AEG | C 9 18 43-4i | Operating instructions | AEG C 9 18 43-4i Operating instructions

AEG C 9 18 43-4i Operating instructions
OPERATING INSTRUCTIONS UPS
PROTECT C.R
PROTECT C. 1000 R (S)
PROTECT C. 2000 R (S)
PROTECT C. 3000 R (S)
PROTECT C. 6000 R
Thank you for purchasing the PROTECT C.R. from AEG
Power Solutions.
Safety information and operating instructions are
included in this manual. To ensure correct use of the
UPS, please read this manual thoroughly before
operating it. Save this manual properly.
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
C. 1000 R (S), PROTECT C. 2000 R (S), PROTECT C. 3000 R (S)
or PROTECT C. 6000 R as well as the associated external
battery units PROTECT C. 1000 R BP, PROTECT C. 2030 R BP
or PROTECT C. 6000 R BP, – all referred to as PROTECT C.R
in this document – safely and properly, and for its intended
purpose. These operating instructions contain important
information necessary to avoid dangers during operation.
Please read these instructions carefully prior to
commissioning!
These operating instructions are a composite part of the
PROTECT C.R.
The owner of this unit is obliged to communicate the full
content of these operating instructions to all personnel
transporting or starting the PROTECT C.R or performing
maintenance or any other work on the unit.
Validity
These operating instructions comply with the current technical
specifications of the PROTECT C.R at the time of delivery.
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, prior to start-up or as a result of service work.
Claims in connection with supplied goods must be submitted
within one week of receipt, along with the packing slip.
Subsequent claims cannot be considered.
3
The warranty does not apply to damage caused by noncompliance with these instructions (such damage also
includes damaging the warranty seal). AEG will accept no
liability for consequential damage. AEG reserves the right to
rescind all obligations such as warranty agreements, service
contracts, etc. entered into by AEG and its representatives
without prior notification in the event of maintenance and
repair work being carried out with anything other than original
AEG spare parts or spare parts purchased by AEG.
Handling
PROTECT C.R 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
pictograms explained in 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
3 Safety ............................................................................... 9
3.1
General Safety Instructions ...................................... 9
3.2
Safety Instructions for PROTECT C.R .................... 9
3.3
CE-Certificate ......................................................... 13
3.4
Technical Data........................................................ 15
4 Set-Up and Operation .................................................... 22
4.1
Unpacking and Inspection ...................................... 22
4.2
Point of Installation ................................................. 23
4.3
Overview: Connections, Operating /Display Elements .. 24
4.3.1
Front view ........................................................ 24
4.3.2
Rear view......................................................... 24
4.3.3
Display............................................................. 26
5 Commissioning .............................................................. 27
5.1
Mechanical Set-Up ................................................. 27
5.1.1
Set-Up in a 19" Rack ....................................... 27
5.2
External Battery Expansions .................................. 28
5.2.1
Electrical Start-Up ........................................... 29
5.3
Operating Statuses ................................................. 32
5.3.1
Normal Operation ............................................ 32
5.3.2
Battery Operation / Autonomy Operation ........ 33
5.3.3
Bypass Operation ............................................ 34
5.3.4
Unit Overload................................................... 35
5.4
Interfaces and communication................................ 36
5.4.1
Data line protection RJ11 and RJ45
(modem / telephone / fax / network) ................ 36
5.4.2
Computer interfaces RS232 ............................ 36
5.4.3
Communication Slot ........................................ 36
5.4.4
Shutdown and UPS management software .... 37
5
Signalling and Error Correction ......................................38
6.1
Signalling.................................................................38
6.2
Fault Diagnosis / Fault Rectification........................40
6.2.1
Error Messages................................................40
7 Maintenance...................................................................42
7.1
Charging the Battery ...............................................42
7.2
Maintenance.. Fehler! Textmarke nicht definiert.42
7.2.1
Visual Check ....................................................43
7.2.2
Checking the Battery .......................................43
7.2.3
Fan Checking...................................................43
8 Storage, Dismantling and Disposal ................................44
8.1
Storage....................................................................44
8.2
Dismantling .............................................................44
8.3
Disposal ..................................................................44
9 Glossary .........................................................................45
9.1
Technical terms.......................................................45
6
6
2
General Information
2.1
Technology
i
PROTECT C.R is an Uninterruptible Power
Supply (UPS) for essential loads such as PCs,
workstations, servers, network components,
telecommunication
equipment
and
similar
devices. 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

Sealed, maintenance-free battery system (  2kVA externally)
as energy storage medium with DC/DC converter unit

IGBT inverter for continuous supply of connected loads
with sinusoidal AC voltage

