROTECT 1. is
earthed in accordance with valid regulations, e.g. VDE 0100.
Before the connection work is carried out, check that:
♦ The values of the nominal voltage (input voltage) and
frequency match those on the nameplate of the UPS.
♦ The earth connection matches the prescribed IEC
standards or the local regulations,
♦ The UPS is connected to the electrical mains via a
separate supply line equipped with fuses on the supplyside MI distribution.
♦ The power fuse in the MI distribution has the same or
higher value as the one indicated on the nameplate of
the UPS system.
28
5.1
Safety of Personnel
Note the following points when setting up the UPS system
and its external battery units (special accessories):
♦ Disconnect the unit from the power supply
♦ Secure the unit against being switched back on
♦ Verify that the unit is disconnected from the power
supply
♦ Earth and short-circuit the unit
♦ Provide protection by covers or barriers for any
neighbouring live parts
5.2
Mains Connection (General)
In order to ensure the correct functioning of the UPS and its
additional equipment, it is necessary to equip the mains cable
with the corresponding fuses.
5.3
Checklist for Cable Connections
The connection and earthing terminals of all PROTECT 1.
units are structured in a similar way. The cables are
connected as follows:
♦ Remove terminal cover (retain the four screws).
♦ Insert the cables to be connected into the terminal
space of the PROTECT 1. from the rear.
♦ Connect the wires of the supply lines to the
corresponding terminal block. Connect the PE to the
terminal block of the PROTECT 1.100 or to the strain
relief unit of the PROTECT 1.150 or 1.200.
♦ Fasten the supplied cable clamping unit (no. 9, p. 26/27)
with the previously removed screws.
In the case of the PROTECT 1.150 and 1.200, also
remove the lateral earthing bolts beforehand and use them
to fasten the cable clamping unit as well.
♦ Check to ensure that the cables are secured correctly
and tighten the fixing bolts if necessary.
♦ Remove any cable debris, tools, bolts, etc. from the
connection panel.
29
♦ Mechanically secure the cables with the strain relief
clamps of the cable clamping unit.
♦ Mount the connection cover of the cable clamping unit.
5.3.1
Connection Cross-Sections and Fuse Protection
The required dimensions can be found in the following table:
Max. current consumption
(bypass)
PROTECT
1.100
PROTECT
1.150*
PROTECT
1.200*
46A
68A
91A
Incoming mains
cable (UPS input)
min.
10 mm²
16 mm²
25 mm²
max.
16 mm²
35 mm²
35 mm²
Load connection
(UPS output)
min.
10 mm²
16 mm²
25 mm²
max.
16 mm²
35 mm²
35 mm²
Battery connection
Mains fuse (UPS input)
Via enclosed
battery
connection
cable protectted against
polarity
reversal
50A gl
Min. 16 mm², Max. 35
mm² per terminal
Battery connection cable
is included with the
battery unit
Observe earth-fault- and
short-circuit-proof routing!
80A gl
100A gl
When using line safety switches, observe
trigger characteristic: “D”
Load fuse (recommended
max.)
Line safety switch “B” characteristic
16A
20A
25A
* To ensure a reliable strain relief, individual wires must be
laid especially for connecting the 15 and 20 kVA UPS
systems.
Recommended connection cable acc. to VDE 0298-4:
Specially for 15 and 20 kVA:
Special rubber-insulated wire
NSGAÖU or NSGAFÖU
or NYY or
Radox 4GKW-AX
e.g. Huber & Suhner
30
Alternatively, the 10 kVA UPS system can also be connected
via a multi-wire rubber-sheathed cable.
5.4
Mains Connection
5.4.1
Preparation for the three-phase mains connection
Before connection work is performed on the UPS, make sure
that:
♦ The values of the nominal voltage (supply) and
frequency match those on the nameplate of the UPS.
♦ The earth connection matches the prescribed IEC
standards or the local regulations,
♦ The UPS can be connected to the electrical mains via a
separate supply line equipped with fuses in the supplyside MI distribution.
♦ Back-up fuses or line safety switches are used that
correspond to the values listed in chapter 5.2.2.
♦ The connection cable from the back-up fuse to the UPS
is configured with a minimum cross-section acc. to
chapter 5.2.2 “Connection Cross-Sections and Fuse
Protection”.
The UPS can be live, and the voltage can be
dangerous. The unit may only be installed and
if necessary opened by trained and qualified
personnel. Repairs may only be carried out by
qualified customer service staff!
5.4.2
Connection of the Three-Phase Input Mains Voltage
In order to ensure the safety of personnel during installation
work, make sure that the connections are made under the
following conditions:
♦ No mains voltage present.
♦ The loads are switched off.
♦ The PROTECT 1. is switched off (display completely
blank).
