Pyramid DSP Installation manual
Operating and Installation
Manual for
PYRAMID DSP
120-160kVA
Uninterruptible Power Systems
USER MANUAL
CONTENTS
SAFETY ...................................................................................................................................................1
I.
GENERAL DESCRIPTION ..............................................................................................................2
1.1 Introduction ...............................................................................................................................2
1.2 Design Concept ........................................................................................................................3
1.2.1 OPERATING MODES OF UPS .....................................................................................4
1.3 Technical Specifications ...........................................................................................................6
II.
UPS INSTALLATION.......................................................................................................................7
2.1 Introduction ...............................................................................................................................7
2.2 Unpacking.................................................................................................................................7
2.3 Equipment Positioning..............................................................................................................7
2.4 Connecting the UPS Power Cables .........................................................................................7
2.4.1 Safety Earth....................................................................................................................8
2.4.2 Cable connection procedure ..........................................................................................8
2.4.3 UPS Power Cable Connection Terminals ......................................................................9
2.4.4 Battery Installation..........................................................................................................10
III.
FRONT PANEL................................................................................................................................13
3.1 Introduction ...............................................................................................................................13
3.2 Front Panel Menu Descriptions ................................................................................................13
3.2.1 MEASURES Menu Items ..............................................................................................14
3.2.2 ALARMS Menu Items.....................................................................................................14
3.2.3 INFORMATION Menu Items ........................................................................................14
3.2.4 ADJUST Menu Items......................................................................................................15
3.2.5 OPTIONS Menu Items ..................................................................................................15
3.2.6 COMMAND Menu Items ................................................................................................16
3.2.7 TIME MENU ITEMS .......................................................................................................17
3.2.8 SERVICE Menu Items...................................................................................................17
3.3 STATUS Messages ..................................................................................................................17
3.4 Shutdown messages ................................................................................................................18
3.5 Fault Messages and Quick Troubleshooting ............................................................................18
IV. PARALLEL OPERATION................................................................................................................21
4.1 Introduction ...............................................................................................................................21
4.2 Parallel Operation Modes of PDSP Series UPSs.....................................................................22
4.2.1 PARALLEL mode ...........................................................................................................22
4.2.2 REDUNDANT mode.......................................................................................................22
4.2.3 N+1 REDUNDANT mode ...............................................................................................23
V.
OPERATING INSTRUCTIONS........................................................................................................26
5.1 INTRODUCTION ......................................................................................................................26
5.2 OPERATING INSTRUCTIONS FOR A SINGLE UPS UNIT. (ONLINE OPERATION)............26
5.2.1 Procedure For Turning On The UPS To Supply The Load From A Complete
Power-Off Condition .......................................................................................................26
5.2.2 Power Off .......................................................................................................................26
5.2.3 Switching into Maintenance Bypass Mode ....................................................................27
5.2.4 Switching From Maintenance Bypass Into Normal Operation .......................................27
5.3 OPERATING INSTRUCTIONS FOR PARALLEL CONNECTED UPSs. .................................27
5.3.1 Procedure For Turning on the UPS (First Installation)...................................................27
5.3.2 Power Off .......................................................................................................................28
5.3.3 Switching the Parallel UPS System into Maintenance Bypass Mode
(uninterrupted transfer)...................................................................................................28
5.3.4 Switching the Parallel UPS system into Normal Operation From a
Maintenance Bypass Power Down Condition. (uninterrupted transfer) .........................28
1
VI. MAINTENANCE ...............................................................................................................................29
6.1 Scheduled Maintenance ...........................................................................................................29
6.2 Daily checks..............................................................................................................................29
6.3 Weekly checks..........................................................................................................................29
6.4 Annual maintenance.................................................................................................................30
6.5 UPS Storage and transportation ..............................................................................................30
VII. FAULTS AND TROUBLESHOOTING.............................................................................................31
General Procedure For Fault Checking And Troubleshooting .................................................31
VIII. UPS REMOTE MONITORING AND CONTROL ...........................................................................32
Using Serial Port.......................................................................................................................32
Communication Routing Switch .....................................................................................32
Serial Communication Cable ....................................................................................................33
Modem Connection .................................................................................................................33
8.3.1 Hardware Configuration .................................................................................................33
8.3.2 Functioning Principle ......................................................................................................33
8.3.3 Modem programming procedure ...................................................................................34
8.3.3.1 SMART Modem Programming (PC modem)..................................................34
8.3.4 Modem –UPS Connection Cable ...................................................................................34
8.5 Dry Contact (Interface) Connections ........................................................................................34
8.6 Remote Monitoring Panel .........................................................................................................35
SAFETY
IMPORTANT NOTICES
1.
2.
3.
4.
5.
6.
7.
Read instructions carefully before installing and starting the UPS
All warnings in the manual should be adhered to.
All operating instructions should be followed.
The unit should be supplied by a grounded outlet. Do not operate the unit without a ground source.
Power cord of the UPS should be routed carefully so that they are not to be walked on.
Please save this manual.
Please save or recycle the packaging materials.
WARNING!
• Do not insert any object into ventilation holes or other openings.
• To reduce the risk of fire or electric shock, install in temperature and humidity controlled indoor area free of
conductive contaminants.
• To reduce the risk of fire, replace fuses with the same type and rating when necessary.
CAUTION!
• Only qualified personnel should install or service UPS/batteries.
• Risk of electric shock, do not remove covers. No user serviceable parts inside, refer
qualified service personnel.
servicing to
• The output may be energized when the unit is not connected to a mains supply.
• Risk of electric shock! Hazardous live parts inside. This unit is energized from the battery supply
even when the input AC power is disconnected.
• To reduce the risk of electric shock, disconnect the UPS from the mains supply before installing a computer
interface signal cable. Reconnect the power cord only after signaling interconnections have been made.
ABOUT THE BATTERIES
CAUTION: RISK OF ELECTRIC SHOCK!
The battery circuit is not isolated from the mains voltage. Hazardous voltages may occur
between the battery terminals and the ground!
• A battery can present a risk of electric shock or burn from high short circuit currents. The following
precautions should be taken when working on batteries :
* Remove watches, rings or other metal objects.
* Use tools with insulated handles.
• The batteries in this UPS are recyclable. Batteries must be disposed of according to local environmental
laws. The batteries contain lead and pose a hazard to the environment and human health if not disposed of
properly.
• Do not dispose of batteries in a fire. The batteries may explode. Do not open or mutilate the batteries. They
contain an electrolyte which is toxic and harmful to the skin and eyes. If electrolyte comes into contact with
the skin the affected area should be washed immediately.
• The internal energy source (the battery) cannot be de-energized by the user.
• When changing batteries, install the same number and same type of batteries.
I. GENERAL DESCRIPTION
1.3 Introduction
INFORM PDSP Series Uninterruptible Power Supplies are double-conversion, on-line UPS’s, manufactured
with the latest IGBT and PWM technology, to produce an uninterruptible, microprocessor controlled pure sine
wave output to critical loads.
INFORM PDSP Series units are 3-phase in/3-phase out devices, and they are installed between a three phase
critical load, and a 3-phase+N mains supply
The advantages of using PDSP UPS:
• Power blackout protection:
If the mains power fails, the UPS continues to supply the critical load using the energy stored in its
batteries, keeping the load immune from power disturbances.
• Increased power quality:
The UPS has its own internal voltage and frequency regulating circuits, which ensure that, its output to the
critical load is maintained within close tolerances, independent of voltage and frequency variations on the
mains power lines.
• Increased noise rejection:
By rectifying the input AC power to DC power and then converting it back to AC (Double-Conversion) any
electrical noise present on the input mains supply line is effectively isolated from the UPS output. Therefore
the critical load is supplied with only clean and uninterrupted AC power.
Basic Features
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:
Microprocessor Controlled
Double Conversion, on-line UPS
IGBT Rectifier (PWM)
High Input PF
Low THDI
IGBT Inverter (PWM)
Sinusoidal output Waveform.
Low output Voltage THD
High Nonlinear Load capacity (CF 3:1)
High Unbalanced loading capability.
Efficiency Up to 94%
Overload and short circuit Protection
Over temperature protection
Static Bypass Switch
Maintenance Bypass Switch
Separate bypass input facility (split Bypass)
Parallel Operation (Optional)
LCD Display
Alarm History (Up to 128 Alarms)
Real time clock (date and time)
Emergency Power off (EPO)
Cold-start feature
Dual Polarity Batteries (Internal and/or external)
Automatic and manual Battery Test
Automatic and manual Boost Charge
Battery current limit adjust
Deep discharge protection
Remaining battery time indication
AC input filter
AC output filter
Alarm relay contacts (Standard)
RS232 communication port (Standard)
RS485 interface (Optional)
SNMP adapter (Optional)
1
•
•
•
•
Remote monitoring Panel (Optional)
RS232 port multiplexer (Optional)
MODBUS adapter (Optional)
Diagnostic and adjustment via PC.