Automatic bypass as additional passive redundancy

Microprocessor controlled control unit
Automatic
bypass
PFC
Mains
~
Filter
~
Rectifier
Mains
filter
Load
Inverter
DC/DC booster
~
CPU
control unit
Battery
charger
Battery system
View of the PROTECT C.R components
7
RS232
SNMP
2.2
System Description
The UPS is connected between the public utility's 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, so the service life of the
battery is increased even more. The inverter is responsible
for converting the DC voltage into a sinusoidal output voltage.
A microprocessor-controlled control system based on pulsewidth modulation (PWM) in conjunction with an extremely
quickly pulsating IGBT power semiconductors of the inverter
guarantee that the voltage system on the protected busbar is
of the highest quality and availability.
In the event of mains faults (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. No switching
operations are necessary; this means there is no interruption
in the supply to the load.
For safety reasons (as required by German standards, VDE),
the mains input in the unit will be disconnected by a two-pole
switch in the event of a mains failure. Energy backfeed to the
mains and voltage supply to the pins of the mains connector
are thus reliably avoided.
The automatic bypass serves to increase the reliability of the
supply further. It switches the public mains directly through to
the load if there is an inverter malfunction. As a result, the
automatic bypass represents an extra passive redundancy for
the load.
8
3
Safety
3.1
General Safety Instructions
Read these operating instructions prior to start-up of the
PROTECT C.R UPS and its external battery modules (special
accessories), and observe the safety instructions!
Only use the unit if it is in a technically perfect condition and
always in accordance with its intended purpose, while being
aware of safety and danger aspects, and in accordance with
the operating instructions! Immediately eliminate any faults
that could be detrimental to safety.
The following pictograms are used in these operating
instructions to identify dangers and important information:
Danger!
Identifies risk of fatal injury to the operator.
Attention!
Identifies risk of injury and risk of damage to the
unit and parts of the unit.
i
3.2
Information!
Useful and important hints for the operation of the
UPS and its external battery modules (special
accessories).
Safety Instructions for PROTECT C.R
This chapter contains important instructions for the
PROTECT C.R UPS and its external battery modules (special
accessories). These must be followed during assembly,
operation and maintenance of the uninterruptible power
supply and the battery systems (internal and, if appropriate,
external as well).
9
The UPS carries high voltage. Danger! The unit
may only be opened by trained and qualified
personnel. Repairs may only be carried out by
qualified customer service staff!
The output may be live, even if the UPS is not
connected to the mains, since the UPS has its
own internal power supply (battery)!
For health and safety reasons, the unit must be
earthed correctly!
PROTECT C.R may only be operated with or connected to a
220 V / 230 V / 240 V mains with protective grounding using a
CE marked mains connection cable with PE conductor
(included in the delivery) that has been tested in accordance
with national standards.
Danger! 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 C.R is
exhausted or when the UPS is not working in its
normal mode (see also chapter 6.1).
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!
10

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 start-up. As a
result, leave it to acclimatise for at least two hours.

Never connect the mains input to the UPS output, and
vice versa!

Ensure that no fluids or foreign bodies can penetrate the
housing!

Do not block the air vents of the unit! Keep children away
from the unit and ensure that objects are never inserted
through the air vents!

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.

The mains connection should be near the unit and easily
accessible to facilitate disconnecting the AC input or
pulling out the plug!

During operation, do not disconnect the mains connection
cable from the UPS or from the socket outlet in the building
(shockproof socket), otherwise the protective grounding of the
UPS and all the loads connected to it will be cancelled.
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 authorised persons are allowed in the
vicinity of the batteries!
11
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.
Take the following safety precautions when working with the
batteries:

Take off watches, rings and other metallic objects!