To disconnect the PROTECT 1, carry out the following steps
as well:
31
♦ Place the “maintenance switch” manual bypass on the
back of the UPS in the “bypass” position. To do this, first
remove the 4 screws of the cover (no.3, p. 26/27).
♦ Put the mains input miniature circuit breaker (no. 2,
p. 26/27) in the “OFF” position.
Connect the UPS terminal “
/ PE “
(earth)
with
the
corresponding earth terminal in the distribution cabinet.
Connect the supply cable from the MI distribution to the
terminals 1.1 of the UPS that are marked with “INPUT”:
/ PE
=
Ground
N
=
Neutral conductor
L1/L2/L3 =
Phases
Check the jumper between “JP1” and “JP2”
(terminal designation “JUMPER”).
Only remove the cable if you want to use the UPS
in parallel operation with further PROTECT 1. units
of the same type (see also chapter 9).
5.4.3
Preparation of the Output Cabling
Before you connect the loads to the UPS, the nominal output
listed on the nameplate must be greater than or equal to the
sum of the load power outputs.
The output of the PROTECT 1. should supply further separate
circuits in a subdistribution. Make sure that the fuse protection is
selectively designed (see also chapter 5.2.2).
For the connection between the PROTECT 1. and the
subdistribution, cable cross-sections acc. to the table
“Connection Cross-Sections and Fuse Protection” on p. 30
must be used. In the subdistribution, note at least the
following information:
♦ Maximum permissible total load
♦ Maximum permissible load of the individual load circuits
i
In the case of a common distribution cabinet
(circuits with mains as well as UPS voltage), label
each circuit with the respective supply (mains or
UPS).
32
5.4.4
Connection of the Loads
In order to ensure the safety of personnel during installation
work, make sure that the connections are made under the
following conditions:
♦ No mains voltage present.
♦ The loads are switched off.
♦ UPS is switched off (display completely blank).
To disconnect the PROTECT 1., carry out the following steps:
♦ Place the “maintenance switch” manual bypass on
the back of the UPS in the “bypass” position. For
this purpose, first remove the 4 screws of the
cover (no. 3, p. 26/27).
♦ Put the mains input miniature circuit breaker (no. 2, p.
26/27) to the “OFF” position.
Connect the loads as follows (terminals 1.3, p. 26/27):
Connect the UPS terminals
/ PE = ground, N = neutral
conductor, L = phase that are marked with “OUTPUT” with the
corresponding terminals of your UPS subdistribution.
5.5
Connection of External Battery Modules
The PROTECT 1. requires the use of at least one external
battery module. Two preconfigured battery cubicle types are
available. Both versions guarantee an increase in the
attainable standby time due to their parallel connection
capability (see also chapter 2.3).
PROTECT 1.100
PROTECT
1.100 BP
PROTECT
1.BP20
PROTECT 1.150
PROTECT 1.200
-
-
No
mix !
The two cubicle types are distinguished in the following.
Follow 5.4.1 if you use the PROTECT 1.100 BP or 5.4.2 when
using the PROTECT 1.BP20.
33
5.5.1
Connection of the Battery Cubicle PROTECT 1.100 BP
This battery cubicle is completely preconfigured. The
connection to the UPS unit is ready to be plugged in as a
result of the supplied battery connection cable.
PROTECT 1.100 with 1 battery unit PROTECT 1.100 BP
i
PROTECT 1.100 BP is only intended
for connection to the UPS type PROTECT 1.100.
Connect further battery cubicles of identical design (!) to the
second battery connection socket of the neighbouring battery
cubicle. Insert the battery connection plugs quickly and firmly
into the battery connectors.
34
5.5.2
Connection of the Battery Cubicle PROTECT 1. BP20
Fig.: Rear view of the PROTECT 1.BP20 with cover removed.
The battery cubicle is supplied with a separate battery string
and separately enclosed battery fuses for safety and transport
protection reasons. Please also note the separate
documentation enclosed with the battery cubicle.
After the battery cubicle has been removed from the pallet,
first remove the rear cover. Now create the electrical
connections with the enclosed connectors (see also circuit
diagram X1/X2/X3) and
The PROTECT 1.100 is connected to the UPS at the socket
using the special battery connection cable enclosed with
the UPS, and in the case of the PROTECT 1.150 or
PROTECT 1.200 with the battery connection cables enclosed
with the battery cubicle at the terminals. Make sure to observe
the terminal block assignment concerning the correct polarity
"+" and "-" as well as an earth-fault- and short-circuit-proof
routing, in addition to the proper earthing of the battery
cubicle.
35
If the battery cubicle is used in connection with the
PROTECT 1.1.50 or PROTECT 1.200, the strain relief is
implemented with clamps.
The battery system can now be activated. To do this, insert
the two fuses .
As the last step, fasten each cover that was initially removed.
Fig.: PROTECT 1.BP20 in connection with the PROTECT 1.100
PROTECT 1.100 & 1.BP20: When connecting
the battery connection cable, make sure that the
plugs are inserted quickly and firmly in the
battery connectors.
