PowerWave 33 Series 3 60 – 120 kW
User Manual
PowerWave 33 Series 3
60 – 120 kW
© Copyright 2016 ABB, All rights reserved
Document information
File name
:
4NWP100532R0001_OPM_ABB_PW33_S3_60-120kW_EN_REV-A.docx
UPS model
Date of issue
:
:
PowerWave 33 Series 3
Article number
:
4NWP100532R0001
Document number
:
4NWD003253
Revision
:
A
02.02.2016
Foreword
OPERATIONS INSIDE THE UPS MUST BE
PERFORMED BY A SERVICE ENGINEER FROM THE
MANUFACTURER OR FROM AN AGENT CERTIFIED
BY THE MANUFACTURER.
This user manual contains guidelines for delivery, installation and commissioning of the UPS, and is
intended for personnel who plan the installation, commissioning, use and service of the UPS. The reader
is expected to know the fundamentals of electricity, wiring, electrical components and electrical
schematic symbols.
CAREFULLY READ THE USER MANUAL BEFORE
OPERATING THE UPS OR WORKING ON IT.
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Contents
1 Safety regulation ....................................................................................... 5
1.1 Safety rules ............................................................................................................ 5
1.2 Safety symbols and warnings ............................................................................... 6
2 General characteristics ............................................................................. 7
2.1 Environmental requirements ................................................................................. 7
2.2 CE marking and declaration of safety and emc conformity ................................. 7
2.3 Inquiries .................................................................................................................. 7
2.4 Type plate and model identification ...................................................................... 8
3 Transport – storage – unpacking .............................................................. 9
3.1 Visual inspection .................................................................................................... 9
3.2 Storage ................................................................................................................... 9
3.3 Unpacking ............................................................................................................ 10
3.3.1 Standard packaging .............................................................................................................. 10
3.3.2 Optional sea freight packaging (wooden box) ........................................................................ 12
4 Installation and wiring ............................................................................. 14
4.1 Positioning of the UPS and battery cabinet........................................................ 14
4.2 Electrical installation ............................................................................................ 16
4.3 Block diagram ...................................................................................................... 17
4.4 Wiring ................................................................................................................... 17
4.4.1 Conversion from single input feed to dual input feed and vice-versa...................................... 20
4.4.2 Installation checklist ............................................................................................................... 20
5 Connectivity ............................................................................................. 21
5.1 Customer interface .............................................................................................. 21
5.1.1 Customer inputs .................................................................................................................... 22
5.1.2 Customer outputs (OPTIONAL USB port & Relay card) ......................................................... 22
5.2 Connectivity options ............................................................................................ 23
5.2.1
5.2.2
5.2.3
5.2.4
Remote SHUT DOWN (EPO) ................................................................................................. 23
Generator on facilities ............................................................................................................ 23
Wavemon Shutdown and management software .................................................................. 24
SNMP CARD/ADAPTER for network management / remote monitoring ................................ 25
6 Operation ................................................................................................. 27
6.1 Commissioning .................................................................................................... 27
6.2 Parallel - multicabinet- configuration .................................................................. 27
6.2.1 Installation instructions .......................................................................................................... 27
6.2.2 Paralleling of UPS-Cabinets ................................................................................................... 28
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6.2.3 Dip switch SW1-9 ................................................................................................................. 29
6.2.4 Multidrop Master/Slave configuration - Dip switch SW2 ....................................................... 29
6.3 Control panel ........................................................................................................ 30
6.3.1 Led indicators ....................................................................................................................... 30
6.3.2 Buttons................................................................................................................................. 31
6.3.3 Status screens ...................................................................................................................... 31
6.3.4 Main menu screen ................................................................................................................ 32
6.3.5 Event log screen ................................................................................................................... 32
6.3.6 Measurements screen .......................................................................................................... 33
6.3.7 Commands screen ............................................................................................................... 33
6.3.8 Ups data............................................................................................................................... 34
6.3.9 Set-up user........................................................................................................................... 34
6.3.10 Set-up service ...................................................................................................................... 34
6.4 Operating modes .................................................................................................. 35
6.4.1
6.4.2
6.4.3
6.4.4
Mode "ON LINE" (INVERTER MODE) .................................................................................... 35
Mode"OFF-LINE"(ECO- or BYPASS MODE) ......................................................................... 35
"Maintenance bypass" - mode.............................................................................................. 36
Output switch/parallel isolator (ia2) ....................................................................................... 36
6.5 Operation procedures .......................................................................................... 37
6.5.1
6.5.2
6.5.3
6.5.4
Start-up procedure ............................................................................................................... 37
Shutdown procedure ............................................................................................................ 38
Load Transfer: from Inverter operation to Maintenance Bypass ............................................ 39
Load Transfer: from Maintenance Bypass to Inverter operations .......................................... 40
7 Maintenance ............................................................................................ 42
7.1 User responsibilities ............................................................................................. 42
7.2 Preventative maintenaince................................................................................... 42
7.3 Deep battery test.................................................................................................. 42
7.4 Battery maintenance, disposal and recycling ..................................................... 43
8 Troubleshooting....................................................................................... 44
8.1 Alarms ................................................................................................................... 44
8.2 Menu, commands, event log and measurements ............................................... 44
8.3 Fault identification and rectification .................................................................... 44
9 End of life treatment ................................................................................ 45
9.1 UPS and material disposing ................................................................................ 45
10 Revision History ................................................................................... 46
11 Attachments ......................................................................................... 48
11.1 Technical data sheet .......................................................................................... 48
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1 Safety regulation
1.1 Safety rules
This UPS operates with mains, battery or bypass power. It contains components that carry high currents
and voltages. The properly installed UPS is grounded to earth and IP20 rated against electric shock
and foreign objects. Installation and service have to be performed by the manufacturer’s qualified
technicians or their certified service partners.
THERE IS DANGER OF ELECTRICAL SHOCK
WARNING!
This user manual contains guidelines for delivery, installation and commissioning of the UPS, and is
intended for personnel who plan the installation, commissioning, use and service of the UPS. The reader
is expected to know the fundamentals of electricity, wiring, electrical components and electrical
schematic symbols.
READ THE INFORMATION IN ORDER TO AVOID EQUIPMENT DAMAGE
NOTE!
The only user operations permitted are:
• Use of the LCD control panel (LCD) and of the maintenance bypass
• Start-up and shut-down of the UPS user field (except during commissioning start-up)
• Operation of additional connectivity modules:
• SNMP adapters and their software
• Modem/GSM or modem/Ethernet adapters and their software
The user must take the precautions set out in this manual and only perform the operations described.
The UPS operator must adhere to the instructions in this manual. Any deviations from the instructions
could be dangerous to the user or could cause accidental load loss.
THE MANUFACTURER DOES NOT TAKE ANY RESPONSIBILITY FOR DAMAGE CAUSED BY
INCORRECT USE OF THE UPS.
IT IS PROHIBITED TO REMOVE ANY SCREWS FROM THE UPS OR FROM
THE BATTERY CABINET. THERE IS A DANGER OF ELECTRIC SHOCK.
WARNING!
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HIGH FAULT CURRENTS (LEAKAGE CURRENTS):
BEFORE CONNECTING THE MAINS, YOU MUST ENSURE THAT THERE IS A
PROPER EARTH CONNECTION!
WARNING!
WARNING!
THE USER MUST DISPLAY A WARNING SHIELD ON ALL PRIMARY UPS
CIRCUIT BREAKERS. THE SERVICE PERSONNEL HAS TO BE INFORMED
ABOUT DANGEROUS VOLTAGES. THE WARNING PANELS MUST CONTAIN
THE FOLLOWING TEXT: “ BEFORE STARTING WITH MAINTENANCE WORK
ON THE CIRCUIT BREAKERS, MAKE SURE THE UPS IS ISOLATED.”
1.2 Safety symbols and warnings
The following symbols are used in this manual; the list below provides a description of each symbol.
DANGER – Serious damage to health / risk to life
This symbol in conjunction with the signal word "DANGER" indicates an
imminent electrical hazard. Failure to observe the related safety note may cause
personnel injury or death or equipment damages.
WARNING – Bodily injury
This symbol in conjunction with the signal word "WARNING" indicates a
potentially dangerous situation. Failure to observe the related safety note may
cause personnel injury or death or equipment damages.
IMPORTANT (NOTE)
This symbol indicates operator tips, particularly useful or important information
for the use of the product. This symbol and wording does not indicate a
dangerous situation.
PE – Protective Earth terminal
The PE terminal must be connected to earth prior to making any other
connection to the equipment.
AC – alternating current or voltage
A terminal to which or from which an alternating current or voltage is applied or
supplied.
DC – direct current or voltage
A terminal to which or from which direct current or voltage is applied or supplied.
Battery
This symbol indicates a battery (source of DC voltage and current) which can be
both internal or external to the UPS system and accessories (battery cabinet).
Power ON/OFF or shutdown
Symbol used to indicate the action of Powering ON, Idle or shutdown the UPS.
Recycle
Do not dispose with ordinary trash.
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2 General characteristics
2.1 Environmental requirements
THIS IS A PRODUCT FOR COMMERCIAL AND INDUSTRIAL APPLICATION
IN THE SECOND ENVIRONMENT – INSTALLATION RESTRICTIONS OR
ADDITIONAL MEASURES MAY BE NEEDED TO PREVENT DISTURBANCES.
WARNING!
To operate the UPS at the best efficiency point, your installation site should meet the environmental
parameters outlined in this manual. Excessive amount of dust or moisture in the operating environment
may cause damage or lead to malfunction. The UPS should be always protected from the outside
weather and sunshine. The operating environment must meet the weight, airflow, size and clearance
requirements specified in the section 4.1 of this manual or in the technical datasheet (TDS) of the same
product (separate document).
Under no circumstances, the UPS should be installed in an airtight room, in the presence of flammable
gases, or in an environment, exceeding environmental requirements specified here below.
The ambient temperature for operating the UPS must be in the range 0 °C to +40 °C. The Ideal
temperature also recommended to achieve a long life of the UPS and VRLA batteries is +20°C to +25°C.
The relative humidity should be below 95% (non-condensing) and the max. altitude without de-rating is
1000m above sea level.
2.2 CE marking and declaration of safety and emc conformity
The product has the CE marking in compliance with the following European directives
• Low Voltage Directive:
2006/95/EC
• EMC Directive:
2004/108/EC
The product applies the actual UPS standards, listed in the Table 1 below.
Table 1: UPS Standards.
Description
Product standards
General standards
Safety
IEC/EN 62040-1
Electromagnetic Compatibility (EMC)
IEC/EN 62040-2
Emission cat. C3
Immunity cat. C3
IEC/EN 60950-1
IEC/EN 61000-4-2
IEC/EN 61000-4-3
IEC/EN 61000-4-4
IEC/EN 61000-4-5
IEC/EN 61000-4-6
IEC/EN 61000-4-8
IEC/EN 61000-2-2
Performance
IEC/EN 62040-3
Environmental aspects
IEC/EN 62040-4
2.3 Inquiries
Address inquiries about the UPS to the local office or agent CERTIFIED by the supplier. Please note the
type code and the serial number – shown in the type plate of the product (see section 2.4) – of the
equipment and contact your nearest agent CERTIFIED by the supplier.
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2.4 Type plate and model identification
The type plate shown in Figure 1 here below is positioned on the internal side of the UPS door in a
center position. It contains the basic electrical characteristics as well as, product name, serial number
and production date. The identification table (Table 2) helps to crosscheck the Type (first part of the
serial number) with the UPS model.
Figure 1: Type plate of PowerWave 33 Series 3.
Table 2: identification table with dimensions of PowerWave 33 Series 3.
TYPE
UPS MODEL
Dimensions w/o
packaging in mm
Dimensions with
std. packaging in
mm
Dimensions w/
wooden box in
mm
615 x 19541) x 480
615 x 19782) x 480
615 x 19923) x 480
873x2133x873
884x2182x730
PWAxxxx PowerWave 33 S3 60kW
PWAxxxx PowerWave 33 S3 80kW
PWAxxxx PowerWave 33 S3 100kW
PWAxxxx PowerWave 33 S3 120kW
1) without adjustable feet
2) with adjustable feet, adjusted all downwards.