Always use tools with insulated handles!
i
Do not switch loads on and off using the UPS
main switch. Do not use multiple outlet adapters
with a central on/off switch, in order to avoid
peak inrush currents.
Switch OFF the UPS using its main switch “OFF” if you do not
intend to use it for some time. PROTECT C.R must be
switched off every evening if the electricity supply in your
company is switched off every night. Otherwise, the battery
will be discharged (assumed power failure). Frequent and
complete 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 C.R is disconnected!
12
3.3
CE- Certificate
13
14
3.4
Technical Data
Type power
PROTECT C. 1000 R (S)
1000 VA (cos  = 0.7 lag.)
700 W
PROTECT C. 2000 R (S)
2000 VA (cos  = 0.7 lag.)
1400 W
PROTECT C. 3000 R (S)
3000 VA (cos  = 0.7 lag.)
2100 W
PROTECT C. 6000 R
6000 VA (cos  = 0.7 lag.)
4200 W
UPS Input
Rated input voltage
220 / 230 / 240 Vac
Voltage tolerance range
C. 1000 R (S) – C. 3000 R (S) 160 Vac – 300 Vac ± 5 Vac
Bypass 80 Vac – 264 Vac
C. 6000 R
176 Vac – 276 Vac ± 3 %
Bypass 176 Vac – 261 %
Nominal frequency
50 Hz / 60 Hz
(automatic detection)
Frequency tolerance range
± 4 Hz
Curr. consumption (full load)
PROTECT C. 1000 R (S)
PROTECT C. 2000 R
PROTECT C. 2000 R S
PROTECT C. 3000 R (S)
PROTECT C. 6000 R
7A
10 A
12 A
16 A
31 A
Input power factor
C. 1000 R (S) – C. 3000 R (S)
C. 6000 R
 ≥ 0.96
 ≥ 0.98
Connection
C. 1000 R (S) – C. 3000 R (S)
C. 6000 R
non-heating
appliance connector
Terminal block
15
Overvoltage
dataline protection
RJ11 (phone, fax, modem)
RJ45 (Ethernet 10/100 MBit/s)
UPS Output
Rated output voltage
C. 1000 R (S) – C. 3000 R (S)
C. 6000 R
Nominal frequency
C. 1000 R (S) – C. 3000 R (S)
C. 6000 R
Voltage waveform
Connection
Current Crest Ratio
220 / 230 / 240 Vac ± 2 %
220 / 230 / 240 Vac ± 1 %
(configuration via software
“CompuWatch”)
50 Hz / 60 Hz ± 0.2 %
50 Hz / 60 Hz ± 0.1 %
(depending on mains)
Pure sine wave
Harmonic distortion:
≤ 4 % THD (linear load)
≤ 7 % THD (non-linear load)
Non-heating appliance connectors
3:1
Overload behaviour in battery mode
C. 1000 R (S) – C. 3000 R (S) up to 105 % ± 5 % continuous;
> 105 % ± 5 % – < 150 % ± 5 %
for 25 s;
150 % ± 5 % for 200 ms
C. 6000 R
up to 105% continuous;
> 105 % for 10 s
Overload behaviour with existing mains
C. 1000 R (S) – C. 3000 R (S) up to 105 % ± 5 % continuous;
> 105 % ± 5 % – < 150% ± 5 %
for 30 s;
150 % ± 5 % for 300 ms
Then automatic inverter to
Bypass in < 4 ms (switches
back when overload damps =
Load < 90 %))
16
C. 6000 R
up to 105 % continuous;
> 105 % – < 130 % for 10 min;
130 % for 1 s
Then automatic inverter to
Bypass in 0 ms (switches
back when overload damps
= Load < 90 %)
3 x IN for 140 ms
Short circuit behavior
Battery
Autonomy time (full load with internal battery)
PROTECT C. 1000 R
6 min.
PROTECT C. 2000 R,
C. 3000 R and C. 6000 R
at least one battery module
required
Autonomy time with external optional battery expansions
(only for PROTECT C. – models):
Coupled
battery modules
Autonomy time (full load)
C.1000 R
C. 2000 R
1
37 min.
10 min.
5 min.
8 min.
2
75 min.
30 min.
17 min.
25 min.
3
-
50 min.
30 min.
45 min.
4
-
75 min.
48 min.
60 min.
5
-
90 min.
60 min.
70 min.
Rated direct voltage (intermediate circuit)
PROTECT C. 1000 R (S)
36 V
PROTECT C. 2000 R (S)
96 V
PROTECT C. 3000 R (S)
96 V
PROTECT C. 6000 R
240 V
Battery charging current
PROTECT C. 1000 R
PROTECT C. 1000 R S
PROTECT C. 2000 R
1A
7A
1A
17
C. 3000 R
C. 6000 R
PROTECT C. 2000 R S
PROTECT C. 3000 R
PROTECT C. 3000 R S