Prepare further PROTECT 1.BP20 battery cubicles as
described above and then connect them to the terminals
(X2 and X3) of the previously installed battery cubicle with the
enclosed battery connection cables. Observe the correct
polarity "+" and "-" as well as an earth-fault- and short-circuitproof routing during connection.
i
5.6
Mechanical Blocking of PROTECT 1.
After completing the connection work, fasten the connection
terminal cover again. At the final installation site, block the
cubicles against slipping.
36
6
Start-Up
Compare the setting of the nominal output voltage of the UPS
with the rated voltage valid in your country. The factory
presetting is 230 V. Changes to 220 VAC or 240 VAC can be
made with the software “CompuWatch”.
Switching on the PROTECT 1. on the mains
1.
Make sure that all connections have been made
according to the installation instructions.
2.
Make sure that all loads are switched off.
3.
Put the “maintenance switch” manual bypass
switch (no. 3, p. 26/27) on the back of the UPS
back to the “USV “ position. Next fasten the cover
again with the 4 previously removed screws.
4.
Now insert the back-up fuse in your low-voltage main
distribution (where the UPS system is connected to
the mains on the input side) or switch on the
corresponding line protection switch there.
5.
Next actuate the mains input miniature circuit
breakers on the UPS (no. 2, p. 26/27). Move this
to the "ON" position.
i
6.
7.
Factory presetting: The loads are supplied via
the integrated bypass, which connects the
phase L1 with the UPS output. Do not switch on
your loads yet, however.
Now switch on the inverter of the UPS. To do this,
press the ON pushbutton for approx. 2 seconds.
After switching on, the UPS carries out a self-test,
during which the LED’s for load and battery state
go on and off consecutively in increasing order.
After the successful synchronization of the
inverter, the Inverter LED lights up a few seconds
later, whereby the UPS is now in normal
operating mode. When the mains supply is intact
(mains within tolerance), the "Line" LED also
lights up.
37
Please shut down the entire system again if you
cannot solve a problem that occurs. To do this,
press the OFF pushbutton for approx. 2 seconds.
Disconnect the UPS from the mains by actuating
the mains input miniature circuit breaker (no. 2,
p. 26/27). Please contact our hotline (see p. 4).
i
8.
6.1
When the displays are correctly lit as described,
switch on your loads one after the other. When
doing this, take care not to exceed the maximum
permitted load capacity of the UPS.
Operating Modes
The following operating modes are distinguished:
Operation with mains supply (6.1.1)
Operation with faulty mains supply (6.1.2)
Operation with faulty inverter (6.1.3)
Manual bypass (6.1.4)
6.1.1
Normal Operation
Power circuit with
mains supply
Manual bypass path
REC
Main
s
SBS
INV
Mains input
miniature circuit
breaker
Schematic
diagram
Manual
bypass
Load
REC
Battery
Secured
busbar
Load
Once you have connected the UPS to a suitable mains
connection, you can start operation using the UPS main
switch. Normally, the UPS operates continuously. The UPS
now supplies the output with voltage, which is signalled by the
mains symbol (Line LED) and the inverter symbol (Inverter
LED) being lit.
This operating mode, generally referred to as “online” mode,
ensures the greatest protection, in particular when there are
mains fluctuations and mains failures, because the loads are
38
continuously supplied with reliable and “clean” voltage with no
interruptions in this operating mode.
The bar graph LED (LED chain above the pictograph)
indicates the current capacity utilisation of the UPS in this
operating mode (see chapter 8, p. 45).
6.1.2
Battery Operation / Autonomous Operation
Power circuit with
faulty mains supply
Manual bypass path
REC
Mains
SBS
INV
Mains input
miniature circuit
breaker
Schematic
diagram
Manual
bypass
Load
REC
Secured
busbar
Load
Battery
The mains is not within the required tolerance range or has
failed. In this case, power is supplied to the inverter from the
charged battery without interruption. The power supply to the
loads is therefore also ensured in the event of a mains failure.
This drains the capacity of the battery and it is discharged.
This status is signalled by the battery symbol lighting up
(Battery LED), as well as an intermittent acoustic signal, at
first every 4 seconds and then every second shortly before
switching off. The initial alarm can be suppressed by pressing
the “Alarm off” button. The alarm is automatically reactivated
when the battery capacity decreases. Depending on the
expansion level, age and condition of the battery and in
particular on the load to be supplied, the standby time can
vary from a few minutes to several hours.
39
The inverter is switched off if the battery voltage drops below
a factory-set minimum voltage value.
Never store the unit in this condition! The discharged battery
system should be recharged within a week at the latest.
When the voltage and frequency are within the tolerance
range again after the mains is restored, the rectifiers switch
back on automatically. The supply of the inverter through the
mains is resumed and the battery charger charges the
battery.