1.2 Design Concept
Maintenance Bypass Switch
Static Bypass
S3
SB
S2
(F4-F5-F6)
3 PHASE
MAINS I/P
S1
(F1-F2-F3)
K1
-
̃-
̃
Rectifier /
Charger
K2
Inverter
S4
(F7-F8-F9)
3 PHASE
AC Output
S5
(F10-F11-F12)
Battery
(Dual Polarity)
Figure 1.1 Block Diagram Of The UPS
S1 (F1-F2-F3)
S2 (F4-F5-F6)
S3
S4 (F7-F8-F9)
S5 (F10-F11-F12)
K1
K2
: Rectifier Input Switch / Fuses
: Bypass Input Switch
: Maintenance Bypass Switch
: Output Switch
: Battery Switch / Fuses
: Rectifier Input Contactor
: Inverter Output Contactor
DESCRIPTION OF BLOCKS
RECTIFIER: In PDSP Series UPSs, a PWM controlled IGBT rectifier is used to increase input power factor
(PFC) and to decrease input current harmonics (THDI).
The IGBT rectifier accepts 3-phase AC input and produces a dual polarity DC voltage for both supplying the
inverter and charging the batteries.
BATTERIES: Batteries are used as reserve DC power supply for the Inverter in case of mains failure. In
PDSP Series, batteries are connected in series with a center-tap output to obtain a dual polarity DC supply.
Batteries are discharged by the inverter during mains failure. The discharged batteries are re-charged by the
IGBT Rectifier on a constant current / constant voltage basis, if AC mains power is available.
INVERTER: It is manufactured by using the latest IGBT technology and Pulse width Modulation (PWM)
technique. The Inverter converts the DC BUS voltage supplied by the IGBT Rectifier and / or the batteries into
a well regulated 3-phase AC voltage with fixed voltage and frequency.
The output of the inverter is used to supply the critical loads connected to the UPS output.
2
STATIC TRANSFER SWITCH (STATIC BYPASS) : This is an electronically controlled transfer switch, which
enables the critical load to be connected either to inverter output or to a by-pass power source. During normal
operation, the load is supplied by the inverter output, but in case of an overload it is automatically transferred
to the bypass source without any interruption.
MAINTENANCE BYPASS SWITCH (MBS) : This is a manually controlled mechanical switch, which is used to
supply the critical load, using the bypass source, when the UPS is shut down for maintenance or
troubleshooting purposes.
The load is unprotected against mains supply disturbances and black-outs when it is connected to either static
or maintenance bypass supply.
1.3.1
OPERATING MODES OF UPS
PDSP series UPSs are capable of operating in various different modes for maximum application flexibility.
These modes are:
-
ONLINE mode: This is the normal operation mode for a single UPS. As long as the mains supply is
available and in required tolerances, the load is supplied by the well regulated inverter output and the
batteries are charged at the same time. In case of mains failure, the inverter keeps supplying the load
using the energy stored in the batteries.
-
ECO-mode: This is the off-line operation mode for a single UPS. As long as the mains supply is
available and in required tolerances, the load is supplied by the mains supply (bypass supply) via the
Static Bypass Switch of the UPS and the batteries are charged at the same time. During that time
inverter keeps running under no-load conditions and takes over the load in case of a mains supply
(bypass supply) failure, without any interruption. After restoration of the mains supply the load is
transferred back to bypass supply again.
-
PARALLEL, REDUNDANT and N+1 REDUNDANT modes are used for parallel operation of two or
more UPS units and will be explained in parallel operation section later in this manual.
When operating in one of the above operating modes, UPS may be in one of the following operating
conditions:
A. Normal Operation (If Mains supply is available):
All fuses and power switches are closed (except the Maintenance Bypass Switch), and the load is supplied
by the Inverter Output. During normal operation, the Rectifier supplies DC power to the Inverter and
charges the Batteries at the same time.
B. Battery Operation :
The Batteries are connected to the Rectifier output. In case of a mains failure (mains power outage or AC
input voltage out of tolerance), the Rectifier stops operating and the DC voltage necessary for the inverter
operation is supplied by the batteries. Therefore the AC voltage output supplying the critical load is not
interrupted, until the batteries are fully discharged. At the end of the discharging time the Inverter is turned
off and it start again automatically, together with the Rectifier, when the mains power is restored, and the
UPS returns o normal operation.
The Rectifier is also turned off and Inverter operates on batteries during automatic or manual battery test
procedure.
C. By-Pass Operation :
If the Inverter output is overloaded or in case of a problem in the UPS, the static switch transfers the load to
the bypass supply without any interruption, provided that the bypass supply is available and within the
tolerated limits.
At the end of the overloading period, if the fault condition is restored, static switch transfers the critical load
again to the inverter output. Note that, during operation from the bypass supply, the critical load may be
affected by any possible disturbances or power failure in the bypass supply.
3
Battery
CB Input
Emergency
Stop
Line Failure
Relay
Battery Low
Relay
Bypass
Relay
( RS232 / SNMP )
Communication
Select Switch
Dry Relay Output Contacts
Parallel
Communication
Sockets
S6
Manual Bypass
Switch
S7
ON/OFF Switch
S4
AC Output
Switch
S3
Maintenance
Bypass Switch
S2
Static Bypass
Switch
S1
AC Input
Switch
S5
Battery Input
Switch
Figure 1.2
120-160 kVA Switch Configuration
4
RS232
Communication Port
(DB9 Female)
1.4
Technical Specifications
MODEL
Output (kVA)
Output (kW)
Output Power Factor
INPUT
Number of Phases
Input Voltage
Input Voltage Tolerance
Input Power Factor (PF)
Input THDI
Input Frequency
By-pass Voltage
By-pass Frequency
By-pass Frequency Tolerance
RFI Level
Split By-pass Connection
OUTPUT
Number of phases
Output Voltage
Output Voltage Tolerance
Output Frequency
Output Frequency Tolerance (line synchron)
Output Frequency Tolerance (free running)
Efficiency (at full linear load)
Load Crest Factor
Output Voltage THD
Overload
BATTERIES
Total Number
Float Charge Voltage (250C)
End of Discharge Voltage
Battery Test
Boost Charge
INTERFACE
RS 232 comm. Port
RS 485 comm. Port
Remote Monitoring Panel
SNMP Adapter
Modbus Adapter
PDSP3120
120
96
PDSP3160
160
128
0,8
3 Phase + Neutral
220/380 Vac , 230/400Vac or 240/415Vac 3phase+N
+20%,-25% (+15% , -30% for 240/415Vac)
0,99 (at full load)
≤ 5 % (at full load)
50Hz ± 5 %
220/380 Vac , 230/400Vac or 240/415Vac 3phase+N
50Hz
(± 2 % )
EN50091
Available
3 Phase + Neutral
220/380 Vac , 230/400Vac or 240/415Vac 3phase+N
±1%
50 Hz
(± 2 % )
± 0,2 %
up to 94 %
3:1
≤3%
125% Load 10min. , 150% Load 1min.
60 (2x30) pieces 12V
± 405 Vdc
± 300 Vdc
Automatic and Manual
Available
Standard (Optional port multiplexer available)
Optional
Optional
Optional
Optional
3x Dry Relay Contacts
(Line failure, battery low, bypass)
Standard
Alarm Relay Contacts
EPO Input
ENVIRONMENT
Operating Temperature
Operating Humidity
Acoustic Noise
Dimensions (HxWxD) (mm)
Protection Class
Weight (Without Batteries) (approx. kgs)
0
0 – 40 C
< 90% (Non-Condensing)
<70 dB
1900 x 780 x 890
IP20
375
5
425
II. UPS INSTALLATION
2.1 Introduction
WARNING!!!
• Do not apply electrical power to the UPS equipment before the arrival of authorized service personnel.
• The UPS equipment should be installed only by qualified service personnel.
• The connection of the batteries and the maintenance should be done by qualified service personnel.
• Do not make any short- circuit to the battery poles. Because of high voltage and high short-circuit current,
there is risk of electrical shock or burn.
• Eye protection should be worn to prevent injury from accidental electrical arcs. Remove rings, watches and
all metal objects. Only use tools with insulated handles. Wear rubber gloves.
This chapter contains location installation information of the UPS and the batteries. All the establishments
have their own specialties and needs. So in this part, the installation procedure is not being explained step by
step. Instead, general procedure and the applications are explained for the technical personnel.
2.5 Unpacking
The UPS is packed and enclosed in a structural cardboard carton to protect it from damage.
1) Inspect for damage that may have occurred during the shipment If any damage is noted, call the
shipper immediately and retain the shipping carton and the UPS.
2) Carefully open the carton and take the UPS out.
3) Retain the carton and packing material for future use.
Unit package contents:
1) A user manual and Guarantee certificate.
2) Battery cabinet and/or shelf (Optional)
3) Battery connection cables.