PROTECT C. 6000 R
9.6 A
1A
9.6 A
2A
Recharge time PROTECT C. – models
(to 90% of rated capacity)
Coupled
battery modules
C. 1000 R
Integr. battery
5h
C. 2000 R
C. 3000 R
C. 6000 R
-
-
-
1
24 h
5h
5h
5h
2
40 h
14 h
14 h
14 h
3
-
24 h
24 h
24 h
4
-
32 h
32 h
32 h
5
-
40 h
40 h
40 h
Type
PROTECT C. 1000 R
PROTECT C. 1000 R BP
PROTECT C. 2030 R BP
PROTECT C. 6000 R BP
Comment for “S” versions
Sealed, maintenance-free
12 V 7.2 Ah x 3
12 V 7.2 Ah x 3 x 2
12 V 7.2 Ah x 8
12 V 7.2 Ah x 20
UPS with increased battery
charger for charging external
battery systems (no integrated
battery)
Communication
Ports
Shutdown Software on CD
RS232 SUB-D (9-pin)
additional: communication slot
for expansion (z.B. AS/400 /
SNMP, ...)
“CompuWatch” for all popular
operating systems like
Windows, Linux, Mac, Unix,
FreeBSD, Novell, Sun
18
General Data
Classification
VFI SS 211 to IEC 62040–3
Double conversion technology
Overall efficiency (full load)
PROTECT C. 1000 R (S)
PROTECT C. 2000 R (S)
PROTECT C. 3000 R (S)
PROTECT C. 6000 R
≥ 85 %
≥ 85 %
≥ 88 %
> 88 %
Noise level (1m distance)
PROTECT C. 1000 R (S)
PROTECT C. 2000 R (S)
PROTECT C. 3000 R (S)
PROTECT C. 6000 R
< 45 dB (A)
< 50 dB (A)
< 50 dB (A)
< 55 dB (A)
Type of cooling
Forced cooling
by variable speed fans
Operating temperature range
0°C to +40°C
Recommendation +15°C to
+25°C (due to battery
system)
Storage temperature range
0°C to +40°C
Relative humidity
< 95%, non-condensing
Max. site altitude
up to 1000 m at full load
If the UPS is installed or used
in a place where the altitude
is above than 1000m, the
output:
Altitude (m)
1000
1500 2000 2500 3000
Derating
Power
100%
95%
19
90%
85%
80%
Outlets
PROTECT C. 1000 R (S)
PROTECT C. 2000 R (S)
PROTECT C. 3000 R (S)
PROTECT C. 6000 R
4 x IEC 320-10A
4 x IEC 320-10A
1 x IEC 320-10A
+ 1 x IEC 320-16A
4 x IEC 320-10A
+ connection via terminal block
Equipment colour
Black line
Weights:
PROTECT C. 1000 R
PROTECT C. 1000 R S
PROTECT C. 1000 R BP
PROTECT C. 2000 R
PROTECT C. 2000 R S
PROTECT C. 3000 R
PROTECT C. 3000 R S
PROTECT C. 2030 R BP
PROTECT C. 6000 R
PROTECT C. 6000 R BP
16.5 kg
9.5 kg
19 kg
10 kg
11 kg
11 kg
12 kg
29 kg
18 kg
64 kg
Dimensions W x H x D:
PROTECT C. 1000 R (S)
PROTECT C. 1000 R BP
PROTECT C. 2000 R (S)
PROTECT C. 3000 R (S)
PROTECT C. 2030 R BP
PROTECT C. 6000 R
PROTECT C. 6000 R BP
482.6 mm x 88 mm x 450 mm
482.6 mm x 88 mm x 450 mm
482.6 mm x 88 mm x 450 mm
482.6 mm x 88 mm x 450 mm
482.6 mm x 88 mm x 450 mm
482.6 mm x 132 mm x 600 mm
482.6 mm x 132 mm x 600 mm
20
Guidelines
The PROTECT C.R complies with the product norm EN 50091.
The CE symbol on the unit certifies the compliance to the EG
guidelines for 73/23 EEC low voltage and for 89/336 EEC
electromagnetic compatibility (EMC), when following the
installation instructions in the manual.
For the 73/23 EEC low voltage guidelines
Reference number
EN 62040-1-1: 2003
For 89/336-EMC guidelines
Reference number
EN 50091-2: 1995
EN 61000-3-2: 1995
EN 61000-3-3: 1995
21
4
Set-Up and Operation
4.1
Unpacking and Inspection
The device has been fully tested and inspected. Although the
device has been packed and shipped with the usual degree
of care, damage during transport cannot be ruled out
completely.
Claims for damage during transport must always
be made with the transport company!
i
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
member of staff from the transport company. Don’t turn on
the unit and register the damage with the AEG representative
or dealer immediately.
Check the delivery is complete:

PROTECT C.R (S) with 1000, 2000, 3000 or 6000 VA

Communication cable

CD with "CompuWatch" shutdown software

Operating instructions
PROTECT C.R (S) with 1000, 2000 or 3000 VA include
additionally:

Mains connection cable with shockproof plug

3 load connection cables (10 A)
Delivery of external battery modules includes:

External battery unit

Special battery connection cable
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.
22
Please keep the 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, particularly
in the case of the 2 and 3 kVA models and if
there are external battery units.
4.2
Point of Installation
PROTECT C.R is designed to be installed in a protected
environment. When installing the unit, pay attention to such
factors as sufficient ventilation and suitable ambient
conditions.
PROTECT C.R is air-cooled. Do not obstruct the
air vents!
The UPS and in particular its external battery
modules should preferably be operated at room
temperature (between 15°C and 25°C).
Install the units in a room that is dry, relatively dust-free and
free of chemical vapours.
Make sure that no magnetic storage media are stored and/or
operated close to PROTECT C.R
Check the nameplate to make sure the voltage
and frequency data correspond to the values
applicable to your loads.
23
4.3
Overview: Connections, Operating /
Display Elements
4.3.1
Front view
PROTECT C. R (S) with 1000, 2000, 3000 VA
PROTECT C. R with 6000 VA
4.3.2
Rear view
PROTECT C. 1000 R (S)
PROTECT C. 2000 R (S)
24
PROTECT C. 3000 R (S)
PROTECT C. 6000 R
Comments
1. Mains connection (UPS input)
PROTECT C. 6000 R via terminal block (Pos. 11)
2. Mains input circuit breaker
3. Load connections (UPS outputs) PROTECT C. 3000 R (S)
with additional load connection (IEC 320-16A – Pos.9).
PROTECT C. 6000 R additionally via terminal block (Pos.11)
4. Connection for external battery module
5. Data interface for telephone, modem fax (RJ11)
or 10/100 MBit/s network (RJ 45)
6. Vent (Attention: At least 10 cm of free area are
required behind the vent for free ventilation!)
7. Communication interface RS232 (SUB-D9)
8. Communication slot for optional expansion cards:
SNMP, AS/400
9. Outlet 16A (only for PROTECT C. 3000 R (S))
10. Circuit breaker for appliance connectors
(PROTECT C. 3000 R (S) and PROTECT C. 6000 R)
11. Connector via terminal block (only C. 6000 R)
25
4.3.3
Display
Explanations
1.
2.
3.
4.
5.
6.
7. - 11.
7.
8.
9.
10.
11.
12.
ON-Pushbutton
OFF-Pushbutton (Off) / Alarm off
Green LED rectifier (UPS ON)
Orange LED for battery mode (BATTERY)
Orange LED bypass (BYPASS)
Green LED for net state (AC INPUT)
Bar graph LEDs ( 7-10 green, 11 orange) for
UPS battery utilization respectively capacity
(remaining autonomy time)
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 (ALARM)
You will find detailed explanations of the displays on page 38.
26
5
Commissioning
5.1
Mechanical Set-Up
Note the following points when setting up the UPS system
and its external battery units (special accessories):

Make sure the rack is able to support the weight. This is
particularly important in conjunction with external battery
units (special accessories).

Install the units so that adequate air circulation is
assured. There must be at least 100 mm clearance at the
back 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.