The bar graph LED (LED chain above the pictograph)
indicates the remaining battery capacity during this operating
mode (see chapter 8, p. 45).
6.1.3
Bypass Operation
Power circuit with
faulty INV
Manual bypass path
REC
Mains
SBS
INV
Mains input
miniature circuit
breaker
Schematic
diagram
Manual
bypass
Load
REC
Battery
Secured
busbar
Load
If the inverter is overloaded or if overtemperature is detected,
e.g. also if an inverter defect is detected, voltage is supplied
to the load without interruption via the static bypass switch
(SBS) that switches on automatically. This is signalled by the
Bypass LED.
40
This so-called passive redundancy protects against the total
failure of the voltage supply on the secured busbar; however,
in this operating mode, mains faults would directly affect the
load. As a result, the electronics continuously attempt to
switch back to "online" / normal operating mode (e.g. when
the overload or overtemperature goes away).
The bypass consists of an inverse-parallel thyristor stack and
functions as an extremely rapidly switching link between a
load and the mains. The synchronization unit ensures that the
frequency and phase of the inverter voltage is synchronized
with the mains and can therefore be switched over without
interruption (within the tolerance limits).
i
6.1.4
The bar graph LED functions as the display of
the UPS capacity utilisation. The acoustic signal
sounds every 2 seconds during this operating
mode.
Manual Bypass
41
The manual bypass enables maintenance and service
personnel to perform work on the PROTECT 1. without
having to switch off the load circuit.
If the current supply fails while the manual
bypass is active, a total failure of the load supply
results. For this reason, it should be switched
back to normal operating mode as soon as
possible.
6.1.5
Unit overload
The load on the UPS should never exceed the specified rated
load of the unit. If a unit overload occurs nevertheless (from
105% of the specified unit rated load) then the Fault LED lights
up and an acoustic signal sounds (twice per second). The
connected loads continue to be supplied for a certain length of
time depending on the level of the overload. However, the
connected load must be reduced without delay.
Non-observance of the "unit overload" condition may cause
the total loss of all UPS functions!
Also avoid short-term unit overloads, which may, for example,
occur when connecting a laser printer or laser fax machine.
Do not connect any household appliances or machine tools to
the UPS.
Never connect or switch on any additional loads
to the UPS if there is a mains failure, i.e. if the
UPS is working in emergency power mode!
As a rule, if there has never been an overload during normal
mode, there will not be one in battery mode either.
When the Fault LED lights up in connection with
a continuous acoustic signal, this is an indication
of a deactivating fault. Follow the instructions on
page 49.
42
7
Interfaces and Communication
7.1
Computer Interface RS232
For the control of the UPS and convenient reading of status
messages and measured values, various interfaces are
available. The interface protocol is designed for operation with
the "CompuWatch" shutdown and UPS management software
from AEG. Use the supplied RS232 communication cable to
connect your PC. Plug the cable into a corresponding serial
port on your PC.
RS232 interface: The RS232 is connected via the 9-pin Sub-D
socket strip on the back of the unit (no. 8, p. 26/27). Pin
assignment: 2 = TxD; 3 = RxD; 5 = GND.
7.2
Communication Slot
On the back of the UPS, there is a cover (see p. 26/2727, no.
7). When this is removed, additional, optionally available
communication components can be installed there, e.g.:
AS/400 board: Slot board with status messages, realised via
potential-free relay contacts
USB board: Slot board for communication via USB
SNMP board: Slot board for direct connection of the UPS to
the Ethernet network with RJ 45 (TCP/IP)
Details can be found in the description enclosed with the
particular optional component. Other boards in preparation.
i
7.3
Using the communication slot deactivates the
RS232 interface from chapter 7.1.
Shutdown and UPS Management Software
The "CompuWatch" software specially developed for these
purposes by AEG continuously checks the mains supply and
the UPS status.
In conjunction with the “intelligent” UPS, this guarantees the
availability of the EDP components as well as the data
security.
43
The "CompuWatch" shutdown software supports different
operating systems, e.g. Windows 98SE/ME, Windows
NT/2000/XP, Windows Vista, Linux, Novell Netware, IBM AIX,
HP-UX, SUN Solaris, Mac OS X, and others.
Example of a “CompuWatch” screen
Refer to the manual on the CD for details about installing the
software on the various operating systems. Download of
updates at www.aegpartnernet.com >> PRODUCTS >>
Software >> CompuWatch
44
8
Displays and Troubleshooting
8.1.1
Signalling
1.
2.
3.
4.
5.
OFF pushbutton Press the button for approx.
2 seconds to switch off the UPS.
ON button: Press the button for approx. 2
seconds to switch the UPS on.
Deactivate acoustic alarm: Press the button
during the alarm for approx. 2 seconds to switch
off the alarm.