2.6 Equipment Positioning
1.
2.
3.
4.
5.
6.
The equipment’s installation place must be an easy serving place.
Install the UPS in a protected area with adequate air flow and free of excessive dust.
You must therefore allow for a minimum gap of 800 mm behind the unit to allow adequate air flow
Select a suitable place (temperature between 0°C and 40°C) and the relative humidity (%90 max)
It is recommended to place the equipment in an air-conditioned the room (24°C)
Temperature is a major factor in determining the battery life and capacity. Keep batteries away from main
heat sources or main air inlets etc.
7. In case of an operating the UPS in a dusty place, clean the air with a suitable air filtration system.
8. Keep out of your equipment from explosive and flammable items.
9. Avoid direct sunlight, rain, and high humidity.
WARNING!!!
DO NOT LIFT THE BATTERY RACK OR CABINET AFTER THE BATTERIES HAVE BEEN
INSTALLED.
2.7 Connecting the UPS Power Cables
WARNING!!! A separate power line should be used to supply the UPS AC input. Never use the same
line to supply another electrical device. Do not use any additional cable to increase the length of the
UPS’s input cable. It is advised to use an MCCB suitable for the input current on the UPS’s input line.
The connection of the electrical panel should be supplied by a grounded outlet.
6
Otherwise, the UPS and the load connected to the output will be left ungrounded. The grounding system
must be checked, and must be strengthen if required. Potential difference between ground and neutral
must be less than 3V AC.
Descriptions of the UPS input output cable connection terminals are shown in figure 2.1
Recommended input line cable and fuse ratings are given in the table below.
UPS
RATING
(KVA)
AC INPUT
120
160
50
70
NOTES
Recommended cable size (mm2)
AC Input /AC
External
Bypass INPUT
Output Cable
Battery
/ AC OUTPUT
Terminals
INPUT
U-V-W-N
50
70
M8 bolt
70
70
M8 bolt
Battery
Terminals
+&M8 bolt
M8 bolt
:
The neutral conductor should be sized for 1,5 times the output/bypass phase current. These
recommendations are for guideline purposes only and are superceded by local regulations
and codes of practice.
WARNING :
THERE ARE NO INTERNAL FUSES ON THE BYPASS INPUT AND ON THE AC OUTPUT
OF THE UPS. THEREFORE, IT IS RECOMMENDED THE USE EXTERNAL FUSES OR
MCCBS OF SUITABLE RATINGS BOTH ON THE AC INPUT AND OUTPUT OF THE UPS.
2.7.1
Safety Earth
The safety earth cable must be connected to the earth BUSBAR and bonded to each cabinets in the system
and also the grounding and neutral bonding arrangements must be in accordance with the local laws.
ATTENTION!!! Failure to follow adequate grounding procedures can result in electric shock hazard to
personnel, or the risk of fire.
2.7.2
Cable connection procedure
WARNING!!! All connections of the UPS must be done by qualified service personnel
After positioning the UPS, the cables must be connected as described below:
1. Verify all switches in front of the UPS are at “0” position. (OFF)
2. Connect the 3 phase AC input coming from the mains distribution panel to the AC input terminals as shown
on the label. (Figure 2.1)
ATTENTION!!!:
ENSURE CORRECT PHASE SEQUENCE.
If there is a phase sequence error, UPS doesn’t transfer the load to INVERTER output. If
you can’t see SYNC:OK in the INFORMATION MENU on LCD, then change the input
phase sequence.
3. Connect the output of the UPS to the load distribution panel.
4. Connect the battery groups. Refer to battery installation section.
WARNING:
- CHECK BOTH OF THE BATTERY GROUPS FOR CORRECT POLARITY AND VOLTAGE
- DO NOT TURN ON THE BATTERY SWITCH (S5) BEFORE STARTING THE UPS
5. Connect the copper earth bus, to the safety earth of the mains distribution panel.
NOTE: The earth and the neutral connections must be in accordance with the local rules.
WARNING: NEVER TURN ON THE UNIT WITHOUT AN INPUT NEUTRAL CONNECTION (N1).
7
2.4.5
UPS Power Cable Connection Terminals :
1
0
AC OUTPUTS
1
0
BYPASS INPUTS
1
0
AC LINKS TO
BYPASS INPUT
AC INPUTS
1
0
AC INPUT
FUSES
AC INPUT NEUTRAL
BYPASS AND
OUTPUT NEUTRAL
1
0
NEUTRAL
BUSBAR
BATTERY
FUSES
BATTERY BATTERY
BATTERY INPUT
Figure 2.1 120-160 kVA Power Cable Connections
8
NOTES :
• As shown on the power cable connection diagram of the UPS, U1, V1 and W1 phase of the incoming 3
phase supply are used as the bypass inputs under normal conditions, if there is not a separate bypass
supply (split bypass). (U1, V1, W1 and U2, V2, W2 are the same in this case)
• If there is a separate 3- phase AC supply for bypass (Split Bypass):
a-) Remove the links from AC Inputs to Bypass Inputs.
b-) Connect the phases of the bypass source U2, V2 and W2 to the indicated terminals for Bypass Inputs.
c-) Connect the Neutral (N2) of the Bypass source to K11. (Neutral Busbar)
Note that the Neutral of the 3 phase input supply (N1) and the Neutral of the 3-phase bypass supply (N2) must
always be connected together to form the Neutral of the AC output.
2.4.6
Battery Installation
WARNING
!!!
ATTENTION !!!
Be careful while connecting batteries.
NEVER TURN ON THE BATTERY SWITCH (S5), BEFORE STARTING THE UPS
AFTER COMPLETING AND CHECKING ALL THE POWER CONNECTIONS.
The battery racks used for the UPS units should be sited and assembled in accordance with the battery
manufacturer’s recommendations. In general, batteries require a well-ventilated, clean and dry environment at
reasonable temperatures to obtain efficient battery operation.
In general a minimum space of 10 mm must be left on all vertical sides of the battery block. A minimum
clearance of 20 mm should be allowed between the cell surface and any walls. All metal racks and cabinets
must be earthed.
1. Unpack each battery and check its terminal voltage. Any battery with terminal voltage less than 10,5V
must be charged before installation.
2. Please check the battery connecting hardware and documents. (cables, trays, connection diagrams)
3. Please locate suitable number of batteries on each rack, according to the battery installation and
connection diagram given with the unit.
4. Start locating the batteries from top to the bottom on the racks.
5. Be careful about the connection between the racks and polarities.
6. After interconnecting the batteries as shown in Figure 2.2 connect “+”, “0” and “-“ leads of the batteries to
the battery input terminals on the UPS. Be careful to connect the batteries correctly and do not turn on
(S5) before checking all connections and before starting the UPS. In PDSP Series UPS, 60 blocks of
batteries are connected in series, in such a way that they form two strings of batteries with opposite
polarity; with a center tap connection to the NEUTRAL (N1-N2) internally.
NOTE THAT SEPARATE CABLES FROM EACH BATTERY GROUP SHOULD BE CONNECTED TO K2
TERMINALS ON THE NEUTRAL BUSBAR TO FORM THE MIDPOINT CONNECTION.
WARNING!!!
NEVER TURN ON S5 (BATTERY SWITCH) WITHOUT CENTER POINT CONNECTION TO
NEUTRAL BUSBAR.
9
NEUTRAL
BUSBAR
NÖTR BARASI
BATTERY
AKÜ
K1
+
(+)
360V
+++++-
30x12V
Batts.
+++++-
30x12V
Batts.
K2 K2
(0)
(0)
BATTERY
AKÜ
K3
360V
Figure 2.2 Battery Connections (60x12V)
10
(-)
UPS
NEUTRAL BUSBAR
BATT.
BATT.
30x12V BATTS.
30x12V BATTS.
Figure 2.3 PDSP 120-160 KVA Battery Connections
11
III. FRONT PANEL
3.1 Introduction
The front panel of UPS, consisting of a 2 lines alphanumeric display, 6 status lamps, plus 4 function keys,
allows the complete monitoring of the UPS status. The mimic flow diagram helps to comprehend the
operating status of the UPS. By using the function keys operator can move on menus and change some
parameters.
Figure 3-1
Line
Battery
By-pass
Maint.Sw.
Inverter
O/P Sw.
Control and display panel
If lamp is lit mains is okay
If lamp is lit UPS is operating on batteries
If lamp is lit static bypass is active and load is connected to mains voltage
If lamp is lit mechanical bypass switch is on
If lamp is lit inverter feeds the load
If lamp is lit S4 power output switch “1” on position.
There are 4 function keys on front panel these are ENTER, DOWN, PLUS and MINUS.
DOWN key helps moving on menus, PLUS and MINUS keys select options , ENTER key means the
selected option or menu is valid.