3) with adjustable feet, adjusted all upwards.
Table 3: weight table of PowerWave 33 Series 3.
TYPE
UPS MODEL
PWAxxxx PowerWave 33 S3 60kW
PWAxxxx PowerWave 33 S3 80kW
PWAxxxx PowerWave 33 S3 100kW
PWAxxxx PowerWave 33 S3 120kW
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NET weight in kg
198
206
228
230
Weight with
Weight with
standard packaging
wooden box in kg
in kg
219
269
227
277
249
299
251
301
3 Transport – storage – unpacking
3.1 Visual inspection
Upon receiving the goods, make sure that they corresponds to the material indicated in the delivery
note. Carefully examine the packed unit(s) for any sign of physical damage. Two TiltWatch indicators
(see Figure 2) are placed on two sides of the packed unit, in a well visible position. They should both be
intact and not red color. If tipping has occurred the white arrow becomes red, like shown on the Figure
2 below.
In case of damaged unit(s) or even only suspect of damaged (TiltWatch is red) inform immediately:
•
•
The carrier
The manufacturer
VISIBLE TRANSPORT DAMAGES MUST BE CLAIMED TO THE CARRIER
IMMEDIATELY AFTER RECEIPT.
OTHER CLAIM FOR SHIPPING DAMAGE MUST BE FILED ALSO
IMMEDIATELY AND THE CARRIER MUST BE INFORMED WITHIN 7 DAYS
OF RECEIPT OF THE EQUIPMENT. THE PACKING MATERIALS SHOULD
BE STORED FOR FURTHER INVESTIGATION.
IMPORTANT
NOTES!
Figure 2: TiltWatch indicator: left when intact and right when tipping has occurred.
3.2 Storage
The packing of the goods protects it from mechanical and environmental damage. UPS and Battery
cabinets should be store in its original packaging. Make sure that the goods are stored indoor, protected
from water and sunshine in a clean environment.
IMPORTANT
NOTES!
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THE RECOMMENDED TEMPERATURE FOR STORAGE OF THE UPS
SYSTEM AND BATTERIES IS BETWEEN +20 °C AND +25°C, HUMIDITY <
95% (NON-CONDENSING).
FOR UPS SYSTEM ONLY THE STOREAGE TEMPERATURE CAN BE
BETWEEN -25 °C AND +70°C, HUMIDITY < 95% (NON-CONDENSING).
BEFORE SWITSIHG ON THE UNIT(S), MAKE SURE THE AMBIENT
TEMPERATURE HAS REACHED THE OPERATION TEMPERATURE RANGE
WHICH IS 0°C - +40°C.
3.3 Unpacking
Prior unpacking make sure that the floor surface is solid and suitable for supporting the weight of all the
equipment. Bring the unit(s) close to the end position and unpack them by removing the packing and
shipping materials as described next.
WARNING!
3.3.1
UPS AND BATTERY CABINETS ARE HEAVY AND TALL. MAKE SURE YOU
ARE ALWAYS WORKING SAFELY BY USING APPROPIRATE TOOLS AND
EQUIPMENT. WHEN MOVING THE UNITS AROUND USING FORKLIFT,
ALWAYS MAKE SURE THE UNITS ARE IN UPRIGHT POSITION AND MOVE
WITH SLOW SPEED AND SLOW ACCELERATIONS.
Standard packaging
Perform the following steps to unpack the UPS equipment from the standard packaging:
1. Remove the plastic film from the UPS, by cutting it where there is the cardboard underneath (on
one edge),
2. Remove the 4x cardboard edges carefully by paying attention that the accessory box placed on
top of the UPS does not fall down. Lower the accessory box with the help of a stool or ladder;
make sure you are safe by doing that. The std. content of the accessory box is: user manual, 2x
painted sockets, screws, 4x feet and keys.
3. Remove the bubble-film by removing the small type pieces by hand.
4. Disassemble the front and back fixing bars (see Figure 3, right inside here below as well as Figure
4 on the next page) by unscrewing 8x M8 hexagonal screws.
5. Mount the 4x adjustable feet (feet are in the accessory box) as shown in Figure 5 on the next page.
6. After having placed the UPS in its final position, disassemble the left and right socket as shown in
Figure 6 on the next page and mount the front and back painted sockets.
7. You may want to keep some packaging materials for later use. Alternatively, in case in makes more
sense to dispose the packing material, it must be disposed in accordance with the applicable laws
in the country where the UPS is installed.
1)
2)
3)
Figure 3: Photographs of PowerWave 33 S3 being unpacked step-by-step.
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4)
Figure 4: side view of the lower part of PowerWave 33 S3 with the socket (base).
5)
Figure 5: front view of the lower part of PowerWave 33 S3 showing the adjustable feet.
6)
Figure 6: side view of the lower part of PowerWave 33 S3 showing the socket and its screws.
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3.3.2
Optional sea freight packaging (wooden box)
Perform the following steps to unpack the UPS equipment from the sea freight package:
1. Disassemble the wooden box by removing all screws.
2. Remove the plastic film and bag from the UPS, by cutting it without causing damage to the cabinet;
the edges are not protected.
3. Remove the accessories form its location, see Figure 8 on the next page. The std. set of
accessories is: user manual, 2x painted sockets, screws, 4x feet and keys.
4. Tear out the 2x humidity-absorber. One is inside the front part of the UPS: open the door using the
keys and then tear out the absorber. The other one is at the back as shown in Figure 9 (next page)
5. Follow the steps 5) - 7) of the previous section 3.3.1.
1)
2)
Figure 7: Photograph and 3D drawing of PowerWave 33 S3 with sea freight packaging.
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3)
Figure 8: Photograph of the accessories zone, PowerWave 33 S3 front bottom.
4)
Figure 9: Photographs showing the 2x humidity-absorber. One on the inside front part of the UPS (left) and another on the
rear (right).
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4 Installation and wiring
4.1 Positioning of the UPS and battery cabinet
The UPS is designed for location in a restricted access location only and should be located where:
•
The relative humidity does not exceed 95% (non-condensing) and the temperature remains always
between 0°C and +40°C. Note: an optimal temperature for the UPS and especially for VRLA
batteries is 20°C- 25°C. The UPS room shall have temperature control (air-cooling)
•
Any kind of dust or corrosive/explosive gases must be absent
•
Fire protection standards are respected
•
The place is vibration free
•
The floor material should be non-flammable and strong enough to support the heavy load.
•
Cabling can be performed easily
•
Available front accessibility of 1m from front of the unit for service or maintenance
•
Only front access is necessary for service and maintenance
•
If the UPS will be installed in bayed enclosures, partition walls have to be installed as well
Also the needed clearances to allow proper airflow on the UPS system and to allow proper service and
maintenance shall be respected as reported in the Table 4 below.
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Figure 10: Top view and indication of the minimum clearances for UPS + other cabinets in row.
Table 4: minimum clearances for UPS + other cabinets in row.
PowerWave 33 Series 3 Cabinets
A
Back clearance for ventilation
(forced air outlet)
B
Front clearance needed to allow
a correct door opening
C
Maximum door opening angle
D
4)
Top Clearance
(Top clearance is only needed if there is no
side clearance)
60 / 80 / 100 / 120
UPS + battery cabinets
in row.
0 mm
100mm 4)
1000 mm
115°
400 mm
Battery cabinet requires 100mm clearance for natural ventilation. The UPS does not require any back clearance.
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4.2 Electrical installation
The electrical installation procedure is described in the following text.
To ensure correct operation of the UPS, the voltage Total Harmonic Distortion (THDu) of the mains shall
not exceed the values according to Standard IEC 61000-2-2. In case of exceeding of the indicated
values, please contact the manufacturer.
The installation inspection and initial start-up of the UPS and extra battery cabinet must be carried out
by a qualified service personnel such as a licensed service engineer from the manufacturer or from an
agent CERTIFIED by the manufacturer.
THE INSTRUCTIONS IN THIS USER MANUAL HAVE TO BE FOLLOWED
ALWAYS IN ORDER TO AVOID INJURIES FROM ELECTRICAL SHOCK.
WARNING!
WARNING!
ALL THE OPERATIONS DESCRIBED IN THIS MANUAL MUST BE
PERFORMED BY CERTIFIED ELECTRICIANS OR BY QUALIFIED INTERNAL
PERSONNEL.
DO NOT OPERATE IF WATER OR MOISTURE IS PRESENT.
BY OPENING OR REMOVING THE UPS COVERS YOU RUN THE RISK OF
EXPOSURE TO DANGEROUS VOLTAGES.
PHYSICAL INJURY OR DEATH MAY FOLLOW, OR DAMAGE MAY OCCUR TO
THE UPS OR THE LOAD EQUIPMENT IF THESE INSTRUCTIONS ARE
IGNORED.
To ensure correct operation of the UPS and its ancillary equipment it is necessary to provide the appropriate
wiring and with fuse protection in accordance with the prescribed local standards or with the local regulations/law.
Alternatively refer to the suggested appropriate wiring and fuse protection in the next subsections 4.3 and 4.4.
The UPS unit has the following power connections:
Rectifier input: three-phase (1-L1, 1-L2, 1-L3)
Bypass input :three-phase (2-L1, 2-L2, 2-L3)
Neutral: (N) The Neutral connection at UPS input (upstream) is mandatory.
Load output : three-phase (3-L1, 3-L2, 3-L3)
Battery: (+) and (-) Note: The battery (-) is at the same potential and is the same connection point as N.
Protective earth (PE)
INPUT NEUTRAL IS REQUIRED TO OPERATE THE RECTIFIER.
In TN-S Systems, no 4-pole input switches or circuit breakers should be used. If you have
to use a 4-pole switch for another reason, you have to be aware that, when open, the
system - UPS and all downstream equipment - are floating against the PE.
IMPORTANT
NOTE
Figure 11: Input neutral
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4.3 Block diagram
Figure 12: Block diagram of PowerWave 33 S3. On the left with single input feed configuration and on the right with dual
input feed configuration.
4.4 Wiring
Before proceeding to wire the UPS, make sure that you have read and understood the chapter above
4.2 Electrical installation and make sure that the following is respected:
•
The cable sections and fuse ratings are respecting the local standards. Alternatively, you can
use the recommended cable sections and fuse rating in the tables 6 and 7, which are according
to (IEC 60950-1).
Table 5: SINGLE INPUT FEED (CABLE LINKS TO ACHIEVE SINGLE INPUT ARE OPTIONAL)
Fuse A
Fuse E
Rated
Cable A
Cable D
Type:gL or
Type:gR or
Cable E
output
(quantity x
(quantity x
CB
CB
(quantity x mm2)
2
2
power
mm )
mm )
(quantity x A)
(quantity x A)
60 kW
3x100
5x(1x35)
5x(1x35)
2x160
2x(1x50)
80 kW
3x125
5x(1x50)
5x(1x50)
2x200
2x(1x95) @ 42-45 batt. blocks
2x(1x70) @ 46-50 batt. blocks
100
kW
3x160
5x(1x70)
5x(1x70)
2x250
2x(1x120) or 2x(2x50) @ 42-45 batt.
blocks
2x(1x95) @ 46-50 batt. blocks
2x300
2x(1x150) or 2x(2x50) @ 42-45 batt.
blocks
2x(1x120) or 2x(2x50) @ 46-50 batt.
blocks
120
kW
3x200
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5x(1x95)
5x(1x95)
Table 6: DUAL INPUT FEED (STANDARD VERSION)
Rated
output
power
Fuse B
Type:gL or
CB
(qty. x A)
Cable B
(qty. x
mm2)
Fuse C
Type:gL or
CB
(qty. x A)
Cable C
(qty. x
mm2)
Cable D
(qty. x
mm2)
Fuse E
Type:
gR or
CB
Cable E
(qty. x mm2)
60
kW
3x100
5x35
3x100
5x35
5x35
2x160
2x(1x50)
2x200
2x(1x95) @ 42-45
batt. blocks
2x(1x70) @ 46-50
batt. blocks
2x250
2x(1x120) or 2x(2x50)
@ 42-45 batt. blocks
2x(1x95) @ 46-50
batt. blocks
2x300
2x(1x150) or 2x(2x50)
@ 42-45 batt. blocks
2x(1x120) or 2x(2x50)
@ 46-50 batt. blocks
80
kW
100
kW
120
kW
•
•
•
•
•
•
•
•
•
3x125
3x160
3x200
5x50
5x70
5x95
3x125
3x160
3x200
5x50
5x70
5x95
5x50
5x70
5x95
No mains voltage is present on the wires
All Loads are shut down and disconnected
UPS is shut down and voltage-free (no battery is connected)
Make sure the unit is pre-configured as you need: single input or dual input feed (see Figure 12).