UPS test: Press this button during normal mode
for approx. 2 seconds to carry out a UPS self-test.
Bypass LED: The orange-coloured LED lights up
when voltage is supplied via the integrated bypass
of the UPS.
Inverter LED: The green LED lights up when
voltage is supplied via the inverter of the UPS
system.
Battery LED: The orange-coloured LED lights up
when power is supplied from the battery system.
45
6.
Line LED (mains status): The green LED lights
up when the mains voltage present is within the
specified tolerance range. If this LED flashes,
either the UPS connection has an incorrect pin
assignment (observe phase sequence / neutral
conductor connection position) or the mains is
outside of the specified tolerance range.
7. to 11. Bar graph LED as the measure of the UPS
capacity utilisation or the remaining battery
capacity.
These LED’s show the current UPS capacity
utilisation when mains voltage is present (normal
mode):
11. Orange LED
96% – 105%
10. Green LED
76% – 95%
9. Green LED
56% – 75%
8. Green LED
36% – 55%
7. Green LED
0% – 35%
In battery mode, the LED’s indicate the capacity of
the batteries:
11. Orange LED
0% – 25%
10. Green LED
26% – 50%
9. Green LED
51% – 75%
8. Green LED
76% – 95%
7. Green LED
96% – 100%
12.
Fault LED: The red LED lights up with an acoustic
warning signal when a fault is present in the UPS
system.
46
Overview Table of LED Displays / Acoustic Warning Signals
LED display (see chapter 8 on page 47)
No. Operating mode
Warning
signal
none
2
36% – 55%
utilisation
none
3
56% – 75%
utilisation
none
76% – 95%
utilisation
none
96% – 105%
utilisation
none
4
5
(mains present)
0% – 35%
utilisation
Normal mode
1
6
0% – 20%
capacity
1 acoustic
signal per sec.
7
21% – 40%
capacity
1 acoustic signal
every 4 seconds
41% – 60%
capacity
1 acoustic signal
every 4 seconds
61% – 80%
capacity
1 acoustic signal
every 4 seconds
81% – 100%
capacity
1 acoustic signal
every 4 seconds
8
9
Battery mode
8.1.2
10
11
Load supply via
bypass of the UPS
1 acoustic signal
every 2 minutes
12
Unit overload UPS in
INV mode
2 acoustic
signals per sec.
13
Unit overload UPS
in bypass mode
2 acoustic
signals per sec.
14
Mains abnormal
15
Overload in battery
mode, early warning
2 acoustic
signals per sec.
16
Overload in battery
mode, switch-off
Continuous
warning signal
17
Overtemperature fault
Continuous
warning signal
18
Inverter fault
Continuous
warning signal
Note:
= LED lights up
= LED flashes
= Display / acoustic signal state undetermined;
unimportant for displayed operating mode
47
Overview table of LED displays / warning signals, cont.
LED display (see chapter 8 on page 47)
No. Operating mode
Warning
signal
19
Short-circuit output
side
Continuous
warning signal
20
BUS voltage
abnormal
Continuous
warning signal
21
DC circuit faulty;
poss. battery fault
1 acoustic
signal per sec.
22
Battery
faulty
Continuous
warning signal
23
Fan fault
1 acoustic
signal per sec.
24
Fault in inverter
output relay
Continuous
warning signal
25
Communication
faulty
Continuous
warning signal
26
Parallel
fault
Continuous
warning signal
Note:
charger
operation
= LED lights up
= LED flashes
= Display / acoustic signal state undetermined;
unimportant for displayed operating mode
48
8.2
Faults
PROTECT 1. outputs detailed error messages by means of
which you or the service personnel can quickly and accurately
localise and interpret any malfunctions that occur. You can
find suggestions for action / solutions in the following to
correct problems using error descriptions according to chapter
8.1.2:
8.2.1
Error Messages
Message / display
Cause
Solution
No display, no acoustic
signal although system
is connected to the
mains current supply.
Mains and/or
battery voltage not
in tolerance range,
poss. totally
discharged battery.
Check mains connection
again. Check the backup fuse and the mains
input miniature circuit
breaker as well.
Mains OK, but UPS
does not switch to
bypass
PositionMains input
use is in “OFF”
position
Switch mains input
miniature circuit breaker
to “ON”
“Line” LED flashes and
“Battery” LED lights up
Mains voltage
and/or mains
frequency are
outside of tolerance
Check the mains
(voltage, frequency)
“Inverter" LED and
"Battery" LED light up.
The acoustic signal
sounds every 4 seconds
(operating states 7-10).
Mains voltage
supply interrupted.
Automatic
switchover to
battery mode.
Try to re-establish the
mains voltage (poss.
fuse triggered in the
subdistribution?).When
the acoustic signal
sounds every second,
the battery is almost
completely discharged.
Carry out a system
shutdown of your IT
equipment at this point
in time at the latest.