3.2 Front Panel Menu Descriptions
By using the buttons on the front panel, you can move on main menu functions. You can enter the
submenus of the item seen on the LCD panel (MEASURES, ALARMS, INFORMATION etc.) and navigate
within it by using (↓), (+), (-)and (E)ENTER keys.
The Main Menu items are listed below. You can choose any requested menu using (+) and (-) keys. By
pressing ENTER key, you can choose that menu and you can reach all submenu items using (↓) key
again. At the end of submenus of each MENU, an <ENTER> EXIT message is seen, and if you press
ENTER, you exit from the selected menu and go back to the beginning of the Main Menu.
Main Menu items
STATUS MENU
MEASURES MENU
ALARMS MENU
INFORMATION MENU
ADJUST MENU
OPTIONS MENU
COMMAND MENU
TIME MENU
SERVICE MENU
Go to STATUS MENU
Function
The status message which shows the UPS status
→ Enter
"go to Meausures submenu"
→ Enter
"go to Alarms submenu"
→ Enter
"go to İnformation submenu"
→ Enter
"go to adjust submenu"
→ Enter
“go to options submenu”
→ Enter
“go to Command submenu”
→ Enter
“go to Time and date submenu”
→ Enter
“go to service submenu”
12
3.2.9
MEASURES Menu Items
In this menu you can see all measured values. Use (↑) and (↓) keys for moving on submenu items.
Submenu item
LD%: 060 074 080
OPV: 220 221 220
FREQU: 50.0 Hz
IPV: 240 235 220
BYP: 230 232 231
IPI: 022 010 030
+BATT: 405 V 000 A
7
-BATT: 405 V 000 A
8 TEMP: 030 c
9 BATT.CAPACI:068%
10 ENTER <EXIT>
Go to STATUS MENU
Function
Output load percentage
Output voltages
Output frequency
Input voltages
Bypass source voltages
Input currents (amperes)
“+” Battery voltage and charge / discharge current
“-” Battery voltage and charge / discharge current
Cabinet inside temperature
Battery charge level
→ Enter
(↵ ) exit from menu
1
2
3
4
5
6
3.2.10 ALARMS Menu Items
In this menu you can see recorded log events and valid alarms
1
Submenu item
UPS STATUS
2
000>311201 23:15
3
ENTER CLEAR LOG
4
PARR.ERR.NR : 017
5
ENTER <EXIT>
Go to STATUS MENU
Function
Alarm status at that instant
Monitoring past alarms :
The first 3 digit number indicates the event number. 000 numbered event is
the last event. Date ddmmyy time:hh:mm
On the second line of LCD PANEL you can see al recorded alarms.
Use PLUS and MINUS keys for moving on events.
→ Enter
(↵ ) clear log event records
After you cleared events you see EMPTY LOG message.
Parallel control board fault number. (if the parallel board is installed)
0 means that there is no error on parallel board
→ Enter
(↵ ) exit from submenu
3.2.11 INFORMATION Menu Items
This menu gives information about the UPS.
Submenu item
1
SYNC :OK COMM :OK
2
3
POWER: 120000 VA
VERSION : B12
4
FREQUENCY : PLL
5
6
7
NOM.FRQ: 50 Hertz
MODEL: PDSP3120
ENTER <EXIT>
Go to STATUS MENU
Function
If the UPS is operating in syncron to mains SYNC:OK ,if not syncron SYNC:If communication is active COMM:OK ,if not active COMM:-The maximum power rating of the UPS
Shows the UPS control software version.
Frequency generation mode
PLL :phase locked loop is generating the frequency
SLAVE : in parallel system master is generating the frequency
Nominal output frequency
Model name of the UPS
→ Enter
(↵ ) exit from submenu
13
3.2.12
ADJUST Menu Items:
Only service personnel can use this menu ,the incorrect use of this menu can cause damage to the UPS.
Submenu item
1 PASSWORD : XXX
2 ENTER <EXIT>
Go to STATUS MENU
Function
Service password input
(-) key 100,
UP key 10,
(+) key 1 changes
after you write the password on screen press ENTER key ,if the password is
wrong the is no action.
If the password is okay a beep sounds and you see ADJUST MODE at the
second line.
→ Enter
(↵ ) exit from submenu
3.2.13 OPTIONS Menu Items
In this menu the user can set some important parameters for UPS operation..
Submenu item
1 MODE: ONLINE
2 UPS No : 001
3 REMOTE :ENABLE
4 RESTART:ON/OFF
RELAY:BATT.LOW
/COMMON
BATTERY
6
TEST:ON/OFF
7 ENTER <EXIT>
Go to STATUS MENU
5
Function
By using (+) and (-) keys you can move on 5 different operation modes.
ONLINE : stand alone mode
PARALLEL : 2 UPS in symmetric parallel operation
N+1 REDUNDANT : 2 or more UPS in N+1 redundant parallel mode
REDUNDANT: 2 UPS in redundant parallel mode.
ECONO: Off-line mode.
→ press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change number 0 to 3.
In parallel operation select different number for each UPS. If you select the
same number DUBL UPS NUMBER message tells the fault.
→ press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change enable and disable options.
Enable : remote battery test, shutdown and bypass functions are enabled
disable : these functions are disabled
→ press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change on and off options.
ON: during mains failure, at the and of battery discharge UPS shutdowns, and
after mains is restored UPS starts again.
(battery trip out is on every time)
OFF: after mains restoration UPS doesn’t start by itself again. (You must turn
off and then turn on the UPS)
(battery trip out is off)
→ press ENTER for 3 seconds and then the selection is valid
By using (+) key the function of the RL3 Relay on the interface board can be
selected between Battery Low or Common Alarm.
By using PLUS and MINUS keys you can change on and off options. Used to
enable or disable automatic battery test.
→ Enter
(↵ ) exit from submenu
14
3.2.14 COMMAND Menu Items
This menu is used to give various commands, to the UPS or to perform some tests on it. .
Submenu items
1 SOUND : ON/OFF
2 ENTER B.TEST>405
3 ENTER <BYPASS>
Function
Used for turning on/off the audible alarm.
If you press ENTER key the option will change (push ON, push OFF)
If the OFF option is selected, audible alarm is turned off but in case of a new
alarm, UPS changes the option to ON state.
If you press enter for 3 seconds battery test starts and lasts for 15 seconds. If
battery test fails A6 BATT FAULT message is shown on panel and this
message stays until you press ENTER key for 3 seconds.
The value on the right indicates the battery voltage during battery test.
Starting time of battery test is recorded to log event menu. If the test is
performed successfully you can see only BATTERY TEST message on log
records. If the test is unsuccessful a BATT.FAULT message will also be
recorded. On the bottom line of LCD, BAT FAULT message will stay, and the
user will be warned audibly every 15 seconds until this message is cleared
by pressing the ENTER key for 3 seconds.
If you press ENTER key for 3 the load is transferred to bypass.
If the load is on bypass, in this submenu you see ENTER<INVERTER>
message at this position. If you press ENTER key for 3 seconds UPS
transfers the load on inverter this time.
In parallel modes this function is disabled and you see BYP.FUNC.DISABLE
message on this submenu item.
4 ENTER:MODEM INIT
If you press ENTER key the connected modem of RS232 port is installed
UPS sends AT command set to modem for installation.
If the function is completed you must hear a beep sound.
At the and of this function modem is ready to answer dial up connection.
5 ENTER <BOOST>
If you press ENTER key for 3 seconds boost charge starts. The given time
for boost charge is 10 hours. At the end of this time UPS stops boost
charging.
If the boost charge is active this submenu item changes to STOP BOOST>
005H message. 005H indicating that boost charge has lasted for 5 hours.
If the number is 10, boost charge stops. If you press ENTER key before this
time boost charge stops immediately.
Boost charge starting and boost charge end times are recorded in log event
menu.
If boost is active UPS beeps every 15 seconds
6 SIMULATION OFF
The purpose of this submenu is to check dry contact connections. Normally
to check line failure contact you must turn off mains power. This is not
necessary with this utility. 3 options are available.
SIMULATION OFF simulation mode is off
SIM: LINE FAILURE if you press ENTER key for 3 seconds, the line failure
relay on the interface board is energized.
SIM: LIN.F+BT.LOW if you press enter key for 3 seconds line failure and
battery low relays are energized.
SIM: BYPASS if you press ENTER key for 3 seconds bypass relay is
energized.
This way, you can check dry contact connections
7 ENTER <EXIT>
Go to STATUS MENU
→ Enter
(↵ ) exit from submenu
15
3.2.15 TIME MENU ITEMS
You can see date and time of RTC (real time clock) on UPS. And you can adjust date and time.