Avoid extreme temperatures! We recommend an ambient
temperature of 15 °C to 25 °C in order to maximise 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 4.2, page 9 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, leave the unit to acclimatise for 2 hours before
you switch it on.
5.1.1
Set-Up in a 19 " Rack
PROTECT C. 1000 R (S), C. 2000 R (S), C. 3000 R (S) and
C. 6000 R are to be installed in a 19"- Rack. Mount the units
preferable in the lower third of your rack considering the
centre of gravity of the rack and an adequate air circulation.
You will receive adequate rack rails at your specialist dealer.
27
5.2
External Battery Expansions
PROTECT C. 2000 R, C. 3000 R and C. 6000 R require at least
one external battery module for accurate operation. To achieve
longer backup time, it is possible to connect multi-battery
packs. Connect exclusively the following products together:
PROTECT C. 1000 R with
PROTECT C. 1000 R BP
PROTECT C. 2000 R with
PROTECT C. 2030 R BP
PROTECT C. 3000 R with
PROTECT C. 2030 R BP
PROTECT C. 6000 R with
PROTECT C. 6000 R BP
PROTECT C.R with 1 battery expansion
Fig.: PROTECT C. 2000 R and C. 2030 R BP
1.
Check the correct fit of the UPS and the battery
unit (compare the stated DC voltage on the label
of the UPS and the battery unit).
Never connect different battery voltage levels
with each other!
2.
Now connect both battery connectors using the
supplied battery connection cable. When
connecting, make sure that you push the plug
quickly and firmly in the battery connectors.
28
PROTECT C.R with 2 battery expansions
Fig.: PROTECT C. 2000 R and 2 units C. 2030 R BP
1.
Check the correct fit of the UPS and the battery
unit (compare the stated DC voltage on the label
of the UPS and the battery unit).
Never connect different battery voltage levels
with each other!
2.
Now connect the corresponding battery connectors
using the supplied battery connection cables as
shown in the figure above. When connecting, make
sure that you push the plug quickly and firmly in
the battery connectors.
To connect additional battery modules follow the procedure
explained above.
5.2.1
Electrical Start-Up
Verify that UPS voltage of your country
1.
corresponds to your equipment voltage. The
default setting is set to 230 V. Output voltage on
the UPS system can be adjusted with the software
“CompuWatch” in steps of 220, 230 and 240 Vac.
Turn on the PROTECT C.R to the mains
To guarantee an accurate function of your UPS and all
additional devices, the mains have to be provides with the
corresponding protection. Connect the models PROTECT
C. 1000 R (S), C. 2000 R (S) and C. 3000 R (S) with the
29
provided mains connection cable to a customary shockproof
socket. Make sure that the dimension of the circuit breaker is
sufficient. Especially the PROTECT C. 3000 R (S) needs a
circuit breaker with 16A.
The PROTECT C. 6000 R is connected directly with the
modules via the terminal block. The cable diameter of each
conductor is 6 mm². The circuit breaker has to have the
dimension of 32 A.
After connecting the unit to the mains, connect the outputs of
your UPS to your loads. Use the load connection cables
provided for this. Don’t switch on the loads yet. Please
contact your dealer if you require additional load connection
cables.
If you are using combined rack (circuit with
mains and UPS-power) mark each circuit with
the corresponding supply (mains or UPS).
The output of PROTECT C. 6000 R should supply additional
separated circuits. Make sure that circuit protection is set up
selectively. The cables for the connection between
PROTECT C. 6000 R and the sub distribution must have a
diameter of 6 mm². Please note the following information in
the sub distribution.
 Maximal allowed total load
2.
i
i
3.
 Maximal allowed load for each loads output
Activate the mains input circuit breaker. If
necessary switch it to “ON”.
Default setting for PROTECT C. 1000 R (S),
C. 2000 R (S) and C. 3000 R (S): No automatic supply
for load over integrated bypass after executing
step 1 and 2 (Modification of the configuration
with the provided Software ”CompuWatch“).
Default setting for C. 6000 R: Automatic supply for
load over integrated bypass after executing step 1
and 2 (Modification of the configuration with the
provided Software ”CompuWatch“).
Now switch on the UPS. To do this, press and hold
the UPS ON switch for about 2 seconds.
30
4.
i
5.
i
When being powered on, the UPS will perform
self-diagnosis, the Load/Battery level LEDs will be
turned on and then off one after another in
ascending order. After synchronising the inverter
successfully the LED “UPS ON” will go on after
some seconds, with the UPS in normal mode. If
the power supply is in order (mains within the
range) an additionally LED “AC INPUT” will go on.
If this LED is flashing, the phase and neutral of the
UPS are exchanged. In this case turn the mains
connector 180° in the shockproof socket
(C. 1000 R (S), C. 2000 R (S) and C. 3000 R (S)),
respectively correct the wiring (C. 6000 R).
Please shut down the entire system if you
cannot solve any problems which occur. Press
the OFF button for about 2 seconds. Disconnect
the UPS from the mains by pulling the mains
connector. Please contact our hotline (s.p. 4).
When all displays are lit as described, switch on
your loads one after the other. Note the maximum
permitted UPS load when doing this. Keep in mind
that especially loads like laser printers and big
CRTs have high power consumption and can
cause an overload of the UPS quickly.
Behaviour when switching on / off:
The behaviour after switching on (ONPushbutton) or off (OFF-Pushbutton) the UPS
can be defined with the Software “CompuWatch”:
Activation of the automatic bypass (factorymade presetting PROTECT C. 6000 R) or either
deactivation (PROTECT C. 1000 R (S), C. 2000 R (S)
and C. 3000 R (S)).
31
5.3
Operating Statuses
5.3.1
Normal Operation
Autom.
bypass
REC
~
Mains
Power circuit with
mains supply
INV
~
Safe busbar:
Load
~
Battery
charger
Diagram
Battery
Once you have connected the UPS to a suitable mains
connection, you can start operation using the UPS main
switch (see also "Electrical Start-Up" on page 29). Normally,
the UPS operates continuously. The UPS now supplies the
output with voltage, this being signalled by the symbols mains