Overload of the
UPS System.
Immediately reduce the
capacity utilisation of the
UPS by disconnecting
part of your loads.
“Inverter"
LED
and
"Battery" LED light up.
The
acoustic signal
sounds every second
(operating state no. 6).
“Fault” LED lights up,
warning signal sounds
twice per second (error
descriptions no. 12/13).
49
Message / display
Cause
Solution
Duration of the
emergency power
supply shorter than
setpoint.
Batteries not
completely charged
/ batteries aged or
faulty.
Charge the batteries for
at least the recharging
time acc. to chapter 2.3,
and check their capacity.
If the problem remains,
contact your dealer.
“Line” LED and “Fault”
LED light up, continuous
warning signal (error
description no. 17).
Switch-off due to
UPS internal
overtemperature
detection
Make sure that no
overload is present, the
UPS fans are not
blocked and the ambient
temperature is in the
tolerance range. Wait for
10 min. cooling down
phase, then switch on
again.
Error description no. 19
Switch-off due to
short-circuit in UPS
output
Correct short-circuit.
Switch UPS on again,
connect loads one after
the other again.
“Fault” LED lights up,
“Battery” LED flashes,
warning signal sounds
once per second (error
description 21).
Fault in DC circuit
or battery system
faulty.
Notify dealer!
“Fault” LED lights up,
continuous warning
signal.
Fault in the UPS.
Notify dealer!
Further diagnoses can also be found in the table list in
chapter 8.1.2.
If you cannot solve the problem that has occurred, stop the entire
procedure, switch off the UPS and disconnect the UPS from the
mains. Please contact our hotline in this case (see p. 4).
Please have the serial number of the unit as well as the
purchase date at hand. The hotline will provide you with
technical support and can inform you about further
procedures once you have described the problem.
50
9
Parallel Operation
9.1
Principle of Operation
PROTECT 1. has been designed for parallel operation with n+x
technology (“n” here stands for the number of units required for
load supply, “x” for the degree of redundancy). Up to 3 units of the
same type can be connected in parallel here to increase the
output power and/or achieve higher availability.
NS Hauptverteilung
USV Einspeisung
Parallelfeld / Handumgehung plus USV
Unterverteilung
MI main distribution
UPS feed
Parallel field / manual bypass plus UPS
subdistribution
This results in the following constellations with n+x technology:
1 + 0 Use of 1 unit
1 + 1 Use of 2 units
1 + 2 Use of 3 units
2 + 0 Use of 2 units
2 + 1 Use of 3 units
3 + 0 Use of 3 units
max. 10, 15
20 kVA
max. 10, 15
20 kVA
max. 10, 15
20 kVA
max. 20, 30
40 kVA
max. 20, 30
40 kVA
max. 20, 30
40 kVA
51
or
No redundancy
or
Single redundancy
or
Double redundancy
(max. expansion level)
No redundancy
or
or
Single redundancy
(max. expansion level)
or
No redundancy (max.
expansion level)
The actively redundant parallel operation automatically
switches to power-increasing operation if the output power
requirement exceeds the UPS single block power, i.e. the
degree of redundancy is decreased or is completely eliminated.
Conversely, the active UPS redundancy degree automatically
increases again when the power consumption decreases.
The connection normally takes place in the low-voltage main
distribution, which also contains the external manual bypass
and the following subdistribution of connected load circuits.
Such a parallel board can be purchased in a wall housing incl.
external HU as well as feeder and load distribution board from
AEG Power Solutions via your specialist dealer.
9.2
Set-up / Connection of Parallel Operation Board
The mains connection of each individual UPS takes place in
the same way as described in chapter 5.
The three-phase mains connection secured for
each UPS must always have the same phase
sequence, i.e. all UPS units are supplied at the
input terminals L1, L2 and L3 by the same
phase each time (no mix!).
In UPS bypass mode, the phase L1 is used to
connect the single-phase load with the mains.
The central external manual bypass, which must
have an all-pole design, must also be supplied
by this phase L1.
The UPS outputs are each connected with the parallel
operation busbar via an isolator. The instructions from
chapter 5 apply here too.
The following always holds true for the UPS input and output
conductors: The difference in length in conductors up to 20 m
per UPS can be max. 20% and max. 10% for lengths > 20 m
per UPS.
The jumper installed between “JP1” and “JP2” on the
connection panel of every UPS at the factory must be
removed. The UPS output distribution also has to take place
according to the instructions in chapter 5. In particular, make
sure that the individual switching elements are correctly
labelled, in order to prevent operating errors later as well. The
52
communication of the units switched in parallel takes place
via the 25-pin parallel operation cable(s) included in the scope
of delivery.
For this purpose, first remove the parallel port covers
(no. 5, p. 26/27) and connect the UPS units with each other
with one parallel operation cable each. Use one parallel
operation cable for 2 units and two parallel operation cables for
3 units (do not create a ring structure!).