Factory standard is dual input feed, single feed is optional and if ordered with the units it comes
pre-assembled. To convert single feed into dual or vice-versa go to subsection 4.4.1.
All 4x switches (IA1 Maintenance Bypass – IA2 Output Isolator – IA3 Bypass Input – IA4 Rectifier
Input) are in position OFF
Mains voltage (Input Voltage) and frequency (Input Freq.) correspond to the values indicated on
the type plate of the UPS. The type plate (Figure 1) is on the inside part of the door in a center
position.
Make sure that the total power of the load is equal or lower than the rated power of the UPS
(Output power) indicated on the type plate of the UPS.
PE wiring is performed in accordance with the prescribed IEC Standards or with local regulations;
UPS is connected to the mains through a Low Voltage (LV)-Distribution Board with a separate
mains line (protected with a circuit breaker or fuse) for the UPS.
The wiring must be done in the following order:
1. Connect first the PE wire coming from the LV Distribution Board (mains) to the terminal "PE".
2. Connect the input wires 3-phases + N coming from the LV Distribution Board (mains). Keep the
phase rotation in clock-wise sense. In case of dual input with 2xN wires, the 2xN have to be at the
same potential, ideally they have to be joined together somewhere upstream the UPS. Dual input
feed with just 1xN is also possible.
3. Connect the output wires 3-phases + N. N at the output is not mandatory (depends on the type
of load).
4. Connect the battery wires, make sure the polarity (+) and (-) are correct.
Make sure you are using the recommended tightening torque (Table 7) and you are connecting each
wire at the correct terminal, on the unit itself each terminal is labelled, as shown here below in Figure
13.
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Figure 13: bottom front view and connection terminals of PW33 S3 60-80-100-120 kW models.
Table 7: connection terminals overview and tightening torque.
PW33 S3
Model
Input
Rectifier
Input
Bypass
Output
Batt (+)
N / Batt. (-)
PE
Tightening
torque (Nm)
60 kW
2xM8
1xM8
1xM8
2xM8
1xM10
5xM8
5xM8
12.3 (M8)
25.1 (M10)
80 kW
2xM8
1xM8
1xM8
2xM8
1xM10
5xM8
5xM8
12.3 (M8)
25.1 (M10)
100 kW
2xM8
1xM8
1xM8
2xM8
1xM10
5xM8
5xM8
12.3 (M8)
25.1 (M10)
120 kW
2xM8
1xM8
1xM8
2xM8
1xM10
5xM8
5xM8
12.3 (M8)
25.1 (M10)
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4.4.1
Conversion from single input feed to dual input feed and vice-versa
The Figure 14 below shows the situation with single input feed which is achieved thank to 3x link wires
which are factory mounted in case the unit is ordered with single input feed.
To convert the unit from single into dual input feed simply remove the 3x link wires which connect
the INPOUT RECTIFIER 1-L1, 1-L2, 1-L3 with the INPUT BYPASS 2-L1, 2-L2, 2-L3. All link wires have
M8 ending.
To convert the unit from dual into single input feed first you need to have the 3x link wires (for PW33
60-80kW Art. 04-3820) (for PW33 100-120kW Art. 04-3822) then connect the INPOUT RECTIFIER 1L1, 1-L2, 1-L3 with the INPUT BYPASS 2-L1, 2-L2, 2-L3. All link wires have M8 ending, apply a
tightening torque of 12.3 Nm.
Link wires
Link wires
Figure 14: Detail of the single input feed configuration.
4.4.2
Installation checklist
 All units and accessories have been unpacked properly. Some packaging material has been
kept for future use.
 Each unit has been positioned at the planned spot.
 The area around the installed UPS system(s) and surrounding devices is clean and dust-free
and respect the recommended clearances.
 The PE wire(s) is(are) properly sized, routed and terminated.
 All power wire(s) is(are) properly sized, routed and terminated.
 Battery cabinet installation instructions have been completed.
 Air conditioning equipment is installed and operating properly.
 Adequate lighting is provided around all UPS equipment.
 Any optional accessories are mounted in their installed location and properly wired.
 Summary alarms and/or building alarms are wired appropriately. (OPTIONAL)
 Startup and operational checks performed by CERTIFIED service personnel.
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5 Connectivity
5.1 Customer interface
Each UPS cabinet is provided with customer interface ports (also called communication ports) which
provides information about the UPS (single units) or the UPS system (parallel system). The customer
interface is composed by:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Slot for optional USB & relay card (customer outputs)
Slot for optional SNMP card
PC / laptop connection
JD1 (RS232 Sub D9/female)
Status LED’s
1 red LED and 1 green LED
Customer inputs
X1 1-10 Phoenix terminals
Multidrop connector
JR2 (RJ 45)
Parallel BUS connector
JD1 (Sub D25/female)
Multi-Cabinet Configuration
SW1-9 (DIP-SWITCH), see chapter 6.2.3
SW2 – Multidrop configuration
SW2 (DIP-SWITCH), see chapter 6.2.4
1
2
7
3
4
5
8
9
6
Figure 15: Overview of the customer interface.
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5.1.1
Customer inputs
The customer input interfaces are standard for each model and are located in the front bottom part of
the unit.
All voltage free contacts are rated 60 VAC max. and 500 mA max.:
All the interfaces are connected to Phoenix Spring terminals with wires : 0.5 mm2
Table 8: details of the customer inputs.
Block
X1
5.1.2
Terminal
Contact
Signal
Function
X1 / 10
GND
GND
12 Vdc source
X1 / 9
IN
+12Vdc
(Max 200mA load)
X1 / 8
GND
GND
Remote Shut down
X1 / 7
IN
+12Vdc
(Do not remove the factory mounted bridge until an external remote shut down is connected)
X1 / 6
GND
GND
Temperature Battery
X1 / 5
IN
+3.3Vdc
(If connected, the battery charger current is batt. temperature dependent)
X1 / 4
GND
GND
Customer IN 1
X1 / 3
IN
+12Vdc
(Function on request, to be defined)
X1 / 2
GND
GND
GEN_OPERATION
X1 / 1
IN
+12Vdc
(NC = Generator ON)
Customer outputs (OPTIONAL USB port & Relay card)
The customer output interfaces are on an optional relay card which goes into slot 2 of the UPS.
All voltage free contacts are rated 60 VAC max. and 500 mA max.:
All the interfaces are connected to Phoenix Spring terminals with wires: 0.5 mm2
Table 9: details of the customer outputs + USB on the relay card.
Block
15
1
X2
Terminal
Contact
X2 / 15
C
X2 / 14
NC
X2 / 13
NO
X2 / 12
C
X2 / 11
NC
X2 / 10
NO
X2 / 9
C
X2 / 8
NC
X2 / 7
NO
X2 / 6
C
X2 / 5
NC
X2 / 4
NO
X2 / 3
C
X2 / 2
NC
X2 /1
NO
+ USB
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Signal
On Display
Function
Common
ALARM
COMMON_ALARM
NO Alarm Condition
Common Alarm
(System)
Common
Message
LOAD_ON_MAINS
(Load on Inverter)
Load on bypass (Mains)
Common
ALARM
BATT_LOW
Battery OK
Battery Low
Common
Message
LOAD_ON_INV
(Load on Mains bypass)
Load on Inverter
Common
ALARM
MAINS_OK
Mains Failure
Mains Present
5.2 Connectivity options
5.2.1
Remote SHUT DOWN (EPO)
The REMOTE SHUT DOWN must use a normally closed contact, which opens to operate the remote
shut down sequence. Usually the shutdown procedure is disabled and it should be activated by a
Hardware Code on “Setup Service” menu”. Please contact your distributor to enable this operation.
THE UPS IS PROVIDED WITH AN “EMERCENCY BYPASS” WHICH IS
AUTOMATICALLY ENABLED IN CASE OF A SINGLE MODULE
CONFIGURATION. IN THIS CASE THE EPO WILL BE AUTOMATICALLY
DISABLED AND MUST BE ACHIEVED IN THE BUILDING/FACILITY. THE
FACIULITY EPO MUST OPEN THE BYPASS PATH.
NOTE
The remote shutdown terminals are on the input interfaces X1, pin 7 and 8.
In order to allow removal, maintenance or testing of any remote shut down facility without disturbing
the normal operation of the UPS, it is recommended that a terminal block, be installed between the
UPS and the emergency stop button, as shown in Fig. 13. Use a screened cable with 1 pair (section of
wires can be chosen from 0.5 to 1.5mm2) and maximum length of 100 m. The Switch must be a
normally closed (dry contact).
X1/8
X1/7
Figure 16: Drawing of the wiring for the REMOTE SHUT DOWN SWITCH
5.2.2
Generator on facilities
The Generator ON facility must use a normally open contact that closes to indicate that a generator is
running and supplying input power to UPS. The remote Generator ON terminals are on the input
interfaces X1, pin 1 and 2.
When used, this facility disables the UPS static bypass and prevents the UPS from transferring the load
on to the generator power supply and/or block the battery charger during the time the UPS is supplied
from the genset.
X1/2
X1/1
Figure 17: Drawing of the wiring for the GENERATOR ON FACILITIES
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5.2.3
Wavemon Shutdown and management software
WAVEMON Software is an external monitoring and shutdown software which was designed to operate
with all UPS products, both with the DRY PORT (Relays) on Terminal block X2 …X4 and RS232 port
JD11 on the communication card
The software packet consists of a CD ROM for most diffused operating systems (Windows, Unix, OS/2,
DEC VMS, Novell, Apple), a standard connection and a user manual.
The dry port X2…X4 with voltage-free contacts may also be used for automatic shutdown in connection
with WAVEMON Software. It is necessary to provide a cable of 0.5 mm2 to connect Terminals X2..X4
of the UPS and the serial port of the server.
Figure 18: Monitoring image
The main characteristics of WAVEMON Software are:
• Automatic unattended master/slave shutdown in heterogeneous networks
• On-screen autonomy time / battery time countdown
• On-screen server log off and shutdown procedure
• Extensive logging of all UPS activity and power quality data, with timestamp
• Scheduled UPS economy mode, service mode, other systems status
• Graphical user interface for Windows compatible platforms
• Automatic unattended local shutdown
• Special software modules to close and save open MS-Office documents.
• Compatible for all optional modules like UPSDIALER, SNMP adapters, Temperature sensors,
etc.
The UPS-Management Software is a client-/server-application for networks and local workstations.
Basically WAVEMON-Software consists of two parts: the server-module of the UPS-Management
Software is UPSServ, which communicates via RS-232 cable with the UPS. Working as a background
process the UPSServ collects messages, received from the UPS. The UPSServ interprets received
messages and makes them available to the client-module UPSCli and to any SNMP-based
management station.
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When UPSServ detects voltage variations or a power failure it can execute various so called system
„event routines“, which for example may shutdown the server or send warning to connected users.
These system event routines which are a part of the UPS-Management Software can be adjusted to
your demands.
The UPS management software includes with every serial number the licence for using the UPS service
on one server with one UPS and an unlimited numbers of connected WINDOWS workstations. When
operating with two or more servers a licence for every additional server is required. It doesn’t matter if
the UPS service runs at that location or if the server is halted by a UPS service via remote command.
The same regulations are applicable to the use of remote send/receive modules RCCMD and
multiserver shutdown under NT, UNIX and other operating systems. The service programs are generally
delivered as a single-licence. To use a single CD ROM to shutdown multiple servers you have to
purchase additional CD license keys.
Parallel/redundant UPS systems are also manageable by the software.