1
2
3
4
5
6
7
8
9
Submenu item
TIME : 23 :15
DATE : 11-10-2006
SET HOURS: 11
SET MINS : 38
SET DAY : 21
SET MONTH : 06
SET YEAR : 2006
ENTER <UPDATE>
ENTER <EXIT>
Go to STATUS MENU
Function
time
date
(+) and (-) adjust hours (0-23)
(+) and (-) adjust minutes (0-59)
(+) and (-) adjust day (1-31)
(+) and (-) adjust month(1-12)
(+) and (-) adjust year (2000-2099)
→ Enter update new date and time
→ Enter
(↵ ) exit from submenu
3.2.16 SERVICE Menu Items:
1
2
3
4
Submenu item
HOURMTR: 00027
MAX.LOAD:095%
TO B. TEST: 008Hr
ENTER <EXIT>
Go to STATUS MENU
Function
Total operation time of the UPS
Recorded max. load
Time until next automatic battery test.
→ Enter
(↵ ) Exit from submenu
3.3 STATUS Messages
This message group simply shows the UPS STATUS on the upper line of LCD PANEL.
RECTIFIER START !
INVERTER START !
MAINT SWITCH ON !
MANUEL BYPASS !
STATUS ALARM !
STATUS NORMAL !
EMERGENCY STOP !
WAITING SYNC !
STATUS FAULT !
STATUS WARNING !
CLOSE BATT.CB !
INV. OUT FAILURE!
:
:
:
:
:
:
:
:
:
:
:
:
UPS started the rectifier
UPS started the inverter
Maintenance bypass switch is on
Load is transferred to mains manually
Alarm status
UPS is operating normally.
External emergency signal is detected.
Inverter started and waiting for synchronization
Fault status
Warning message is valid on LCD panel
UPS is waiting for battery CB to be closed
The UPS gave four successive “INV. BALANCE” error.
RECTIFIER START :
At start up the UPS controller board checks for input voltage, frequency, battery voltage for starting, if these
parameters are normal, it starts up.
INVERTER START :
If the inverter stops by any reason, controller board tries to restart the inverter. Each time the inverter is
started, this message appears on the first line of LCD PANEL
MAINT SWITCH ON:
Maintenance bypass switch is connected from bypass input to the output of UPS directly .If the maintenance
bypass switch is on (1 position) controller stops the inverter against any accidental short circuits between
mains voltage and inverter output. If the user turns off the maintenance bypass switch, inverter starts again.
EMERGENCY STOP :
If an external EPO switch is installed to system (connected to interface board), it is possible to stop all UPS
parts (rectifier, static bypass, inverter, etc….). After pressing EPO switch, the rectifier and inverter are turned
off and the power to the critical load is turned off. To start again, turn off the ON/OFF switch and turn it on
again.
16
FAULT STATUS:
In some cases controller checks events but can not find solutions, in this case controller decide to stop the
system. For restarting the user must turn off the ON/OFF switch and turn it on again.
WARNING STATUS:
Some events recorded to log event file stays on LCD PANEL but UPS continues to work, these
messages named as warning messages, user can clear this messages by pressing ENTER key for 3
seconds.
These are:
• A20 Boost charge alert
• A6 Charge fault
• A18 Batt capacity low
3.4 Shutdown messages:
PDSP series UPS can operate interactive with the operating system. You can send commands to UPS from
operating system by using some software .UPS takes these commands and produces some messages listed
below:
WAITING SHUTDOWN :
UPS SHUTDOWN
WAITING RESTART
PAR.SHUTDOWN
:
:
:
CANCEL SHUTDOWN
:
Shutdown command is performed by the operating system and UPS is waiting for
a certain delay for shutdown.
UPS is in shutdown status
UPS is shutdown but it is waiting for a certain delay for restart
In parallel systems the other UPS sends shutdown command and UPS is in
shutdown status.
Shutdown command is cancelled.
Only operating system or a PC computer can send these commands.
If the shutdown command is performed during line failure UPS shutdowns and if the mains is okay UPS starts
again automatically.
3.5 Fault Messages and Quick Troubleshooting :
All alarms contained in PDSP UPS control software are listed in the following table.
ALARM
DESCRIPTION
Bypass system failure
A1 BYPASS FAILURE
Possible Causes: Bypass components may be faulty, call service.
Inverter digital start system is failed
A2 INVERTER FAILURE
Possible Causes: Internal failure. Call service.
Overtemperature in UPS repeated 3 times in the last 30 mins.
A3 3 OVERTEMP
Possible Causes: 1) Check for UPS air inlets and outlets for any blocking by dust etc.
2) Fan failure
3) Bad UPS location
4) Check for Overload
UPS output voltage is out of tolerance for 3 times in the last 30 mins.
A4 OUT FAILURE
Internal failure. Call service.
Batteries are completely discharged; wait for restoration of electric power
A5 BATT AUT END
input. This message occurs only at the end of a battery operation during line
failure.
Rectifier could not produce DC bus voltage.
A6 CHARGER FAULT
Battery voltage is low. (either positive or negative)
A7 BATTERY LOW
Possible Causes: 1) UPS operation for long time when line out
2) Charger system failure
Inverter output voltage is higher than the max. tolerated value.
A8 OUTPUT HIGH
Inverter is stopped.
Possible Causes: 1) Inverter failure
17
ALARM
A9 OVERLOAD
Possible Causes:
A10 LINE FAILURE
Possible Causes:
A11 HIGH TEMPER
A12 OVERCURRENT
A13 OUTPUT LOW
A14 BATTERY HIGH
A15 FUSE FAILURE
DESCRIPTION
UPS loaded more than 100% of nominal power rating.
This state is may be continous or temporary. When this alarm is continous
check the loads connected to the UPS output.
Line failure.
1) Mains may be off.
2) Check all three input phases.
3) Check UPS input fuses.
Overtemperature
1) Overload for inverter
2) Excessive ambient temperature.
3) Fan failure or dirty air inlets
4) Bad UPS location (not enough ventilation)
Inverter output system failure
1) Internal overcurrent
2) Output short circuit.
3) UPS failure. Call the service.
Inverter output voltage is lower than the min tolerated value.
Inverter is stopped.
Battery voltage is higher than max. tolerated value for batteries. (either
positive or negative battery groups)
Blown fuse(s). (not used in this power range)
During transfer to bypass, Voltage or frequency value of bypass source
is incorrect and the UPS turns off the load power.
During normal (inverter) operation some times you can see this message
due to fluctuations in bypass supply.
A16 BYP INPUT BAD
During bypass if the bypass protection option is “ON” and if the bypass
source is out of tolerance UPS switches off the static bypass for load
protection.
Battery circuit breaker is off ,batteries are not connected to UPS
At start up If the mains is okay you can start operation having this message
A17 BATT CB OPEN
active.
At start up during line failure UPS waits for the battery CB to be turned on
and then starts.
If the battery charge level is low this message indicates that charge period is
not completed yet. If mains failure occurs during this message, battery
A18 BATT.CAPA.LOW
operation time may be unexpectedly short.
UPS gives beep sound every 15 sec
Battery test aborted. And batteries are not OKAY
A19 BATT FAULT
UPS gives beep sound every 15 sec
You can clear this message by pressing the ENTER key for 3 seconds.
Possible Causes: 1) Rectifier fault
2) Damaged battery cells
3) Poor battery connections
Boost charge is active. At the end of the boost charging time UPS stops the
A20 BOOST CHARGE
boost charge.
UPS gives beep sound every 15 sec
In parallel system, the operation mode of the UPS is different from the others.
A23 MODE FAILURE
Parallel controller board failure
A24 P.FAILURE 17
Parallel controller board failure
A25 P.FAILURE 18
Parallel controller board failure
A26 P.FAILURE 19
Parallel controller board failure
A27 P.FAILURE 20
18
ALARM
P.FAILURE 21
P.TEST MODE
P FAILURE 23
DUBL UPS NR.
Possible Causes:
PSP FAILURE1
DESCRIPTION
Parallel controller board failure
A28
Parallel controller is in test mode
A29
Parallel controller board failure
A30
Same UPS number is used for two UPS in the parallel system.
A31
1) Change number(s) in OPTIONS Menu.
Control Power supply fault.
A39
One of parallel modes is selected but there is no parallel control board
A40 CANT FIND PR
on UPS
Change mode from OPTIONS Menu.
In parallel operation current sharing is not okay
A41 P.BAL.FAILURE
Performing battery test
A42 BATTERY TEST
In parallel system SLAVE UPS is not synchronized to MASTER UPS
A43 P.SYNC.FAIL
UPS is operating on batteries
A44 BT.OPERATION
Possible Causes: 1) AC line voltage is not available or out of tolerated voltage limits.
2) Distribution problems or blown fuse(s)
After mains failure, mains voltage restored again. This message
A45 MAINS OK
appears on screen for 15 seconds after mains restoration.
Boost charging period has been completed, normal float charging
A46 BOOST CH.END
conditions are valid.
Inverter can not start because of an internal fault.
A47 CANNOT START
Load transferred to bypass supply from COMMAND MENU
A52 MANUA. BYPASS
DC balance problem at the Inverter output. Call service.