(LED AC INPUT) and rectifier (LED UPS ON) symbols which
light up permanently.
This is often referred to as “online” mode. It offers the
greatest protection, in particular when there are mains
fluctuations and mains failures, because the loads are
supplied continuously with voltage with no interruptions in this
operating mode.
The LED bargraph (LED chain on the left hand side of the ON
/ OFF button) show during operation the actual utilization of
the UPS (s. page 38).
32
5.3.2
Battery Operation / Autonomy Operation
Autom.
bypass
REC
~
Mains
Power circuit with
faulty mains supply
INV
~
Safe busbar:
Load
~
Battery
charger
Diagram
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 (LED BATTERY)
lighting up, as well as an intermittent acoustic signal every 4
seconds and every second before switching off. This can be
suppressed by pressing the “ALARM OFF” button. With
decreasing battery capacity the alarm is activated automatically.
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.
The LED bargraph (LED chain on the left hand side of the ON
/ OFF button) show during operation the actual utilization of
the UPS (s. page 38 ff).
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 once more, the rectifier and the battery charger switch
back on automatically. The rectifier then continues supplying
the inverter and the battery charger takes over charging the
battery.
33
5.3.3
Bypass Operation
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 via the bypass that switches on automatically. This
is signalled by the LED BYPASS symbol.
Autom.
bypass
REC
~
Mains
Power circuit with
faulty INV
INV
~
Safe busbar:
Load
~
Battery
charger
Diagram
Battery
This function is also referred to as passive redundancy. It
protects against total failure of the voltage supply on the
protected busbar, however in the operating status that is now
attained, mains faults would have a direct effect on the load.
As a result, the electronics continuously attempt to switch
back to "online" / normal operating status (e.g. when the
overload or overtemperature no longer applies).
The bypass is a link that switches extremely rapidly. It is
located between the load and the mains. The associated
synchronisation unit in the bypass ensures that the frequency
and phase of the inverter voltage is synchronised with the
mains.
i
The LED bar graph functions as display for USP
utilisation. The signal goes off during this
operations status every 2 seconds.
34
5.3.4
Unit overload
The load on the UPS should never exceed the specified rated
load of the unit. If a unit overload occurs nevertheless the
fault LED is turned on accompanied with a signal tone (twice
per second). The connected loads continue to be supplied for
a certain 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 operation!
As a rule, if there has never been an overload during normal
operation, there will not be one during battery operation
either.
The signalling of the red fault LED (ALARM) in
combination with a continuous alarm points out
a switching of fault. Follow the instructions in
chapter 6.
35
5.4
Interfaces and communication
5.4.1
Data line protection RJ11 and RJ45
The incoming data lines are connected to the “IN” line at the
rear of the UPS. The “OUT” line is connected via data line
with your terminal.
i
5.4.2
The data line protection supports networks with
transfer rates between 10 and 100 MBit/s.
Computer interfaces RS232
The UPS offers various interfaces to manage the system and
to comfortable readout state information and important
parameters. The communication protocol is optimized for
operation with the shutdown and UPS management software
“CompuWatch” from AEG. To connect to the UPS to your
computer use the provided RS232 communication cable by
attaching them to a free serial port of your pc.
RS232 interface: The interface is connected via a 9 pole
Sub-D connector on the back of the unit (pos. 4 p. 23 / 24).
PINs: 2 = TxD; 3 = RxD; 5 = GND.
5.4.3
Communication Slot
If the cover on the rear of the UPS is removed (pos. 8 p. 25),
additional optionally available communication components
can be installed there.
AS/400 board: Slot card with status messages, realised via
potential-free relay contacts
SNMP board: Slot card 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 are in preparation.
i
Using the communication slot deactivates the
RS232 interface of chapter 5.4.2.
36
5.4.4
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 ensures that the
availability of IT components and data security is guaranteed.
The "CompuWatch" shutdown software supports different
operating
systems:
Windows
98SE/ME,
Windows
NT/2000/XP, Linux, Novell Netware, IBM AIX, HP-UX, SUN
Solaris, Mac OS, and others.
Refer to the manual on the CD for details about installing the
software on the various operating systems.
Download
of
Updates:
www.aegpartnernet.com
>>
PRODUCTS >> Software >> CompuWatch
37
6
Signalling and Error Correction
6.1
Signalling
1.
ON push button (ON): Press the ON switch for
about 2 seconds to switch on the UPS.
UPS Test: To execute an UPS self test press this
button for about 2 seconds in the normal operation
mode.
2.
OFF push button (OFF): Press the OFF switch
for about 2 seconds to switch off the UPS
Deactivate
acoustic alarm: By pressing this switch for about
2 seconds during the alarm an acoustic alarm can
be deactivated.
3.
LED UPS ON (inverter): The green LED lights up
if the UPS system is supplying voltage provided
by the mains power via the inverter.
4.
LED BATTERY (battery): The orange LED lights
up when power is supplied by the batteries.
38
5.
LED BYPASS (bypass): The orange LED lights
up when the UPS system is supplying voltage
provided by the mains power via the bypass.
6.
LED AC INPUT (mains status): The green LED
lights up if mains voltage is in a specified range of
tolerance. The LED ON LINE flashes when the
phase and neutral conductor have been reversed
at the input of the UPS system. In this case turn
the mains connector 180° in the shockproof
socket.
7. -11. LED Bargraph for UPS battery utilization resp.
capacity (remaining autonomy time)
These LEDs show the load of the UPS system if
the mains power is available (normal operation):