The main principle is: let introduce a shutdown of a Server only when strictly necessary. A correct
Parallel Handling has therefore to manage a parallel system as a whole and always considering
redundancy. Following statements apply:
Every alarm on any unit is immediately notified, but …
−
… a reaction to a severe fault is introduced only when the minimum number of UPS –Modules
necessary to supply the load exhibits an alarming situation.
−
The real Battery autonomy time of the (whole) parallel system is computed continuously.
−
Maintenance on a redundant unit may be executed without annoyance to the management system
(supervisor).
In order to be managed, a UPS can be integrated into a network in two ways:
1.
2.
5.2.4
By means of the server which is being powered by the UPS and is integrated in the network. In
most of the cases the server is used as sub-agent and you only need the PMC-Software without
any SNMP Adapter. You need a standard serial connection between the RS232 JD11 port of the
UPS and the RS232 port of the computer/server.
In some situations it is preferable to interface the network via an SNMP adapter. By this way up
to 50 computers can be shut down in a RCCMD environment. RCCMD (Remote Console
Command) is an additional software module, which can be triggered by the SNMP device to
executes a command (typically a shutdown command) on a remote system.
SNMP CARD/ADAPTER for network management / remote monitoring
The Simple Network Management Protocol (SNMP) is a worldwide-standardized communicationprotocol. It is used to monitor any device in the network via simple control language. The UPSManagement Software also provides its data in this SNMP format with its internal software agent. The
operating system you are using must support the SNMP protocol. We offer our software with SNMP
functionality for Novell, OS/2, all Windows running on INTEL and ALPHA, DEC VMS, Apple.
Two types of SNMP interfaces with identical functionality are available: an external SNMP-Adapter (Box)
and an internal SNMP-Card. Both can manage a parallel system (N modules) and return either global
values - which are consistent for the whole parallel system - or specific values from the single modules.
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Figure 19: SNMP card or box wired between the UPS and the WEB/Ethernet
The adapter may be configured via Telnet, HTTP (Web-Browser) or serial connection (Terminal). For
normal operation at least one network connection (Ethernet) is required.
The SNMP adapter can be used, utilizing the RCCMD send function, for an automatic network wide
shut down or just for informing connected users. The shut down procedure can be initiated on a low
residual battery autonomy time (downtime) or by a countdown timer which is started at the beginning
of the alarm. A shut down is therefore possible without extra input from the operator, and is fully software
controlled.
The small (125x70 mm) External SNMP adapter comes with following interfaces:
Figure 20: External SNMP Adapter
1. RJ-45 connector for 10/100 Base-T (autoswitchable)
2. Serial Port for configuration (COM2) or optional ModBus
interface.
3. Error/Link LED for UPS status
4. Aux Port
5. DIP Switch
6. Serial Port to the UPS (COM1)
7. DC Supply (9 VDC or 9-36 VDC supply, depending on model);
The Internal SNMP-Card can be inserted into an appropriate
extension slot of the PMC. This adapter communicates via the serial
port of the UPS and makes a direct multiple server shutdown
possible without additional SNMP management software.
Figure 21: Internal SNMP Adapter
For detailed information please see Software Manual provided with the PMC-Software CD
ROM.RCCMD - Remote Console Command module for a multi-server shutdown. This stand-alone
software module is designed to receive and execute a command issued by a remote device. Thanks
to RCCMD it is possible to execute a shutdown in a heterogeneous multiplatform network. The new
release RCCMD2 is an application available for all Operating Systems, analogous to PMC-Software.
Our SNMP Interfaces are compatible to RCCMD.
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6 Operation
6.1 Commissioning
The PowerWave 33 is a high quality electronic machine, which must be commissioned by a fully trained
and certified field service engineer before being put into use.
The commissioning of the UPS involves the connection of the UPS and battery, the checking of the
electrical installation and operating environment of the UPS, the controlled start-up and testing of the
UPS and customer training.
OPERATIONS INSIDE THE UPS MUST BE PERFORMED BY A SERVICE
ENGINEER FROM THE MANUFACTURER OR FROM AN AGENT CERTIFIED
BY THE MANUFACTURER.
WARNING!
6.2 Parallel - multicabinet- configuration
The PowerWave 33 S3 UPS may be paralleled for power capacity or for redundancy indefinitely. The
parallel kit is optional. Every UPS unit in a parallel configuration is provided with a proper output parallel
Isolator (IA2) which, when opened isolates the corresponding unit from the parallel system. Once the
parallel isolator (IA2) of a unit is open that unit (module) is isolated from the rest of the parallel system
and therefore does not provide power to the output. For example if you perform the command “LOAD
TO BYPASS” on any unit, all the units will transfer the load simultaneously to mains and if you perform
the command “LOAD TO INVERTER” on any unit all the UPS’s will simultaneously transfer the load to
the inverters.
6.2.1
Installation instructions
THE OPERATIONS DESCRIBED IN THIS CHAPTER MUST BE PERFORMED
BY A SERVICE ENGINEER FROM THE MANUFACTURER OR FROM AN
AGENT CERTIFIED BY THE MANUFACTURER.
WARNING!
IN ORDER TO ACHIEVE EQUAL LOAD SHARING BETWEEN THE UPSCABINETS, THE INPUT CABLE LENGTHS FROM THE INPUT DISTRIBUTION
BOARD TO THE UPS AND FROM THE OUTPUT CABLE TO THE OUTPUT
DISTRIBUTION BOARD SHOULD BE THE SAME RESPECTIVELY.
NOTE
WHEN CABLING THE UPS’S BEWARE TO CONNECT INPUT AND OUTPUT
WIRES TO THE CORRESPONDING TERMINALS, RESPECTING THE SAME
PHASE SEQUENCE ON ALL UPS CABINETS.
EXAMPLE:
PHASE1 OF UPS1 = PHASE1 OF UPS2 = …… = PHASE1 OF UPS N.
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6.2.2
Paralleling of UPS-Cabinets
For the correct performance of different parallel functions and operations the parallel units communicate
continuously between each other. This is achieved by means of the so-called communication BUSLines.
After terminating the input and output cabling of each single UPS, it is necessary to connect the units
together to form the parallel system. For this purpose a communication BUS line is connected
sequentially between the units. Connect communication BUS lines according to Figure 22.
CONNECT THE BUS CABLES ONLY WITH SWITCHED OFF UPS AND
OPENED PARALLEL ISOLATORS IA2. RESPECT THE FOLLOWING
CONNECTION SEQUENCES.
NOTE
1. Fit the Parallel Adapter over the Connector JD8 on all UPS-cabinets
2. Set DIP Switch SW2-2 on each Parallel Adapter depending on the UPS Cabinet in the parallel
cabinet configuration (see section 6 chapter 6.1.2.2.2)
3. Connect PORT JD6 on Parallel Adapter of UPS-Cabinet 1and PORT JD5 of Parallel Adapter of
UPS-Cabinet 2 with the corresponding BUS-Cable;
4. Connect PORT JD6 on Parallel Adapter of UPS-Cabinet 2 and PORT JD5 of UPS-Cabinet 3
with the corresponding BUS-Cable
5. Continue in the same manner for the remaining UPS-Cabinets.
Figure 22: Connection of the Bus Lines when paralleling UPS-Cabinets by means of Parallel Adapters.
If the UPS-CABINETS are paralleled, the Parallel Adapter will be placed on the Connector JD8 on the
distribution panel and the communications cables between the cabinets will be connected through the
connectors JD5 and JD6, as we are doing now.
NOTE: set the Switch SW2-2 correctly according to the corresponding cabinet configuration.
Parallel
Adapter
JD8
JD 5
JD6
SW2-2
SW 1
SW 2
Single
Unit
ON
ON
First
Unit
OFF
ON
Figure 23: Parallel Adapter and DIP Switch SW2-2
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Others
Unit
OFF
OFF
Last
Unit
ON
OFF
6.2.3
Dip switch SW1-9
The DIP Switch SW1-9 is located on every UPS cabinet. With this switch it is possible to determine the
“position of the cabinet” in a Multi-Cabinet Chain. Define each PowerWave 33 S3 - Cabinet in a MultiCabinet Chain as:
1. The “First”,
2. The “Middle” (there may be more than one) and
3. The “Last”
Cabinet in the Multi-Cabinet Chain by setting the DIP Switch SW1-9 on each cabinet according to the
Table below:
SWITCH SW1-9
1ST UPS
1
2
2
3
4
5
6
7
8
9
6.2.4
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
Other UPS
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Last UPS
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
Single UPS
ON
ON
ON
ON
OFF
ON
ON
ON
ON
ON
Multidrop Master/Slave configuration - Dip switch SW2
To correctly implement the Multidrop feature, the following operation must be carried out on the
installation:
• Set the customer interface board in the master frame as “Master”
• Set all remaining board/s present in the parallel system as “Slave”
• Connect the “Multidrop” cable/s between the different frames in the parallel system
• Set the SW2 DIP switches of each unit, according to the tables here below.
Single UPS:
SW2
First UPS
1
OFF
2
OFF
Parallel UPS:
SW2
Master cabinet
Other cabinets
1
OFF
OFF
2
OFF
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ON
6.3 Control panel
WARNING!
ONLY PERSONS WHICH HAVE BEEN TRAINED BY THE MANUFACTURER
OR HIS CERTIFIED SERVICE PARTNERS ARE ALLOWED TO OPERATE ON
THE CONTROL PANEL WITH CLOSED DOORS.
ALL OTHER OPERATIONS ON THE UPS SYSTEM HAVE TO BE DONE ONLY
BY SERVICE TECHNICIANS OF THE MANUFACTURER..
The standard control panel is composed of:
• LCD DISPLAY
• MIMIC DIAGRAM (dual color-LED)
• BUTTONS
• BUZZER (generating a sound when an alarm is active)
Figure 24: control panel of PowerWave 33 S3, comprising of LCD display, mimic diagram and buttons.
The 2 x 20 character LCD simplifies the communication with the UPS and provides the necessary
monitoring information about the UPS. The menu driven LCD enables the access to the:
• Even register (event log)
• Show measurements such as U, I, f, P, Q, S, load %, battery runtime and others
• Perform commands like start-up and shut-down of UPS and others
• Load transfer from INVERTER to BYPASS and vice-versa
• Diagnosis (SERVICE MODE)
• Adjustments and testing
6.3.1
Led indicators
The mimic diagram serves to indicate the general status of the UPS. The LED-indicators show the
power flow status and in the event of mains failure or load transfer from inverter to bypass and viceversa. The corresponding LED-indicators will change colors from green (normal) to red (warning).
The LEDs LINE 1 (rectifier) and LINE 2 (bypass) indicate the availability of the mains power supply.
The LEDs INVERTER and BYPASS if green indicate which of the two is supplying power to the critical
load. When the battery is supplying the load due to mains failure the LED-indicator BATTERY is flashing.
The LED-indicator ALARM is a visual indication of any internal or external alarm condition. At the same
time an audible alarm will be activated.
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INDICATOR
INDICATOR STATUS
MEANING
ALARM
OFF
No alarm condition
RED
Alarm condition
LINE 1
LINE 2
GREEN
Mains rectifier available
RED
Mains rectifier not available
GREEN
Mains bypass available
RED
Main bypass not ok or not available
OFF
UPS is turned off
BYPASS
GREEN
Load on bypass (Bypass-or Eco-Mode)
OFF
Bypass not operating (switched-off)
INVERTER
GREEN
Load on inverter
RED
Inverter fault or load not transferable to inverter
OFF
Inverter not operating (switched-off)
GREEN
Battery OK
RED
Battery fault or battery is discharged
Flashing RED
Battery in discharge and battery voltage critical or battery fuse
open
Flashing GREEN
Battery in discharge and battery voltage good
BATTERY
6.3.2
Buttons
The buttons allow the user to operate the UPS to perform settings and adjustments, to start-up and
shutdown the UPS, to monitor on the LCD display the voltages, currents, frequencies and other values.