(Communicative) parallel operating connection
... for 2 units:
... for 3 units:
After connecting the parallel operation cables, fasten the
previously removed parallel port covers. Turn these by 180°
so that the slot of the cover is facing downwards.
The hardware-related installation is now complete.
9.3
Operation of the UPS in a parallel system
The start-up process is uncomplicated, does not require any
prior knowledge and is basically oriented to the procedure
described in chapter 6. If you have obtained the parallel
operation board from AEG Power Solutions, you can find
further special instructions there. The displays in the parallel
system function the same way as described for the individual
UPS units in chapter 8.
9.3.1
Start-Up
1.
2.
3.
Make sure that all connections have been made
according to the installation instructions.
Make sure that all loads are switched off.
Make sure that all “maintenance switch” manual
bypass switches (no. 3, p. 26/27) on the back of
53
4.
5.
6.
i
each UPS are in the “Bypass” position and all
mains input miniature circuit breakers (no. 2, p.
26/27) on the back of each UPS are in the “OFF”
position.
Check the position of the central external manual
bypass. This must be in the “Bypass” position, i.e.
supply of the load busbar by the supplying mains.
Now close all isolators in the output of each UPS,
i.e. connect the output of each UPS with the
parallel operation busbar.
Now insert the back-up fuses in your low-voltage
main distribution (where the central external manual
bypass as well as the individual UPS systems are
connected to the mains on the input side) or switch
on the corresponding line protection switches there.
The load supply now takes place via the central
external manual bypass, and the parallel
operation busbar is supplied with power via the
integrated manual bypasses of each UPS.
However, the parallel operation busbar and load
busbar are not yet connected to each other at
this time!
54
7.
8.
i
9.
i
10.
i
Now actuate the mains input miniature circuit breakers
(no. 2, p. 26/27) on each UPS one after the other.
Move them to the "ON" position.
Move the “maintenance switch” manual bypass
switches (no. 3, p. 26/27) on the back of each
UPS to the “UPS” position. Finally, fasten the
covers on each UPS again using the 4 respective
screws that were previously removed.
The voltage supply of the parallel operation
busbar now takes place via the integrated
electronic bypass switches of the UPS systems
used. Check this operating state on the display
panel of each UPS = Bypass (chapter 6.1.3).
Now actuate your central external manual bypass:
Switch from the “Bypass” position to “UPS operation”,
i.e. connect your load busbar to the UPS parallel
operation busbar.
This is done using a manual bypass switch with
overlapping switching contacts without any
interruption in the load voltage, i.e. completely
interruption-free.
Now switch on the inverters of the UPS systems.
To do this, press the ON pushbutton of each UPS
for approx. 2 seconds one after the other.
After switching on, each UPS carries out a selftest and synchronizes itself with the parallel
operation busbar, while the LED’s for load and
battery state switch on and off consecutively in
increasing
order.
After
the
successful
synchronization of all inverters, the Inverter LED
on each UPS lights up a few seconds later,
whereby the UPS systems now work in parallel
normal operating mode and supply the parallel
operation / load busbar with UPS voltage.
The central external manual bypass switch must
be protected against accidental actuation. Never
actuate it when the UPS systems are in inverter
mode.
55
11.
9.3.2
When the displays are lit as described, switch on
your loads one after the other. When doing this,
take care not to exceed the maximum permitted
load capacity of the UPS systems. Also take into
account the reserve capacities if active
redundancy should be required.
Changes to the parallel system
If you would like to add a UPS to the parallel system or
remove a UPS from the parallel system, this step is always
done by returning the UPS systems to BYPASS operating
mode.
i
Load supply through mains operation!
(No UPS protection during this measure).
First, switch off the inverters of the UPS systems one after the
other (actuate the “OFF” pushbuttons). All UPS systems
function in SBS/bypass operation. Check the operating state
on the operating panels. Next, active the integrated manual
bypasses (no. 3, p. 26/27) on the back of each UPS. To do
this, first remove the 4 screws of the covers on the back.
Put the mains input miniature circuit breakers of each UPS
(no. 2, p. 26/27) to “OFF” position. Use your central external
manual bypass to bypass the loads, i.e. activate the bypass
operation and remove the load supply from the UPS busbar.
The voltage of each UPS is disconnected in its low-voltage
main distribution. You can now expand or reduce your parallel
system. Pay attention to the jumpers “JP1” / “JP2” and the
parallel operation cables. The subsequent start-up is carried
out as described in chapter 9.3.1.
i
If you only want to switch off a UPS in the
parallel system, press the “OFF” pushbutton
twice in succession to do this. In this way,
individual UPS systems can be disconnected
from the parallel operation busbar.
56
10
Maintenance
The PROTECT 1. consists of state-of-the-art, non-wearing
components. We do, however, recommend visual checks
(above all battery and fan checks) at regular intervals (at least
every 6 months) to maintain continuous availability and
operational reliability.