A64 INV. BALANCE
AC Input Voltage above the tolerated value
A65 MAINS HIGH
Additional Alarm codes for Parallel Operation (Optional).
ALARM
P05 P.SYNC. ALARM
P07 P.BAL. ALARM
P10 P.CLK ALARM
P16 MODE FAILURE
P17 RS485 ALARM
P19 DATA CABLE
P20 ONLY ONLINE
P21 PLUG IN DIG.
P23 PSP FAILURE 2
P24 DUBL UPS NR.
P25 NO CLOCK
DESCRIPTION
In parallel system SLAVE UPS is not synchronized to MASTER UPS
In parallel operation current sharing is not okay (temporary)
There is an interruption or false status on parallel synchron signal
between 2 UPS (temporary)
SLAVE ups search for the same operating mode with MASTER ups, if
they are different this message is seen on LCD panel.
Change the operation mode of SLAVE ups from OPTIONS MENU.
Don’t forget to press ENTER key for 3 seconds
Turn off the SLAVE ups and turn on again.
There is an interruption or false status in parallel communication
between the UPSs
Data connection cable between parallel UPS is not OK (bad connection
or cable mismatch)
There is an online UPS in parallel system, please change the operation
mode
The digital connection cable between parallel UPSs is unplugged
Parallel controller board isolated power supply is out
Same UPS number is used in parallel system.
Change from OPTIONS MENU
During power up the synchron clock signal is lost by slave UPS
19
IV. PARALLEL OPERATION
4.1 Introduction
Two (or more) identical PDSP series UPSs can be interconnected for parallel operation.
The main purposes for parallel use of PDSP series UPSs are:
-Redundancy for Increased Reliability
-Power Increase
Although recent UPS designs are perfect and have high MTBF figures, a second (or more) UPS can be used
in parallel with the first one, for supplying the critical load in case of any possible failure of the first UPS. In
such an application the faulty UPS is isolated automatically from the parallel system and the other UPS (or
UPSs) continues to supply the critical load. Use of Redundant UPSs in parallel, therefore, provides increased
reliability for the critical load connected to the parallel system output.
If power demand increases in a certain UPS application exceeding the power rating of an already installed
stand-alone UPS, a second (or more) UPS of the same model and power rating can be added in parallel to the
existing UPS to increase the output power capacity.
Schematic diagram of parallel connection of two PDSP series UPS units is shown in Figure 4.1
S3
Maintenance
Bypass Switch
SB
S2
(F4-F5-F6)
S1
(F1-F2-F3)
Static
Bypass
̃
-
-
K1
K2
̃
Inverter
Rectifier /
Charger
S4
(F7-F8-F9)
S5
(F10-F11-F12)
Battery
(Dual Polarity)
3 PHASE
MAINS I/P
3 PHASE
AC Output
S3
Maintenance
Bypass Switch
SB
S2
(F4-F5-F6)
S1
(F1-F2-F3)
Static
Bypass
K1
̃
-
-
̃
K2
Inverter
Rectifier /
Charger
S4
(F7-F8-F9)
S5
(F10-F11-F12)
Battery
(Dual Polarity)
Figure 4.1 Parallel Connection of two UPSs
20
The AC inputs of all UPSs in the parallel system are connected to the same mains, and all the AC outputs are
connected to each other. Each UPS has its own battery group. The critical load is connected to the common
output of the parallel system. There are also some signal cable connections between the UPS units necessary
for parallel operation, and will be described later.
4.2 Parallel Operation Modes of PDSP Series UPSs
NOTE :
Parallel operation hardware (parallel controller boards and some other accessories) are not
installed in a standard PDSP series UPS, but parallel operation option is available and can
easily be added to all UPSs.
Parallel operation is possible in one of the three modes:
1) PARALLEL operation (power increase)
2) REDUNDANT parallel operation
3) N+1 REDUNDANT parallel operation
NOTES:
1- The preferred mode for parallel operation can be selected using OPTIONS MENU.
2- For parallel operation, each UPS must be assigned a unique UPS No again using OPTIONS MENU.
4.2.1. PARALLEL mode
This mode should be selected for increasing the available UPS power capacity. If this mode is selected for
parallel UPS operation, the total VA rating of the parallel system is the sum of the VA ratings of all the
UPSs connected in parallel. The output load is equally shared by each UPS in the parallel system. Mains
power is used as the spare energy supply (BYPASS).
In case of a failure in one of the UPSs, the Static Bypass Switches of all UPSs are turned on
and the load is transferred totally to the spare energy supply (usually mains voltage) without any interruption. If
the fault is cleared and if everything returns to normal operating conditions, the Inverters of all UPSs in the
parallel system resume the load together at the same time.
The output load of the parallel system is shared equally by each UPS, both during Inverter or Bypass
operation.
If this mode is active, you will see ‘’PARALLEL MODE/MS’’ on the LCD panel of one of the UPSs, and you will
see ‘’PARALLEL MODE/SL’’ on the LCD panels of all the other UPSs connected in the parallel system (MS
meaning Master and SL meaning Slave).
In PARALLEL mode, the Static Bypass Switches of all the UPSs in the parallel system act (turns on or off)
simultaneously. During normal PARALLEL operation, the load is shared equally by the inverter outputs of each
UPS provided that the output switches of all UPS units are turned on. In case of a failure in one of the UPS
units or if the output switch of one of the units is turned off, the static bypass switches of all the parallel units
are turned on simultaneously and the critical load is transferred to the bypass supply without any interruption.
In other words, during operation in PARALLEL mode, the parallel UPS system behaves like a single
(stand-alone) UPS with a higher power rating.
4.2.2. REDUNDANT mode
This mode is used for operation of two (or more) UPS units connected in parallel, for increased reliability. If
this mode is selected, the load is shared equally by each UPS available in the parallel system, during normal
operation.
In case of failure of one (or more) of the UPSs, the faulty UPS is isolated from the parallel system and the
critical load is still supplied by the remaining UPSs. If the faulty UPS returns to normal operation , it joins the
parallel system again and starts sharing the load.
In REDUNDANT parallel mode, the total VA rating of the parallel system is equal to the VA rating of a
single UPS used in the system. Only after all the UPS units in the system fail and are isolated from the
system, the critical load is transferred to Bypass supply without interruption.
21
If this mode is active, you will see ‘’REDUNDT. MODE/MS’’ on the LCD panel of one of the UPS units, and
you will see ‘’REDUNDT. MODE/SL’’ on the LCD panels of all the other UPS units connected in the parallel
system.
As explained above, higher degree of reliability for supplying a critical load can be obtained by choosing
REDUNDANT mode for parallel operation and using as many as possible parallel connected UPSs.
4.2.3. N+1 REDUNDANT mode
This mode is used for operation of at least three (2+1 configuration) UPS units connected in parallel for
increased reliability. If this mode is selected, the load is shared equally by each UPS available in the parallel
system (N+1 numbers of UPS units), during normal operation.
In case of a failure of any one of the UPS units, the faulty UPS is isolated from the parallel system and the
critical load is supplied by the remaining N number of UPSs. If any one of those UPS units fails too, then the
critical load is transferred to bypass supply via the static bypass switches of the parallel connected UPSs. If
the faulty UPS returns to normal operation, it joins the parallel system again and starts sharing the load.
In N+1 REDUNDANT parallel mode, the total VA rating of the parallel system is equal to the VA rating
of a single UPS multiplied by N.
If this mode is active, you will see ‘’N+1 REDUNDANT/MS’’ on the LCD panel of one of the UPS units, and you
will see ‘’N+1 REDUNDANT/SL’’ on the LCD panels of all the other UPS units connected in the parallel
system.
More detailed diagrams for two (or more) PDSP series UPSs connected in parallel are given in Figures 4.2
and 4.3
Figure 4.2 PDSP Series Parallel UPS Signal Cable Connections
Parallel Parallel
Port 1 Port 2
Parallel Parallel
Port 1 Port 2
Figure 4.2.a 2 units in parallel
22
Parallel Parallel
Port 1 Port 2
Parallel Parallel
Port 1 Port 2
Parallel Parallel
Port 1 Port 2
Figure 4.2.b 3 units in parallel
Note: One purpose-built signal cable (DB25) is provided for each UPS unit in the parallel system. Parallel
signal cables are interconnected between the UPS units to form a loop, as shown in figure 4.2, for having
higher reliability against any possible signal cable failures.
After completing the parallel connection of all the UPS units as shown in Figures 4.2 and 4.3, turn on each
UPS unit one by one and select the operation mode and assign a UPS No, using OPTIONS MENU.
All the units must be set for the same operation mode and must have a different UPS number.
CAUTION !!!
You must never set the operation modes of parallel connected UPS units to
“ONLINE”, otherwise serious damage may occur in UPSs.