BUTTON
ON/OFF
ON/OFF
UP ()
DOWN ()
RESET
ENTER
6.3.3
FUNCTION
•
•
•
•
•
•
•
•
•
•
By pressing both keys simultaneously it switches the UPS ON
By pressing both keys simultaneously it switches the UPS OFF (shutdown)
Move upwards through the menu
Increase values
Move downwards through the menu
decrease values
Cancel the audible alarm. If the alarm condition remains the LED will remain red
Return to previous menu
Confirms a chosen menu item
Confirms a chosen value
Status screens
DESCRIPTION
LCD-DISPLAY
1
LOAD
PROTECTED
P01
LOAD
NOT PROTECTED
P01
LOAD OFF
SUPPLY FAILURE
P01
LOAD DISCONNECTED
PARALLEL SWITCH OPEN
P01
2
3
4
Load is protected by UPS power. Load is supplied by
inverter(Normal Operation) and the batteries are connected
and o.k.
Load is not protected by UPS power. Load is supplied by
mains power (load on bypass) or it is supplied by the inverter
(normal operation) and the batteries are not o.k.
Load not supplied. UPS is switched off.
To start the UPS press the two ON/OFF buttons
simultaneously.
The UPS/module is not supplying load anymore. The output
switch is open
On the right hand side of the LCD there is a 3-digit indicator defining the UPS “Position” in the MultiUPS system.
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S
P01
P02
P03
stands for Single UPS. The system consists only of one UPS.
stands for Parallel UPS in a Multi- UPS system and 01 stands for the first UPS
(MASTER) in the parallel UPS system.
stands for Parallel UPS in a Multi- UPS system and 02 stands for the second UPS
(SLAVE) in the Multi- UPS system.
stands for Parallel UPS in a Multi- UPS system and 03 stands for the third UPS
(SLAVE) in the Multi- UPS system.
The definition of the UPS “Position” in a parallel system is achieved in the Menu Set-Up Service.
DESCRIPTION
LCD-DISPLAY
Single UPS Systems
SYSTEM CONFIGURATION
SINGLE
SYSTEM CONFIGURATION
PARALLEL
LOAD OFF
SUPPLY FAILURE
Parallel System e.g. first UPS cabinet
Parallel System e.g. second UPS cabinet / Slave
S
P01
P02
Note: The max no. of UPS units is 10.
6.3.4
Main menu screen
DESCRIPTION
1 Logging Control. A log of the last 99 events is stored in the
Power Management Display.
2 In Menu Measurements: monitor voltages, power,
frequencies, currents, autonomy etc.
3 The Command Menu enables to perform the commands
“Load to inverter”, Load to bypass, battery test.
4 The UPS Data are the UPS personalized information “serial
number”
5 Various settings can be performed by the user: Date/Time,
automatic battery test, etc.
6 Various adjustments can be performed by the service staff
6.3.5
LCD-DISPLAY
 EVENT LOG
MEASUREMENTS
 MEASUREMENTS
COMMANDS
 COMMANDS
UPS DATA
 UPS DATA
SET-UP USER
 SET-UP USER
SET-UP SERVICE
 SET-UP SERVICE
NO MORE MENU
Event log screen
DESCRIPTION
LCD-DISPLAY
1 Logging Control; a log of the last 99 events is stored in the
01
LOCAL
02
LOCAL
03
LOCAL
04
LOCAL
Power Management Display.
2 Every stored event is identified with a sequential number and
time stamp.
3 By press ENTER the code of the event will be displayed.
(Press
ENTER to come back to the previous indication)
4 All events and alarms are indicated with their date and time of
appearance.
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05-10-08
LOAD OFF
05-10-08
LOAD TO BYP
8104
LOAD TO INV
05-10-08
LOAD TO INV
14:38:59
14:38:56
14:37:14
6.3.6
Measurements screen
DESCRIPTION
LCD-DISPLAY
1
Battery Runtime
2
UPS-Output Frequency
3
Bypass Frequency.
4
Battery Voltage
5
Battery Charger Current
6
Discharge Current.
7
Rectifier Voltage of all three phases
8
Bypass Voltage of all three phases
9
Output Voltage of all three phases
BATT. RUN TIME (MIN)
00h 00m
OUTPUT FREQUENCY (HZ)
50.00
BYPASS FREQUENCY (HZ)
50.00
BATTERY VOLTAGE (V)
+ 0.0
BATT. CHARGE CUR. (A)
+ 0.0
DISCHARGE CURRENT (A)
00.0
RECTIFIER VOLTAGE (V)
230
230
230
BYPASS VOLTAGE (V)
230
230
230
OUTPUT VOLTAGE (V)
230
230
230
OUTPUT CURRENT (A)
00.0
00.0
00.0
ACTIVE POWER (KW)
00.0
00.0
00.0
REACTIVE POWER (kVAr)
00.0
00.0
00.0
APPARENT POWER (KVA)
00.0
00.0
00.0
OUTPUT POWER (%)
00
00
00
BATT. CAPACITY (%)
00
BATTERY TEMPERATURE
00.0
MODULE TEMP BST/INV
00.0
00.0
00.0
10 Output Current of all three phases
11 Active Output Power of all three phases
12 Reactive Output Power of all three phases
13 Apparent Output Power of all three phases
14 Output Power of all three phases
15 Battery capacity
16 Battery temperature
17 Booster (BST) / Inverter (INV) temperatures
6.3.7
Commands screen
DESCRIPTION
LCD-DISPLAY
1 Transfer Load to inverter
 LOAD TO INVERTER
LOAD TO BYPASS
 LOAD TO BYPASS
PERFORM BATT.TEST
 PERFORM BATT.TEST
PERF. DEEP BATT.TEST
 PERF. DEEP BAT. TEST
ABORT BATT. TEST
 ABORT BATT. TEST
PERFORM ALARM TEST
 PERFORM ALARM TEST
NO MORE COMMANDS
2 Transfer Load to bypass.
3 Battery Test
4 Deep battery test
5 Abort battery test
6 Perform alarm test
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6.3.8
Ups data
DESCRIPTION
LCD-DISPLAY
1 These general UPS Data are set by the manufacturer.
UPS SERIAL NUMBER
PWA nnnnnn
DATE OF MANUFACTURE
15/01/2014
EPROM VERSION
V.V
CCCC
HARDWARE VERSION
00000000
DYNAMIC PASSWORD
YES/NO
DATE
TIME
dd-mm-yyyy
hh:mm:ss
2 Manufacturing date
3 EPROM Version
4 Hardware Version
5 Dynamic password
6 Actual Date and Time
6.3.9
Set-up user
DESCRIPTION
LCD-DISPLAY
1 Set-up Language
 SET LANGUAGE
SET DATE AND TIME
2 Set-up Date and Time
 SET DATE AND TIME
SET-UP BATT. TEST
DD/MM/YY
HH:MM:SS
3 Set-up battery test
 SET BATTERY TEST
SET GENERATOR OP.
DAY OF MONTH
(1-31)
HOUR OF DAY
(1-24)
REPETITIVE (Y/N)
YES/NO
 SET GENERATOR OP.
NO MORE SETTINGS
BATT.CHARGE LOCK
YES/NO
BYPASS LOCK
YES/NO
4 Set-up operation with Gen-Set
6.3.10 Set-up service
DESCRIPTION
LCD-DISPLAY
1 This Menu is reserved for CERTIFIED service engineers. It is
 SET-UP SERVICE
PASSWORD
2 Type in password
 PASSWORD.
not to be used by End-Users
Note: Password is required to enter into the service menu.
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6.4 Operating modes
6.4.1
Mode "ON LINE" (INVERTER MODE)
The ON-LINE-Mode is the UPS-Operating Mode in which the load is supplied through the RECTIFIER
and INVERTER.
LED Indicator
Color
LINE 1
Green
LINE 2
Green
BYPASS
OFF
INVERTER
Green
BATTERY
Green
Using the control panel the UPS can easily be transferred to the ON-LINE-Mode. The ON-LINE-Mode
provides the highest degree of protection, especially in the event of a mains disturbance or failure. This
operating mode is always recommended if the critical loads (computer systems) will not tolerate any
interruption of the supply (not even the shortest). In the unlikely event of an inverter fault or overload
condition the UPS will transfer the load automatically and without interruption to the static bypass-mains
supply (transfer time = 0).
6.4.2
Mode"OFF-LINE"(ECO- or BYPASS MODE)
In the "OFF-Line Mode”, the load is supplied from the mains through the static bypass. Using the control
panel the UPS may be easily transferred to "Bypass Mode”.
LED Indicator
Color
LINE 1
Green
LINE 2
Green
BYPASS
Green
INVERTER
OFF
BATTERY
Green
When the UPS is operating in "Bypass Mode”, the efficiency of the system is higher. In the event of a
mains failure the load will automatically be transferred from mains to inverter within 5 msec (this is valid
for single and parallel systems). The battery charger remains active in the "Bypass-Mode”.
The "Bypass-Mode”, is recommended only if the loads can tolerate interruptions of 3-5 ms (transfer
time from Bypass Mode to ON-LINE Mode).
TO HAVE THE MOST ESSENTIAL SECURITY LEVEL, WE RECOMMEND TO
RUN THE UPS ON NORMAL OPERATION MODE, MEANS ON-LINE MODE.
NOTE
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6.4.3
"Maintenance bypass" - mode
Before transferring the load to Maintenance Bypass (IA1) always make sure all the UPS-modules are in
the "Bypass-Mode” or “ECO-Mode”. The Maintenance Bypass mode is performed by closing (put in
position ON) the IA1 Maintenance Bypass switch on the front of the UPS.
POSITION OF IA1
EFFECT
ON
Bypass-Switch Closed (Load supplied directly from mains)
LCD-indication: “MANUAL BYP IS CLOSED” LED Indicators will indicate
as shown in table below.
OFF
Bypass-Switch Open – Normal operating condition (Load supplied by
inverter)
LCD-indication “MANUAL BYP IS OPEN”
LED Indicators will indicate as shown in table below.
MAINTENANCE
BYPASS
MAINS
Bypass Switch
LOAD
UPS
LED Indicator
ON
OFF
LINE 1
Green
Green
LINE 2
Green
Green
BYPASS
Green
OFF
INVERTER
RED
Green
BATTERY
Green
Green
ON OPERATION MODE “MANUAL BYPASS“ THE LOAD IS NOT
PROTECTED AGAINST ANY MAINS FAILURES OR MAINS DISTURBANCES.
NOTE
6.4.4
Output switch/parallel isolator (ia2)
Every UPS-unit is provided with an output parallel isolator (IA2) which, when opened isolates the
corresponding unit from the PARALLEL BUS and from the LOAD. Once IA2 is open there is no power
on the load coming from the UPS.
In redundant parallel configurations it is used to isolate a unit from the parallel system without the need
of transferring the load to bypass.
POSITION
EFFECT
ON
Normal Operation (Load supplied by UPS)
OFF
UPS isolated from Parallel Bus for maintenance or UPS replacement (UPS not
supplying load)
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6.5 Operation procedures
6.5.1
Start-up procedure
THE OPERATIONS DESCRIBED IN THIS CHAPTER MUST BE PERFORMED
BY A SERVICE ENGINEER FROM THE MANUFACTURER OR FROM AN
AGENT CERTIFIED BY THE MANUFACTURER.
WARNING!
Situation of UPS-System before switching it on:
1.
2.
3.
4.
Make sure the fuses for the supply of UPS-System in the Input Distribution Board on site
are open.
Verify that the Input Switch IA4, Bypass Switch IA3, Maintenance Switch IA1 and Output
Switch IA2 are open (Position OFF).
Make sure all the input and output cabling has been performed correctly and check the
input phase rotation.
Make sure that the external battery cabinets fuses/breaker are open.
Start up procedure of PowerWave 33:
1.
Insert fuses for the supply of UPS-System in the Input Distribution.
2.
Close Input Switch IA4 and Bypass Switch IA3
- The LED-indicator LINE 1 on UPS-Module is lit – green
- On LCD-Display “LOAD OFF, SUPPLY FAILURE” will appear.
3.
UPS 1:
Press both “ON/OFF” Main Buttons to switch on UPS.
Wait until the LED-indicators will appear as shown below:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
Colour
Green
Green
OFF
Green
Flashing Red
4.
Scroll through the menu measurement and check their correctness
5.
Check battery polarity and voltage before battery fuses/breakers.