CAUTION!
Ensure that the work area is cordoned off and
always observe the safety instructions!
10.1
Charging the Battery
The battery is automatically charged when the mains is
connected, irrespective of the operating mode. This is
signalled by the Load LED’s lighting up (see also chapter
4.4.2).
The complete charging time of the battery after a long
discharge time depends especially on the number of
additional external battery units (see chapter 2.3).
10.2
Checks
The following maintenance work should be performed:
10.2.1
Task
Interval
Described in
Visual check
6 months
Chapter 10.2.1
Battery/fan check
6 months
Chapter 0 / 0
Visual Check
When visually inspecting the unit, check whether …
♦ there is any mechanical damage or foreign bodies can
be found in the system,
♦ any conductive dirt or dust has accumulated in the unit,
♦ accumulation of dust affects heat supply and
dissipation.
57
CAUTION!
PROTECT 1. must be disconnected from the
power supply prior to carrying out the following
work.
If large quantities of dust have accumulated, the unit should,
as a precaution, be cleaned with dry compressed air, in order
to ensure adequate heat dissipation.
The intervals at which visual checks should be performed are
largely determined by the site conditions.
10.2.2
Checking the Battery
Progressive ageing of the battery system can be detected by
regular capacity checks. Every 6 months, perform
measurements to compare the achievable standby times, e.g.
by simulating a mains failure. In this case, the load should
always have approximately the same capacity demand.
Please contact our hotline if the time drops drastically
compared to the previous measurement (see p. 4).
10.2.3
Fan Check
Regularly check the fans for dust build-up and noticeably
untypical noise development. Blocked intake openings must
be cleaned. In the case of unusually loud or uneven running,
please contact our hotline (see p. 4).
58
11
Storage, Dismantling and Disposal
11.1
Storage
Long storage times without charging or
discharging the battery at regular intervals may
lead to permanent damage of the battery.
If the battery is stored at room temperature (20 C to 30 C), it
will automatically discharge at a rate of 3-6% per month due
to internal reactions. Storing the battery at temperatures
above room temperature should be avoided. A high storage
temperature also means greater battery self-discharge.
Batteries that are stored at room temperature should be
recharged every six months to maintain their full capacity and
service life.
i
11.2
Connect PROTECT 1. to the mains before
putting it into storage, in order to make sure that
the battery is fully charged. The charging time
should at least match the time specified in
chapter 10.1.
Dismantling
The system is dismantled in reverse order of the installation
instructions.
11.3
Disposal
In the interest of environmental protection and recycling,
please dispose of the individual system components in
accordance with the regulations and legal guidelines when
permanently taking the system out of operation. Please
consider that infringements to these regulations may result in
prosecution.
59
12
List of Terms
12.1
Technical terminology
DC/DC booster
Circuit technology for increasing a DC voltage to a
higher voltage level
SBS
Static Bypass Switch
Appliance protection
Term from overvoltage technology
Classic mains overvoltage protection consists of a
lightning surge arrester (class B), overvoltage
protection (class C) and, finally, the so-called
appliance protection (class D) – see also
http://www.phoenixcontact.de (“TRABTECH” topic)
IGBT
Insulated Gate Bipolar Transistor
The latest design of high-performance transistors with
minimum control power requirement (MOSFET
structure) and minimum losses on the output side
(structure of a bipolar transistor)
Class D
See appliance protection
LED
Light Emitting Diode
Electronic semi-conductor component, commonly
referred to as an LED, used for optic signalling.
PFC
Power Factor Correction
Circuit technology for minimising system disturbances
(particularly important when connecting non-linear
loads)
PWM
Pulse Width Modulation
Here: circuit technology for generating a sinusoidal
voltage of the highest quality from an existing DC
voltage
SNMP
Simple Network Management Protocol
A protocol encountered frequently in networks for
managing / handling components
VFD
Output Voltage and Frequency Dependent on mains
supply. The UPS output is dependent on mains
voltage and frequency fluctuations. Earlier
designation: OFFLINE
VI
Output Voltage Independent from mains supply
The UPS output is dependent on mains frequency
fluctuations, but the mains voltage is prepared by
electronic / passive voltage control units. Earlier
designation: LINE-INTERACTIVE
VFI
Output Voltage and Frequency Independent from
mains supply. The UPS output is independent of
mains voltage and frequency fluctuations. Earlier
designation: ONLINE
60
Guarantee Certificate
Type: …….…………………......................................................
Unit number: ………….……………..........................................
Date of purchase: .…………………...........…………………….
Dealer stamp / signature
Errors and changes excepted.
AEG Power Solutions GmbH
Emil-Siepmann-Str. 32
D-59581 Warstein-Belecke
Germany
Operating Instructions
BAL 8000019452_01 EN
61