23
MAIN AC INPUT
U1
V1
W1
N1
K1
+
K1
+
K1
-
K2
-
K2
-
K2
+
K2
+
K2
+
K2
-
K3
-
K3
-
K3
BATTERIES
UPS1
BATTERIES
AC OUTPUT1
UPS2
AC OUTPUT2
K12 K13 K14
U
K12 K13 K14
U
V W N
FUSES
BATTERIES
V W N
FUSES
K11
K9
K10
K7
K8
K6
K4
+
K5
K11
K9
K10
K7
K8
K6
K4
K5
K9
K10
K7
K8
K6
K4
K5
K11
BYPASS AC INPUT
U2
V2
W2
N2
UPS3
AC OUTPUT3
K12 K13 K14
U
V W N
FUSES
AC OUTPUT
LOAD BRAKE
SWITCH
AC DISTRIBUTION BOARD
U V W N
LOAD
Figure 4.3 PDSP Series Parallel UPS Power Connections
Note: As seen in the figure, the outputs of parallel UPS units should be connected to each other using an AC
distribution board.
ATTENTION!!! The cables from each UPS output to the distribution board must be of the same size
and length for proper load sharing during parallel operation.
24
V. OPERATING INSTRUCTIONS
5.1
INTRODUCTION
After completing the installation of the unit, and connecting all the power cables with all switches and fuses in
“OFF” position,
1. Check the battery polarities.
K1
: + V (+360V Nominal, +405V under float charge)
K2 - K2 (NEUTRAL BUSBAR) : 0 Volts (connected to the midpoint of the 60 blocks battery string)
K3
: - V (-360V Nominal, -405V under float charge)
2. Check the 3 phase AC input and neutral connections. (Phase sequence is important)
NOTE THAT SEPARATE CABLES FROM EACH BATTERY GROUP SHOULD BE CONNECTED TO K2
TERMINALS ON THE NEUTRAL BUSBAR TO FORM THE MIDPOINT CONNECTION!
WARNING!!! The UPS must never be turned on without input neutral connection.
3. Check the output (load) connections.
5.2
5.3.4
OPERATING INSTRUCTIONS FOR A SINGLE UPS UNIT. (ONLINE OPERATION)
Procedure For Turning On The UPS To Supply The Load From A Complete PowerOff Condition
1. Turn on S1 (AC Input)
2. Turn on S2 (Bypass)
3. Turn on S4 (AC Output)
ATTENTION!!!
AS SOON AS YOU TURN ON ON/OFF SWITCH (S7), BYPASS VOLTAGE WILL APPEAR
THE OUTPUT TERMINALS.
4. Turn on S7 (ON/OFF Switch), LCD panel will start running. “RECTIFIER START” message will appear on
the front panel.
5. When “INVERTER START“appears on the front panel turn on S5 (Battery) into “1” position.
After a few seconds, the BYPASS led L4 (red) will turn off and the INVERTER led L6 (green) will turn on. The
UPS is ready for uninterrupted operation when “STATUS NORMAL/ONLINE MODE” message appears on the
front panel.
5.2.2
Power Off
After turning off all the loads connected to UPS output:
1.
2.
3.
4.
5.
Turn off S4 (AC Output) into “0” position.
Turn off S7 (ON/OFF Switch) into “0” position.
Turn off S5 (Battery) into “0” position.
Turn off S2 (Bypass) into “0” position.
Turn off S1 (AC Input) into “0” position.
This is a complete power off condition and both RECTIFIER and INVERTER are not operating in this
case.
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5.2.3
Switching into Maintenance Bypass Mode
1. Use “DOWN” button to choose COMMAND MENU and press ENTER. Use “DOWN” button again to reach
ENTER <BYPASS> message. Press ENTER, the UPS will switch into bypass mode. “MANUAL BYPASS”
and “A52 MANUA. BYPASS” messages will appear on the screen.
2. Remove the padlock on S3 (Maintenance Bypass Switch) and turn it on into “1” position.
3. Turn off S7, S5, S1, S2 and S4.
Now there is bypass voltage directly on the load, note that there is no AC or DC power in the UPS for
maintenance and servicing purposes.
5.2.4
Switching From Maintenance Bypass Into Normal Operation
1. Turn on S1 (AC Input)
2. Turn on S2 (Bypass)
3. Turn on S4 (AC Output)
4. Turn on S7 (ON/OFF Switch), LCD panel will start running. “RECTIFIER START” message will appear on
the front panel. After the rectifier is started, the inverter will not start and the message MAINT. SW. ON will
be seen on the panel instead of INVERTER START.
5. Turn off S3 (Maintenance Bypass Switch) and lock again. The inverter will start automatically.
6. Turn on S5 (Battery).
Now, the UPS is ready for normal operation.
5.3
OPERATING INSTRUCTIONS FOR PARALLEL CONNECTED UPSs.
Procedure For Turning on the UPS (First Installation)
With all the switches (S1, S2, S3, S4 and S5) in “OFF” (“0”) position and with S6 (static bypass switch) in
“NORMAL” position.
Note: S6 is the Manual Bypass Switch used in parallel connected UPSs. In parallel UPSs, the “ENTER
<BYPASS>” item in the COMMAND menu is disabled and static bypass function is controlled by S6.
Turn on the parallel connected UPS units as follows:
1. Make sure that all signal and power connections have been completed properly according to the
diagrams and instructions given before.
2. Turn on S1 (AC Input)
3. Turn on S2 (Bypass)
ATTENTION!!!
NEVER TURN ON S4 (AC Output) BEFORE COMPLETING MODE SELECTION
PROCEDURE FOR ALL UPS UNITS.
4. Turn on S7 (ON/OFF switch) LCD panel starts running and following messages appears on the panel.
- “RECTIFIER START”
- “INVERTER START”
5. Using UP-DOWN keys on the front panel, select “OPTIONS MENU” on LCD and press “ENTER”.
When you see MODE:_display, select one of the following parallel operation modes suitable for your
application, using “+” and “-“ keys.
- PARALLEL
- N+1 REDUNDANT
- REDUNDANT
After selecting one of the parallel modes, press “ENTER”
6. Again using UP-DOWN and “+”, “-“ keys in the OPTIONS MENU enter a number (0 to 3) for each UPS.
26
7. Turn off S7 (ON-OFF) and after a few seconds turn it on again. UPS wilt start running again.
8. When “INVERTER START” message appears on the front panel turn on S5 (Battery) into “1”.
Perform the same procedure given above for all UPS units. Make sure that all the units have the
same operating mode but different UPS numbers.
9. Turn on S4 (AC Output) switches of all UPSs one by one. Now the parallel UPS system is ready to supply
the critical load.
5.3.2
Power Off
After turning off all the loads connected to the Parallel UPS System output, apply the following procedure to
all the UPS units in the parallel system.
1. Turn off S4 (AC Output) into “0” position.
2. Turn off S7 (ON/OFF Switch) into “0” position.
3. Turn off S5 (Battery) into “0” position.
4. Turn off S2 (Bypass) into “0” position.
5. Turn off S1 (AC Input) into “0” position.
This is a complete power off condition and both RECTIFIER and INVERTER are not operating in this case.
5.3.3
Switching the Parallel UPS System into Maintenance Bypass Mode
(uninterrupted transfer)
1. Switch S6 (static bypass switch for parallel UPSs) of either one of the UPS units into “STATIC BYPASS”
position.
2. See that the red-colored by-pass LEDs (L4) on the front panels of all UPSs are turned on.
(Static Bypass Operation)
3. Turn on S3 switches (maintenance bypass) of all UPSs in the parallel system.
4. Turn off S4 switches (AC Output) of all UPS units.
5. Turn off S1 (AC Input) and S2 (Bypass) switches of all UPSs.
6. Turn off S5 (Battery) switches off all the UPS units in the parallel system.
Now all the UPS units which are connected in parallel are completely turned off and the load is
supplied by the common Bypass supply via the Maintenance Bypass Switches of all the UPSs.
5.3.4 Switching the Parallel UPS system into Normal Operation From a Maintenance Bypass
Power Down Condition. (uninterrupted transfer)
With the S6 switches (static bypass) of at least one of the UPSs, in “STATIC BYPASS” position, turn on
all the units as follows:
1. Turn on S1 (AC Input) switches into “1” position.
2. Turn on S2 (Bypass) switches into “1” position.
3. Turn on S4 (AC Output) switches into “1” position.
4. Turn on S7 (ON-OFF) switches into “1” position.
5. When “MAINT SWITCH ON” message appears on LCD, turn off S3 (Maintenance bypass) switches of all
UPSs.
6. Turn on S5 (Battery) into “1” position.
7. Bring S6 (static bypass) switches of all UPS units back to “NORMAL” position.
27
VI. MAINTENANCE
WARNING!!!
DO NOT OPEN the covers of the UPS because there are no user serviceable parts inside. DO
NOT TOUCH battery leads. There is high voltage even if the UPS is off. Therefore no one
should open the covers of the UPS except authorized service personnel. Otherwise, serious
injuries may occur.