6.
If the battery polarity and voltage are correct insert battery fuses/breakers and check the
LED-indicators will appear as shown below:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
7.
Colour
Green
Green
OFF
Green
Green
Testing of Parallel Functions
(The load fuses in output Distribution Board are still open i.e. the loads are
disconnected!).
All UPS-Modules are on INVERTER MODE
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8.
Press simultaneously the two ON/OFF buttons on the UPS-control panel (PMD) on all
control panels to turn the UPSs OFF. On the LCDs message “LOAD OFF, SUPPLY
FAILURE” will appear
9.
Close Parallel Isolator IA2 (position ON) of UPS 1, on LCD: “PARALLEL SW CLOSED”
will appear “EVENT LOG” menu.
10.
Press simultaneously the two ON/OFF buttons on the UPS-control panel (PMD) to turn
the UPS ON. On output Terminal Block there is now UPS power and on all LCDs:
“LOAD PROTECTED” will appear.
11.
Perform step 9. and 10. until all the unit of the system are complete switched in parallel.
12.
Load transfer to Maintenance Bypass
On the control panel go to Menu COMMANDS and choose command “LOAD TO
BYPASS”, (for parallel operation is enough to give the order in one of the units) and
transfer the load to Bypass.
Close Maintenance Bypass Switch IA1 (position ON)
On LCD: “MANUAL BYP IS CLOSED” will appear and the LED-indicator will indicate as
shown below:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
Colour
Green
Green
Green
RED
Green
13.
Connect Load to the UPS Output
Insert fuses in output Distribution Board
Verify on control Panel that the load is on bypass
14.
Open Maintenance Bypass Switch IA1
On LCD: “MANUAL BYP IS OPEN” will appear.
15.
Check on LCD the Output Powers, Voltages Currents and Frequencies.
16.
Load transfer to Inverter
On control panel go to Menu COMMANDS, choose command “LOAD TO INVERTER”
and transfer the load to inverter.
On all LCDs: “LOAD PROTECTED” will appear
17.
Check the output Voltages and Currents once again.
THE LOAD IS NOW PROTECTED BY THE POWERWAVE 33
6.5.2
Shutdown procedure
THE OPERATIONS DESCRIBED IN THIS CHAPTER MUST BE PERFORMED
BY A SERVICE ENGINEER FROM THE MANUFACTURER OR FROM AN
AGENT CERTIFIED BY THE MANUFACTURER.
WARNING!
The POWERWAVE 33 may be shutdown completely, if the load does not need input power for an
extended period of time. It may be switched to Maintenance Bypass Mode for service or maintenance
purposes, or transferred to the OFF-LINE Mode (ECO-Mode), if the load does not need the highest
degree of protection.
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The load may be disconnected by means of the two ON/OFF (LOAD-OFF) buttons for security
reasons.
Complete Shutdown procedure of POWERWAVE 33:
Only in case there is no need to supply the load, the UPS System can be completely shutdown. The
following procedures can only be executed after the load has completely been de-energized.
IN THE CASE THAT THE PARALLEL UPS SYSTEM HAS TO BE TURNED
OFF, THEN BOTH ON/OFF BUTTONS ON ALL UPS MODULES HAVE TO BE
PUSHED. ONLY IN THIS CASE THE POWER SUPPLY TO THE LOAD WILL
BE INTERRUPTED.
NOTE
1.
Verify that the loads are shutdown and that there is no need for power supply to the
load.
2.
If the loads are all disconnected, press simultaneously both ON/OFF-Buttons on UPSControl Panel.
On the LCD: “LOAD OFF, SUPPLY FAILURE” will appear and the LED-indicator will
indicate as shown below:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
3.
4.
5.
6.
Colour
Green
OFF
OFF
OFF
Green
Open all Parallel Isolator Switches IA2.
Open battery fuses/breakers on external battery cabinets or racks.
Open the Input Switch (IA4) and Bypass Switch (IA3)
Open the main fuses/breaker in the building distribution panel.
MAKE SURE THE INTERNAL DC-CAPACITORS (ELCO) HAVE BEEN
DISCHARGED WAITING AT LEAST 10 MINUTES..
NOTE
THE POWERWAVE 33 IS NOW VOLTAGE FREE.
6.5.3
Load Transfer: from Inverter operation to Maintenance Bypass
If it is necessary to perform service or maintenance on the UPS it is possible to transfer the UPS to
MAINTENANCE BYPASS.
THE OPERATIONS DESCRIBED IN THIS CHAPTER MUST BE PERFORMED
BY A SERVICE ENGINEER FROM THE MANUFACTURER OR FROM AN
AGENT CERTIFIED BY THE MANUFACTURER.
WARNING!
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Situation of UPS-System before starting the Transfer Procedure to Maintenance Bypass:
The load is protected by PowerWave 33 running in normal operation. (The UPS is operating on
inverter).
1.
Using LCD panel, select the COMMANDS menu, choose command “LOAD TO
BYPASS” and transfer the load to mains. (for parallel operation is enough to give the
order in one of the units).
2.
Close Maintenance Bypass Switch IA1 (position ON). On a system with multiple UPS in
parallel close IA1 on each UPS.
3.
The message “MANUAL BYP IS CLOSED” will appear on the LCD and the mimic panel
will show as below:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
4.
Colour
Green
Green
Green
RED
Green
Press simultaneously the two ON/OFF buttons on the UPS-control panel (PMD) on all
control panels.
On the LCD’s message “LOAD OFF, SUPPLY FAILURE” will appear and the mimic panel
will show:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
Colour
Green
OFF
OFF
OFF
Green
5.
Open the Output Switch IA2, Input Switch IA4 and Bypass Switch IA3 on all UPSs
6.
Open battery fuses/breakers on the external battery cabinets or racks.
THE UPS SYSTEM IS STILL POWERED (DANGEROUS VOLTAGE).
NOTE
6.5.4
Load Transfer: from Maintenance Bypass to Inverter operations
This procedure describes the sequence of operations to be done in order to restart the UPS and
restore ON-LINE mode (Load on Inverter).
THE OPERATIONS DESCRIBED IN THIS CHAPTER MUST BE PERFORMED
BY A SERVICE ENGINEER FROM THE MANUFACTURER OR FROM AN
AGENT CERTIFIED BY THE MANUFACTURER.
WARNING!
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Situation of UPS-System before starting the Transfer Procedure to ON-LINE mode:
The load is supplied directly by Input Mains through the Maintenance Switch (IA1) and the UPS is
OFF.
1.
Close the Input Switch (IA4) and the Bypass Switch (IA3)
2.
Close battery fuses/breakers in the external battery cabinets or racks.
3.
On the LCD’s: “LOAD OFF, SUPPLY FAILURE” will appear and the mimic panel will
show:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
Colour
Green
OFF
OFF
OFF
Green
4.
Close all Parallel Isolators IA2.
5.
Press simultaneously the two ON/OFF buttons on the UPS-control panel (PMD).
Unit will start-up and after about 60 seconds the mimic panel will show:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
Colour
Green
Green
Green
Red
Green
6.
Make sure that the bypass LED is green, then open the Maintenance Bypass Switch of
each unit (position OFF).
7.
The message “MANUAL BYP IS OPEN” will appear on the LCD and the mimic panel will
show as below:
LED Indicator
LINE 1
LINE 2
BYPASS
INVERTER
BATTERY
8.
Colour
Green
Green
Green
OFF
Green
Using the control panel, select the COMMANDS menu and choose command “LOAD TO
INVERTER” (for parallel operation is enough to give the order in one of the units). This will
transfer the LOAD to Inverter on the complete system (all units).
THE LOAD IS NOW SUPPLIED BY INVERTER POWER AND IS PROTECTED
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7 Maintenance
THE OPERATIONS DESCRIBED IN THIS CHAPTER MUST BE PERFORMED
BY A SERVICE ENGINEER FROM THE MANUFACTURER OR FROM AN
AGENT CERTIFIED BY THE MANUFACTURER..
WARNING!
7.1 User responsibilities
There are no parts within the UPS which need to be serviced by the user, so the maintenance
responsibilities of the user are zero. To maximize the useful working life and reliability of the UPS and
its batteries, the environment in which the UPS operates should be kept cool (20°C - 25°C), dry, dust
free and vibration free. The batteries should be hold fully charged.
7.2 Preventative maintenaince
The UPS system needs a regular and constant maintenance (preventative inspections) at least once a
year, even during the warranty period.
These preventative maintenance inspections are essential to ensure a correct functionality and
reliability of the UPS system. When the UPS is commissioned, the commissioning field service
engineer will attach a service record book to the front of the UPS and this will be used to record the
full service history of the UPS.
During a preventative maintenance the field service engineer might carry out some or all of following
checks:
•
Status and function check of UPS and batteries
•
UPS and batteries visual inspection (dust, mechanical damages, ..)
•
Visual inspection of screws and cable connections
•
Check of air ventilation and room temperature
•
Check the operation and function (commutations, remote monitoring and Signaling)
•
Current, voltage and frequencies measures
•
Measure and record the current load conditions
•
Check the load sharing (only in parallel systems)
•
Battery voltage check
•
Battery discharge test
•
Check transfer of the load from UPS to mains operation via static bypass
•
Unit cleaning
7.3 Deep battery test
The battery test takes approx. 3 minutes and should be performed only if:
•
there are no alarm conditions
•
the battery is fully charged
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•
mains is present.
The battery testing can be carried out independently of the operation mode (OFF-LINE or ON-LINE) and
whether or not the load is connected. The battery test procedure can be performed from the UPS
display, in the service setup mode.
7.4 Battery maintenance, disposal and recycling
The battery maintenance shall be done by a certified Service Partner.
To ensure an optimum operation of the UPS system and a continuous and efficient protection of the
connected load it is recommended to check the batteries every 12 months.
Batteries contain dangerous substances that will harm the environment if thrown away. If you change
the batteries yourself, contact qualified organizations for battery disposal and recycling.
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8 Troubleshooting
8.1 Alarms
In the event of an alarm condition the red LED-Indicator “Alarm” and the audible alarm will turn on.
In this case proceed as follows:
1.
Silence the audible alarm by pressing the button "Reset".
2.
Identify the cause of the alarm condition by means of the EVENT LOG in the MAIN menu.
(see Section-4, Chapter 4.1.3.3 or Appendix D.4.5.1 for graphical display)
3.
In case of doubts please contact the nearest Service centre.
4.
Fault identification and rectification information is given below.
8.2 Menu, commands, event log and measurements
In section 4 there is a detailed description of the Menu, Commands, Event Log and Measurements
that can be operated and displayed on the control panel. The List of Alarms and Messages are shown
below.
8.3 Fault identification and rectification
The major alarm conditions that will be encountered are:
ALARM CONDITION
MEANING
SUGGESTED SOLUTION
The input power to UPS is too low or missing.
MAINS RECT. FAULT
Mains power supply is
If site power appears to be OK, check the input
outside prescribed tolerance.
circuit breakers etc. supplying the UPS.
The input power to UPS is too low or missing.
MAINS BYP FAULT
Mains power supply is
If site power appears to be OK, check the input
outside prescribed tolerance.
circuit breakers etc. supplying the UPS.
OUTPUT SHORT
There is a short circuit at the
output of UPS (on load side).
Check all output connections and repair as
required.
OVERLOAD
Load exceeds the UPS rated
power.
Identify which piece of equipment is causing the
overload and remove it from the UPS.
Do not connect laser printers, photocopiers,
electric heaters, kettles etc. to the UPS.
TEMPERATURE HIGH
UPS temperature has
exceeded the allowed value.
Check that the ambient temperature of the UPS
is less than 40° C.
If the ambient temperature is normal call the
certified service centre for assistance.
INV. PHASE FAULT
Inverter is faulty.
Call the certified service centre for assistance.
SYNCHRON. FAULT
The inverter and mains are
not synchronised.
The frequency of the input voltage to the UPS is
outside operational limits and the UPS static
bypass has been temporarily disabled.
Battery is near end of
autonomy.
Shutdown load connected to UPS before the
UPS switches itself off to protect its batteries.