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 the battery operation, the LEDs 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.
LED ALARM (fault): The red LED lights up and
an acoustic warning signal is issued continuously
when the UPS system is in fault condition.
39
6.2
Fault Diagnosis / Fault Rectification
The PROTECT C.R generates detailed error messages.
Support personal can localise and interpret faults quickly and
precisely.
6.2.1
Error Messages
Problem
Cause
Solution
UPS does not start. No
indication, no warning tone
even though system is
connected to mains power
supply.
Mains and battery voltage Check building wiring
not in the tolerance range, socket outlet and input
cable.
possible battery deep
discharge.
LED AC INPUT flashes and Phase and neutral
Rotate mains power
audible alarm sounding
conductor at input of UPS socket by 180° or
every 3 minutes.
system are reversed.
connect UPS system.
LED AC INPUT flashes and Input power and/or
LED “Bat.” lights up.
frequency are out of
tolerance.
Check input power
source (Voltage,
frequency) and inform
house electrician if
necessary.
LED AC INPUT and LED
BYPASS light up even
though the power supply is
available. No supply of
connected loads.
Inverter not switched on.
Press On-Switch “ON”
for about 2 seconds.
LED UPS ON and LED
BATTERY lights up, and
audible alarm sounding
every 4 seconds.
Mains power supply has
Try to replace mains
failed. Automatic switch to supply (possibly
battery mode.
triggered fuse in sub
distribution). When
audible alarm sounding
every second, battery
is almost empty. At this
point it is time to
proceed with an system
shutdown of all you IT
equipment.
LED ALARM lights, warning Overload of the UPS
tone once a second.
system.
40
Reduce utilizations of
UPS by removing loads
of UPS output.
Emergency supply period
shorter than nominal value
Batteries not fully charged Charge the batteries for
/ batteries old resp. defect at least for the charging
time acc. Chapter 3.4,
page 18 and then
check capacity. If the
problem still persists,
consult your dealer.
LED ALARM lights, LED
BATTERY blinks, warning
tone once a second
Charger or Batteries
damaged
Notify dealer!
LED ALARM lights up,
permanent warning tone
UPS fault
Notify dealer!
If you cannot solve the problem that has occurred, stop the
entire procedure, switch off the UPS and disconnect the
connector from the socket. Please contact our hotline in this
case (see page 4).
Please have the serial number of the unit as well as the
purchase date to hand in this case. The hotline will provide
you with technical support and can inform you about further
procedures once you have described the problem.
41
7
Maintenance
The PROTECT C.R consists of advanced and resistant
components. To guarantee a continuous and high availability
it is recommended to check the unit (especially the batteries
and the fans) in regular intervals (at least every 6 months).
CAUTION:
Follow safety and security regulations
unconditionally!
7.1
Charging the Battery
The battery is automatically charged when the mains is
present, irrespective of the operating mode.
The complete charging time of the battery after a length
discharge period depends, above all, on the number of
additional external battery units.
Charging time up to 90% of rated capacity
Coupled
battery modules
Integr. battery
7.2
C. 1000 R
5h
C. 2000 R
C. 3000 R
C. 6000 R
-
-
-
1
24 h
5h
5h
5h
2
40 h
14 h
14 h
14 h
3
-
24 h
24 h
24 h
4
-
32 h
32 h
32 h
5
-
40 h
40 h
40 h
Maintenance
The following maintenance work should be performed:
Task
Interval
Described in
Visual check
6 months
Chapter 7.2.1
Battery / fan check
6 months
Chapters 7.2.2 / 7.2.3
42
7.2.1
Visual Check
When visually checking 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.
CAUTION:
PROTECT C.R 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.
7.2.2
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 page 4).
7.2.3
Fan Checking
Regularly check the fans for dust build-up and noticeably
untypical noise development. Clean the intake openings if
they are blocked. Contact our hotline if a fan is running
unusually loud or irregularly (see page 4).
43
8
Storage, Dismantling and Disposal
8.1
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
8.2
Connect PROTECT C.R 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 7.1.
Dismantling
The system is dismantled in reverse order of the installation
instructions.
8.3
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
civil or criminal prosecution.
44
9
Glossary
9.1
Technical terms
Appliance protection
Surge technology term
The conventional mains surge protection consists
of an mains earthwire (class B), an overvoltage
protection (class C) and an appliance protection
(class D) – see also e.g. under
http://www.phoenixcontact.de (topic „TRABTECH“)
Class D
see appliance protection
DC/DC Booster
Circuit technology to boost the direct current on a
higher voltage level
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)
LED
Light Emitting Diode
Electronic semiconductor component, commonly
called light diode. Used for optical signalling.
PFC
Power Factor Correction
Circuit technology to minimize circuit backfeed
(important for 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
common protocol in networks to manage / control
appliances
VFD
Output Voltage and Frequency Dependent from
mains supply
The UPS output depends of mains voltage and
frequency variations. Former notation: OFFLINE
VI
Output Voltage Independent from mains supply
The UPS output is independent of mains voltage
and frequency variations. The mains voltage
however is rectified by electronic / passive voltage
regulators. Former notation: LINE-INTERACTIVE
VFI
Output Voltage and Frequency Independent from
mains supply
The UPS output is independent of mains voltage
and frequency variations. Former notation: ONLINE
45
Guarantee certificate
Type: …….…………………......................................................
Serial-no.: ……………………..……………...............................
Date of purchase: …………….............……………………........
Trading stamp / Signature
Specifications are subject to change without notice.
AEG Power Ssolutions GmbH
Emil-Siepmann-Straße 32
59581 Warstein-Belecke
Germany
Operating Instructions
BAL 8000017715_02 EN
46
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