6.1 Scheduled Maintenance
Some semiconductor devices inside the UPS do not require any maintenance. Cooling fans are the only
moving parts. If the environment is clean and cool enough, the scheduled maintenance requirements will be at
minimum level. On the other hand, periodic checks and maintenance based on well prepared documents will
increase the performance of the UPS and prevent some unimportant faults to become serious ones.
The equipment has been designed to require minimum maintenance effort. The user should follow the
instructions below.
6.2 Daily checks
Check the UPS everyday and be careful about the following:
1. Check the operator control panel. Verify that all LEDs and parameter measurements are normal and
there is no alarm message on the indicator panel.
2. Check if the device is overheated.
3. Check the cooling fans’ operations.
4. Check if there is any sensible change in the noise level of the equipment.
5. Check if there is any stoppage on the ventilation path. If so, clean the dust using a vacuum cleaner.
6. Make sure that there is nothing placed on the UPS.
6.3 Weekly checks
1. Record the results on the indicator panel.
2. Measure and record voltages on each phase.
3. Measure and record currents on the output of the UPS.
4. Check batteries status by performing a manual battery test. Use a dry humid gland to clean the cover of the
UPS.
Record the observations if possible. Check if there is any difference with the previous records (observations).
If the last recorded values are significantly different from previous records, please check If the load has been
changed, and if so please record the type, size, and position of this load. These information will be very
valuable in helping the service personal in determining any possible errors.
If there is significant change in the parameter values without any reason please immediately call the qualified
service personnel.
28
6.4 Annual maintenance
To get reliable and efficient performance from the UPS, please call the qualified service personal at least once
a year.
6.5 UPS Storage and transportation
1. Check the batteries charge by performing manual battery test before storage. If the charge is not enough
then charge the batteries at least for 12 hours.
2. Qualified service personal should disconnect the electrical connections.
3. Batteries should be charged every six months during storage period.
4. Keep the UPS and batteries in dry and cool place.
UPS ideal storage temp.: 0 0C ~ 40 0C max.
Battery ideal storage temp.: 10 0C ~ 35 0C max.
5. The UPS must be placed on a suitable palette for transportation purposes.
29
VII. FAULTS AND TROUBLESHOOTING
7.1 General Procedure For Fault Checking And Troubleshooting
UPS contains complicated electronic control circuits. In order to locate any fault occurring circuits, an
advanced knowledge about the circuitry and its operation principles must be known. The aim of this section is
to give the knowledge required at the first intervention.
There is no practical way to locate any possible fault. Most of the faults do not occur as a performance
decrement. Generally, the UPS operates normally or switches into by-pass mode. But in order to determine
any change in load or the system the parameters must be recorded regularly as mentioned previously.
Generally, the output voltage can deviate %2 from the predefined values. If values differ more than this
percentage then reasons must be investigated.
The following general structure must be systematically followed while trying to indicate the error:
Fault determination: First step is to record the messages, indicator panel LEDs, operating parameter
values and last status of switches. This must be done before
Fixing interventions: After recording all indications, check the meaning of the fault and alarm
messages using “The operator control indicator panel”. If anything related, follow the related procedure.
Reporting the fault: Service personal must clearly report the work done. Hence, if any other error
occurs there will be enough information to fix it.
30
VIII. UPS REMOTE MONITORING AND CONTROL
Following external connections are available for PDSP series UPSs.
•
•
•
Communication by serial port connection.
Dry contact (interface board) connections.
Remote monitoring panel.
8.1 Using Serial Port
A standard Serial (RS232) communication port is installed to all PDSP series UPS. By using this port user can
get all information about the UPS. All measured parameters and alarms can be monitored via this port. This
port is interactive and some commands for UPS operation are available. These commands are listed below.
•
•
•
•
•
•
•
•
•
•
•
•
•
Switch to BYPASS
Switch to INVERTER
SOUND on/off
Adjust UPS time and date
Start SIMULATION mode
Quick BATTERY TEST
BATTERY TEST until battery low alarm
CANCEL battery test
Turn off UPS output voltage immediately (SHUTDOWN)
Turn off UPS output voltage after delay (WAITING SHUTDOWN)
Turn off UPS output voltage (SHUTDOWN) and turn on UPS output voltage (WAITING RESTART)
CANCEL SHUTDOWN
RENAME UPS
UPS will give response to these commands only if the REMOTE: ENABLE option is selected from OPTIONS
MENU.
Apply your local distributor, for information on available software for monitoring and controlling the UPS.
RS232
Communication Port
(DB9 Female)
Communication Routing
DIP Switch
Figure 8.
8.1.1 Communication Routing Switch:
RS232 Communication of the UPS can be routed either to an internal (e.g ML100 port multiplexer, MD1
MODBUS adapter, SNMP unit etc.) or to an external device.
There are two sets of DIP switch positions:
INTERNAL
(e.g. SNMP)
RS232
(EXTERNAL)
1
2
3
4
ON
OFF
ON
OFF
OFF
ON
OFF
ON
31
In “RS232” position of DIP switches, RS232 communication with an external device is performed through the
standard DB9 socket shown above. If DIP switches are in “INTERNAL” position, communication through the
standard socket is turned off and routed to an internally connected device. For example, if an ML100 Port
Multiplexer has been installed in the UPS, standard DB9 socket is not used for RS232 communication,
instead, the two ports, COM1 and COM2 on the ML100 can be used for external communication
simultaneously.
8.2 Serial Communication Cable
The maximum length for RS232 communication cable should be 25 meters. Cable connector pin configuration
is as follows:
UPS side
9 Tx
7 Gnd
6 Rx
PC side
2 Rx
5 Gnd
3 Tx
For remote panel and UPS connection the same pin configuration is valid.
8.3 Modem Connection
A PDSP Series UPS can be controlled through a normal telephone line by means of a remote operator
connected through a PC with modem device, who performs a phone call to the UPS connected number. So
the operator can see all parameters and control the UPS (if permitted from OPTIONS MENU).
8.3.1 Hardware Configuration
All requirements for modem connection are as follows:
• PC with modem
• WINDOWS 98
• Available UPS control software
• NULL modem which is connected to UPS
In order to perform this function a PC with UPS control software and an external or internal modem device
connected to telephone line are needed.
A NULL modem device, configured according to NULL and auto answer modes, when installed in the UPS
and, once programmed, following a telephone call of the PC-embedded modem, will connect the UPS to the
telephone line.
8.3.2 Functioning Principle
The remote operator, by means of a PC and a modem device and using the remote connection function of the
control software, calls the UPS through the number to which this is connected.
The NULL modem device, connected to the UPS, will answer the call and convert the data coming from UPS’s
serial port on to the telephone line. This way all measurements and controls allowed by the RS232 serial port
can be carried out.
32
8.3.3 Modem programming procedure
Smart modem (SM) is the one connected to PC, and NULL Modem (NM) is the one connected to the UPS.
Standard Hayes AT programming language is the suitable language for modems. In usual applications a
modem which uses AT command set should be selected.
8.3.3.1 SMART Modem Programming (PC modem)
The connected modem to PC (smart modem) will be programmed from UPS control software automatically.
B0 E1 F1 M1 Q0 V1 X3
BAUD = 2400
PARITY = N
WORDLEN = 8
DIAL = TONE
(TONE which can be programmed)
&A3 &B1 &C1 &D0 &H1 &I0 &K1 &M4
&N0 &R2 &S0 &T5 &Y1
8.3.4 Modem –UPS Connection Cable
The connection cable between NULL modem and UPS is configured as follows:
UPS
DB9 female
6
7
9
MODEM
DB25 male
3
7
2
8.4 Dry Contact (Interface) Connections
Some important events of the UPS can be monitored or controlled by these connections. There is a relay for
each event, which is located on the interface board. The NC-C-N0 contacts of each Relay are available at the
Interface Board output terminals.
These events are:
•
•
•
•
•
•
LINE FAILURE
BATTERY LOW
LOAD ON BYPASS
BATTERY CB input
BATTERY CB output
EMERGENCY STOP input
33
Static
Transfer
Switch
Battery Circuit
Breaker Input
Emergency Stop
Line Failure
Relay
Battery Low Relay
By-Pass
Relay
CN4
CN3
NOTE: Emergency stop terminals (4 and 5) should be short circuited by an external EPO switch to apply an
EMERGENCY POWER OFF to the UPS (No output voltage).
Line Failure, Battery Low and Bypass relays are normally de-energized and they are energized only in case of
an alarm. The behavior of these relays can be reversed by the user. (i.e. all relays are energized normally and
de-energized in case of alarm)
8.7 Remote Monitoring Panel
Remote monitoring panel can be extended to 400 meters away from UPS. Up to 25 meters there is no need
for extra hardware, and RS232 communication is okay. But if the distance is longer than 25 meters additional
RS485 hardware is needed.
Up to 5 remote monitoring panels can be used in the system.
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