BATTERY IN DISCHARGE
Maintenance Bypass
MANUAL BYP IS CLOSED closed. Load supplied by
mains.
This alarm is only displayed if the UPS is on
Maintenance Bypass.
In case of alarms not included in the list above, please contact the nearest certified service centre for
assistance.
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9 End of life treatment
9.1 UPS and material disposing
Whenever the UPS has to be disposed, it is mandatory to contact any local recycling or disposing
treatment facility. They will assure a proper disposing of the unit (recycling, separation for special
treatment, etc.).
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10 Revision History
Revision
number
Chapter
Description
Date
140714
9.1
Cable entry: bottom bottom, bottom rear
Parallel capability: up to 10 frames up to 6 frames
14.07.2014
9.8
Added fuse type on the description of the Fuse E
in tables 13 and 14.
Type: gR or CB
4.4
Removed figure (image) of the connection
terminals for 60-80kW models. One unique image
applies for all models.
Table of the terminals overview and tightening
torque of 60-80kW models merged into the table
for 100-120. One unique table applies for all
models.
9.2
140730
Corrected “Current (r.m.s), maximum (with
charging batt. and input 400/230V)”
102
135
168
202
101
134
167
201
9.7
Added “head dissipation without load” figures
9.3
Added “AC / AC efficiency in normal mode, linear
load” figures for each model.
9.3
Added “Eco-mode efficiency, linear load” figure
9.2
Added “rated short-time withstand current (ICW)”
figure
4.4
Corrected the recommended wiring for batteries
(Cable E) tables 6 and 7
Cable E
Rated
Cable E
(quantity x
output
(quantity x mm2)
mm2)
power
2x70
60 kW
2x(1x50)
2x120 or
80 kW
2x(1x95) @ 42-45
2x(2x50)
batt. blocks
2x(1x70) @ 46-50
batt. blocks
2x150 or
100
2x(1x120) or
2x(2x70)
kW
2x(2x50) @ 42-45
batt. blocks
2x(1x95) @ 46-50
batt. blocks
2x(2x120) or
120
2x(1x150) or
2x(2x95)
kW
2x(2x50) @ 42-45
batt. blocks
2x(1x120) or
2x(2x50) @ 46-50
batt. blocks
Modifications reserved
Page 46/49
30.07.2014
9.1
Added “Acoustic noise (acc. to IEC 62040-3)”
figures
6.2
Added new chapter “6.2 Parralel - multicabinetconfiguration”
9.8
Corrected the recommended wiring for batteries
(Cable E) tables 13 and 14 like in section 4.4
140805
-
Final release for all languages with the revision
140730 implemented
05.08.2014
150206
2.2
Added the following standard compliancy
06.02.2015
2.2
Performance
IEC/EN 620403
Environmental aspects
IEC/EN 620404
new image for CE logo
3.3.1
Changed the following sentence
7) You may want to keep some packaging
materials for later use. Alternatively, in case in
makes more sense to dispose the packing
material, it must be disposed in accordance with
the applicable laws in the country where the UPS
is installed.
4.2
text added:
“To ensure correct operation of the UPS, the
voltage Total Harmonic Distortion (THDu) of the
mains shall not exceed the values according to
Standard IEC 61000-2-2. In case of exceeding of
the indicated values, please contact the
manufacturer.”
4.4
Figure 13:
New image
REV-A
old image
6.2.3
Added the “single cabinet” column on the DIP
Switch SW1-9 settings, and changed the “middle
cabinet” column into “others cabinet”.
9. (new
chapter)
Added new chapter “”9
TREATEMENT”
10. (new
chapter)
The Chapter “10 TECHNICAL SPECIFICATIONS”
changed number from 9. to 10.
N/A
Updated the entire layout of the document
2.1
Added a new warning box at the beginning of the
chapter
2.2
Changed the Electromagnetic Compatibility (EMC)
in to: IEC/EN 62040-2
Modifications reserved
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END OF LIFE
04.02.2016
Emission cat. C3
Immunity cat. C3
4.1
Updated the entire “Positioning of the UPS and
battery cabinet” chapter
4.3
Corrected the IA3 and IA4 references on the block
diagram picture.
4.4
Changed the electrical connections picture
4.4.1
Changed the link wires picture
5
Added the SW2 Multidrop configuration on the
customer interface features details
5.2.2
Corrected the figure 17 text description
5.5.4
Changed the picutres of the entire 5.2.4 chapter
6.2.4
Added the 6.2.4 Multidrop Master/slave
configuration chapter, for the configuration of the
SW2 DIP Switch
6.3.3
Corrected the Note: “the max no. of UPS units is
6” to “the max no. of UPS units is 10”
11 Attachments
11.1
Technical data sheet
Modifications reserved
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Contact us
www.abb.com/ups
ups.sales@ch.abb.com
© Copyright ABB. All rights reserved. Specification
subjects to change without notice.
Technical data sheet
PowerWave 33 Serie 3
60 – 120 kW
© Copyright 2016 ABB, All rights reserved
Document information
File name
:
TDS_ABB_PW33_S3_60-120kW_EN_REV-A.docx
UPS model
Date of issue
:
:
PowerWave 33 Series 3
Article number
:
N/A
Document number
:
4NWD003258
Revision
:
A
02.02.2016
Revision history
Revision number
Chapter
Description
Date
140714
9.1
Cable entry: bottom bottom, bottom rear
Parallel capability: up to 10 frames up to 6
frames
14.07.2014
9.2
Corrected “Current (r.m.s), maximum (with
charging batt. and input 400/230V)”
102
135
168
202
101
134
167
201
9.8
Added fuse type on the description of the
Fuse E in tables 13 and 14.
Type: gR or CB
9.1
Added “Acoustic noise (acc. to IEC 62040-3)”
figures
9.2
Added “rated short-time withstand current
(ICW)” figure
9.3
Added “Eco-mode efficiency, linear load”
figure
9.3
Added “AC / AC efficiency in normal mode,
linear load” figures for each model.
9.7
Added “head dissipation without load” figures
9.8
Corrected the recommended wiring for
batteries (Cable E) tables 13 and 14 like in
section 4.4
150206
N/A
New release for some user manual corrections
06.02.2016
REV-A
N/A
Updated the entire layout of the document
04.02.2016
7
Updated the entire “Installation planning”
chapter
9
Corrected the IA3 and IA4 references on the
block diagram picture.
140730
Modifications reserved
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30.07.2014
Contents
1 System description.................................................................................... 4
2 General characteristics ............................................................................. 5
3 Input characteristics.................................................................................. 6
4 Output characteristics ............................................................................... 7
5 Battery characteristics .............................................................................. 9
6 User interface - communication.............................................................. 10
6.1 Display & mimic diagram ..................................................................................... 10
6.2 Customer inputs .................................................................................................. 11
6.3 Customer outputs (optional usb port & relay card) ............................................ 11
7 Installation planning ................................................................................ 12
8 Heat dissipation....................................................................................... 13
9 Cable and fuse recommendations .......................................................... 14
Modifications reserved
Page 3/15
1 System description
In environments that demand zero downtime, continuous power protection availability is essential. In
order to respond to today’s dynamic IT and process-related environments that experience daily change
through new server technologies, migration and centralization, resilient and easily adaptable power
protection concepts are required.
POWERWAVE 33 is the foundation for continuous power protection availability of network-critical
infrastructures in enterprise data centers where business continuity has paramount importance and in
process control environment where manufacturing continuity is essential.
POWERWAVE 33 is an advanced double conversion UPS, VFI (Voltage and Frequency Independent)
topology that responds fully to both highest availability and environmentally friendly requirements
compliant with IEC 62040-3 (VFI-SS-111) standards.
The POWERWAVE 33 UPS features innovations that combine to deliver the industry’s best key values
like: enhanced power performance, parallel capability and connectivity’s interaction.
Decentralized Parallel Architecture is based on stacking independent UPSs for power capacity increase
or for redundancy purpose for power availability increase. When operating in parallel configuration, each
POWERWAVE 33 can take the leadership role avoiding single points of failure in the parallel chain
ensuring the highest level of power availability.
The most demanding Data Canters starts with low power before achieving its full capacity. It is in this
case essential to be able to recover the missing power requirement without risk for the applied load.
POWERWAVE 33 allows for system upgrades to meet the highest level of availability interruption free
and without a temporary transfer the load to row mains (by-pass).
This Technical Specification provides detailed technical information on the mechanical, electrical and
environmental performance of the POWERWAVE 33 that can support to give answers to tender and
end-user requirements. The POWERWAVE 33 was designed to respond to the most stringent safety,
EMC and other important UPS standards.
POWERWAVE 33 is a stand-alone UPS, which comes in the following rated power: 60-80-100-120
kW. It can be paralleled for power protection increase and/or for redundancy purpose, up to 10 units.
This Technical Datasheet (TDS) provides all technical specification required by IEC 62040-3, providing
mechanical, electrical and environmental characteristics. It can be used for tendering and end-user
requirements. PowerWave 33 S3 is designed to respond to the actual UPS standards which are:
•
Safety, IEC / EN 62040-1
•
EMC, IEC / EN 62040-2
•
Performance, IEC / EN 62040-3
Modifications reserved
Page 4/15
2 General characteristics
PowerWave 33 Series 3
60
80
100
120
KW
120
120
kVA
kW
Photograph
(front view with open doors)
Power, rated:
Apparent
60
80
100
Active
60
80
100
UPS type: on-line, trasformerfree, decentralized parallel architecture
Parallel capability: up to 10 frames
Battery: not included
Performance classification: VFI-SS-111
MECHANICAL
Dimensions
615x1954x480
(width×height×depth)
Weight (w/o batteries)
198
Acoustic noise (acc. to IEC 62040-3)
in normal mode (at <=25°C) at
64 / 59
100% / 50% Load
in battery mode (at <=25°C) at
64 / 59
100% / 50% Load
or with feet 615x1978x480
mm
206
228
230
kg
64 / 60
64 / 61
64 / 59
dBA
64 / 60
64 / 61
64 / 59
SAFETY
Access: operator
Degree of protection against hazards and water ingress: IP 20
ELECTROMAGNETIC COMPATIBILITY
Compliant to IEC 62040-2
Category Emission / Immunity
C3 / C3
ENVIRONMENTAL
Storage temperature range
Operative temperature range
Relative humidity
Max. altitude without de-rating
Modifications reserved
Page 5/15
-25 – +70
0 – +40
≤ 95 (non-condensing)
1000
°C
°C
%
m
ADDITIONAL AND USUAL INFORMATION
Connection
5 wires, 3 phase + N + PE
Cable entry
Bottom
Accessibility
Frontal only
Air outlet
Top
Color
Graphite Grey (RAL 7024)
Color code
PULVERLACKE NR.4222903402 Ver. 09RCCAT1 ORANGE PEEL
OPTIONS
Battery cabinets
Parallel Kit
SNMP Cards
USB port & Relay card with potential-free contacts (Customer outputs)
Back-feed protection
Single input feed KIT
Sea freight packaging (wooden box)
3 Input characteristics
PowerWave 33 Series 3
60
80
Rated voltage
(steady-state, r.m.s)
380 / 220
400 / 230
415 / 240
VAC
Tolerance, referred to
400/230V
-10 / +15 at <100% load
-20 / +15 at <80% load,
-30 / +15 at <60% load
%
Frequency, rated
50
Hz
Tolerance, referred to 50Hz
-30 / +40
%
Current (r.m.s), rated
(with battery charged and input
400/230V)
92
122
152
183
A
Current (r.m.s), maximum
(with charging batt. and input
400/230V)
101
134
167
201
A
Total harmonic distortion
(THDi)
≤ 4% at 100% load
%
In-rush current
(A or % of nominal)
< 100% of the rated current
A or %
Power factor
0.99 @ 100% load
Rated short-time withstand
current (ICW)
10 for 1.5 seconds
AC power distribution system: TN-S, TN-C, TN-C-S, TT
100
120
note: in static bypass mode or eco-mode TN-C and TN-C-S can cause PE current to rise above 5% of phase currents.
Phases required
3
Neutral required
yes
Modifications reserved
Page 6/15
KW
kA, s
ADDITIONAL AND USUAL INFORMATION
Connection:
Cable entry:
Accessibility:
Walk In/Soft Start:
5 wires, 3 phase + N + PE
Bottom
Frontal
Yes
4 Output characteristics
PowerWave 33 Series 3
60
80
100
120
KW
Power, rated:
60
80
100
120
kW
AC power distribution system: TN-S, TN-C, TN-C-S, TT
available phases
3
-
neutral available
yes
-
Rated voltage
(steady state, r.m.s.)
380 / 220
400 / 230
415 / 240
VAC
Variation in
normal mode / battery mode
± 1.5 / ± 1.5
%
Total harmonic distortion (THDu), 100% load, normal mode:
Linear
< 2.0
Non-linear
(acc. to IEC 62040-3)
< 4.0 %
%
Total harmonic distortion (THDu), 100% load, battery mode:
Linear
< 2.0
Non-linear
(acc. to IEC 62040-3)
< 4.0 %
Voltage unbalance and phase
displacement, 100% load
unbalance
0
%
°
Voltage transient and recovery time, 100% step load:
Linear
±4
%
Non-linear
(acc. to IEC 62040-3)
±4
%
Transfer normal mode -->
battery mode
0
%
Frequency (steady-state),
rated:
50 / 60 (selectable)
Hz
Variation in normal mode
(frq. Synchronized with mains)
±2 / ±4
%
Variation in battery mode
(free-running)
± 0.1
Max synch phase error
(referred to a 360° cycle)
<2
Modifications reserved
Page 7/15
°
Max slew-rate
1
Nominal current (In), r.m.s.
rated:
87
Overload on inverter
0.5 @ 150% load; 5 @ 125% load; 20 @ 110% load
min
Fault clearing capability
normal mode and battery
mode (100ms)
2.0 x In
A
Crest factor (Load supported)
3: 1
-
Load power factor, rated
1
-
Displacement
(permissible lead-lag range)
(all range) 0
%, s
Hz/s
116
145
2.0 x In
174
2.0 x In
A
2.0 x In
AC / AC efficiency in normal mode, linear load:
100% load
95.5 1)
95.5 1)
95.7 1)
95.7 1)
75% load
95.8
95.8
96.0
96.0
50% load
96.0 1)
96.0 1)
96.0 1)
96.0 1)
25% load
95.0 1)
95.0 1)
95.0 1)
95.0 1)
Eco-mode efficiency, linear
load
≥ 99.0
%
Transfer time: inverter 
bypass / bypass  inverter / in
eco-mode
<1 / <5 / <6
ms
Rated current
87
Fault clearing capability
(bypass mode) for 20 ms
10 x In 2)
A
Overload on bypass mode
continuously @ 110% load
0.5 @ 150% load
5 @ 125% load
min
Bypass - maintenance
yes, standard
Bypass protection fuse or
circuit breaker rating
Not included
1)
1)
1)
%
1)
Bypass - automatic: static switch
Modifications reserved
Page 8/15
116
145
174
A
5 Battery characteristics
PowerWave 33 Series 3
60
80
100
120
KW
Technology: VRLA, vented lead-acid, NiCd
Number of 12 V blocks (even
and odd)
42 – 48 3)
-
Number of 1.2 V NiCd cells
(even and odd)
420 – 480 3)
-
Battery charger max. current
charger capability
37
49
61
61
A
Battery charger max. power
charger capability
18
24
30
30
kW
Floating voltage (VRLA / NiCd)
2.25 / 1.40
End of discharge voltage
(VRLA / NiCd)
1.65 / 1.05
R.M.S. ripple current (% of the
battery capacity )
2
VDC
%
Temperature compensation: optional
Battery test: automatic and periodic battery test (selectable)
1) Tolerances of ± 0.2% applies
2) With recommended fuses, see section 1.9.
3) IMPORTANT NOTES:
• Autonomies > 60 min are only allowed for loads < 90%. For loads 90 -100%, the max. allowed
autonomy is 60min.
• For autonomies < 20 min, the UPS supports 42 - 50 12V blocks.
Modifications reserved
Page 9/15
6 User interface - communication
STANDARD ITEMS
RS232 on Sub-D9 port
For service (upgrades and event log download) and for SNMP box
X1
Customer INPUTS (see details in 1.6.2)
RJ45 port
Multidrop connection (for a parallel system)
DISPLAY + MIMIC DIAGRAM
2x20 characters LCD display + mimic diagram with 5x dual colour LEDs
OPTIONAL ITEMS
On x1 5/6
Battery temperature sensor
Slot 1
SNMP Card (for monitoring and integration in network management)
Slot 2
USB port & Relay card. Relay card = customer OUTPUTS (see details in
1.6.3)
6.1 Display & mimic diagram
The 2 x 20 character LCD (Figure 1) simplifies the communication with the UPS. The menu driven LCD
enables the access to the EVENT REGISTER, or to monitor the input and output U, I, f, P, Autonomy
Time and other Measurement’s, to perform commands like start-up and shut-down of UPS or load
transfer from UPS to BYPASS and vice-versa and finally it serves for the DIAGNOSIS (SERVICE MODE)
for adjustments and testing.
The mimic diagram located under the logo (Figure 1) serves to give the general status of the UPS. The
LED-indicators show the power flow status and in the event of mains failure or load transfer from inverter
to bypass and vice-versa the corresponding LED-indicators will change colour from green (normal) to
red (warning). The LED’s LINE 1 (rectifier) and LINE 2 (bypass) indicate the availability of the mains
power supply. The LED’s INVERTER and BYPASS if green indicate which of the two are supplying
power to the critical load. The LED-indicator BATTERY is normally lit green, and when it supplies the
load is blinking. The LED-indicator ALARM is a visual indication of any internal or external alarm
condition. At the same time the audible alarm will be activated.
Figure 1: Display & Mimic diagram of PowerWave 33 S3.
Modifications reserved
Page 10/15
6.2 Customer inputs
The customer input interfaces are standard for each model and are located in the front bottom part of
the unit.
All voltage free contacts are rated 60 VAC max. and 500 mA max.:
All the interfaces are connected to Phoenix Spring terminals with wires : 0.5 mm2
Table 1: details of the customer inputs.
Block
X1
Terminal
Contact
Signal
Function
X1 / 10
GND
GND
12 Vdc source
X1 / 9
IN
+12Vdc
(Max 200mA load)
X1 / 8
GND
GND
Remote Shut down
X1 / 7
IN
+12Vdc
(Do not remove the factory mounted bridge until an external remote shut down is connected)
X1 / 6
GND
GND
Temperature Battery
X1 / 5
IN
+3.3Vdc
(If connected, the battery charger current is batt. temperature dependent)
X1 / 4
GND
GND
Customer IN 1
X1 / 3
IN
+12Vdc
(Function on request, to be defined)
X1 / 2
GND
GND
GEN_OPERATION
X1 / 1
IN
+12Vdc
(NC = Generator ON)
6.3 Customer outputs (optional usb port & relay card)
The customer output interfaces are on an optional relay card which goes into slot 2 of the UPS.
All voltage free contacts are rated 60 VAC max. and 500 mA max.:
All the interfaces are connected to Phoenix Spring terminals with wires: 0.5 mm2
Table 2: details of the customer outputs + USB on the relay card.
Block
15
1
X2
Terminal
Contact
X2 / 15
C
X2 / 14
NC
X2 / 13
NO
X2 / 12
C
X2 / 11
NC
X2 / 10
NO
Load on bypass (Mains)
X2 / 9
C
Common
X2 / 8
NC
X2 / 7
NO
Battery Low
X2 / 6
C
Common
X2 / 5
NC
X2 / 4
NO
Load on Inverter
X2 / 3
C
Common
X2 / 2
NC
X2 /1
NO
+ USB
Modifications reserved
Page 11/15
Signal
On Display
Function
Common
ALARM
COMMON_ALARM
NO Alarm Condition
Common Alarm
(System)
Common
Message
ALARM
Message
ALARM
LOAD_ON_MAINS
BATT_LOW
LOAD_ON_INV
MAINS_OK
(Load on Inverter)
Battery OK
(Load on Mains bypass)
Mains Failure
Mains Present
7 Installation planning
Clearances needed to allow proper airflow on the UPS system and to allow door opening.
Figure 2: Top view and indication of the minimum clearances for UPS + other cabinets in row.
Table 3: minimum clearances for UPS + other cabinets in row.
PowerWave 33 Series 3 Cabinets
4)
60 / 80 / 100 / 120
UPS + battery cabinets in
row.
0 mm
100mm 4)
A
Back clearance for ventilation
(forced air outlet)
B
Front clearance needed to allow a
correct door opening
1000 mm
C
Maximum door opening angle
115°
D
Top Clearance
(Top clearance is only needed if
there is no side clearance)
400 mm
Battery cabinet requires 100mm clearance for natural ventilation. The UPS does not require any back clearance.
Accessibility
Totally front accessible for start-up and maintenance
Positioning
Strictly indoor in a temperature and humidity controlled environment. The
UPS can be placed against the wall (back side)
Power and signals wiring
Front bottom
Modifications reserved
Page 12/15
8 Heat dissipation
PowerWave 33 Series 3
kW
Heat Dissipation with 100%
non-lin. load (acc. to 62040-3)
Airflow (25° - 30°C)
with 100% non-lin. load
Heat Dissipation without load
Modifications reserved
Page 13/15
80
100
120
from front to top
Air-flow
Heat Dissipation with 100%
linear load
60
W
2850
3800
4750
5700
BTU
9730
12970
16220
19460
W
3158
4211
5264
6316
BTU
10778
14371
17964
21557
1600
1300
1500
1600
410
530
640
640
m3/h
W
9 Cable and fuse recommendations
Figure 3: block diagram PowerWave 33 S3 60-120kW
Cable Sections and fuse ratings recommended according to (IEC 60950-1).
Alternatively, local standards to be respected!
Table 4: SINGLE INPUT FEED (CABLE LINKS TO ACHIEVE SINGLE INPUT ARE OPTIONAL)
Cable D
Fuse E
Cable E
Rated
Fuse A
Cable A
Type:gR or CB
output Type:gL or CB
(qty. x mm2)
(qty. x mm2)
(qty. x mm2)
(qty. x A)
power
(qty. x A)
60
3x100
5x(1x35)
5x(1x35)
2x160
2x(1x50)
kW
80
2x(1x95) @ 42-45 batt. blocks
3x125
5x(1x50)
5x(1x50)
2x200
kW
2x(1x70) @ 46-50 batt. blocks
100
2x(1x120) or 2x(2x50) @ 42-45
3x160
5x(1x70)
5x(1x70)
2x250
kW
batt. blocks
2x(1x95) @ 46-50 batt. blocks
120
2x(1x150) or 2x(2x50) @ 42-45
3x200
5x(1x95)
5x(1x95)
2x300
kW
batt. blocks
2x(1x120) or 2x(2x50) @ 46-50
batt. blocks
Table 5: DUAL INPUT FEED (STANDARD VERSION)
Rated
Fuse B
Cable B
Fuse C
Cable C
output Type:gL
(qty. x
Type:gL
(qty. x
or CB
power
or CB
mm2)
mm2)
(qty. x A)
(qty. x A)
60
kW
80
kW
100
kW
120
kW
Cable D
(qty. x
mm2)
Fuse E
Type:gR
or CB
Cable E
(qty. x mm2)
3x100
5x35
3x100
5x35
5x35
2x160
2x(1x50)
3x125
5x50
3x125
5x50
5x50
2x200
3x160
5x70
3x160
5x70
5x70
2x250
3x200
5x95
3x200
5x95
5x95
2x300
2x(1x95) @ 42-45 batt. blocks
2x(1x70) @ 46-50 batt. blocks
2x(1x120) or 2x(2x50) @ 42-45
batt. blocks
2x(1x95) @ 46-50 batt. blocks
2x(1x150) or 2x(2x50) @ 42-45
batt. blocks
2x(1x120) or 2x(2x50) @ 46-50
batt. blocks
Modifications reserved
Page 14/15
Contact us
www.abb.com/ups
ups.sales@ch.abb.com
© Copyright ABB. All rights reserved. Specification
subjects to change without notice.
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