NX Series operators Manual version1_10
GES-NX-Series – Three Phase Input, Three Phase Output
GES-103NX33 – GES-1603NX33
Operators Manual
Version 1.10
Always On UPS Systems Inc
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Dear Customer,
We Thank You for selecting our NX Series UPS
system as your power quality solution, and we are
pleased to include you as one of our valued customers
at Always "On" UPS Systems Inc.
We are confident that this Always “On” NX Series
Uninterruptible Power Supply system, developed and
manufactured in our ISO 9001 Certified facilities will
provide the quality and satisfaction you demand.
Please read the Operators Manual carefully as it
contains the necessary information required to extend
the life of this UPS to its fullest and this manual will
also inform you as to how to use this UPS.
Thank you for choosing us.
We Are Always "On"!
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Preface
Congratulations on your choice of NX Series Uninterruptible Power Supply (UPS). This system will
protect your valuable equipment from the electrical noise, spikes, surges and other power aberrations
found in today’s power grids.
This manual describes how to prepare the installation site and procedures for moving, installing and
connecting the UPS, with detailed information of maintenance procedures suggested to allow for
maximum reliability.
It will also explain the function of the UPS module, the purpose and location of the switches, the
meaning of system events identified on the front LCD panel and provides procedures for starting and
stopping the UPS.
While every care has been taken to ensure the completeness and accuracy of this manual, Always "On"
UPS Systems Inc assume no responsibility or liability for any losses or damages resulting from the use
of the information contained in this document.
WARNING!
Installation restrictions or additional measures may be needed to prevent specific disturbances. Ensure
all local and national electrical codes are followed during installation and connection. The information
contained in this manual is to be used as a guideline and recommendation only
We recommend that this manual be kept with the UPS (Holder provided inside the front door) for future
reference. If any problems are encountered with the procedures contained in this manual, please contact
our Service Center before proceeding.
This document shall not be copied or reproduced without the explicit written permission of Always "On"
UPS Systems Inc.
Due to technical advancements and improvements, some of the information contained in this manual
may be changed or modified without prior notice.
Safety Instructions
Read the safety instructions contained on the following pages carefully before the installation, start-up
of the UPS its options and batteries. Also refer to this manual before any maintenance procedures are
undertaken
Please pay particular attention to the text in the rectangular boxes as below:
They contain important information or warnings concerning electrical connections and personnel safety.
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TABLE OF CONTENTS
1
IMPORTANT SAFETY INSTRUCTIONS......................................................................................1
2
INTRODUCTION..........................................................................................................................3
3
2.1
System Description ......................................................................................................................................................... 3
2.2
Definitions ......................................................................................................................................................................... 3
THEORY OF OPERATION...........................................................................................................5
3.1
General Topology........................................................................................................................................................... 5
3.2
Normal Operation Mode .............................................................................................................................................. 6
3.3
Back-Up Mode:............................................................................................................................................................... 6
3.4
Reserve Mode:................................................................................................................................................................. 7
3.5
Maintenance Bypass Mode:......................................................................................................................................... 7
3.6
Features and Advantages ............................................................................................................................................. 8
3.7
Rectifier ...........................................................................................................................................................................10
3.8
Inverter............................................................................................................................................................................11
3.9
Static Switch ...................................................................................................................................................................12
3.10
Maintenance Bypass Switch.......................................................................................................................................12
4
INTER-PCB DIAGRAM ..............................................................................................................13
5
DIMENSIONS & DRAWINGS.....................................................................................................15
6
INSTALLATION .........................................................................................................................19
6.1
Transport........................................................................................................................................................................19
6.2
Delivery............................................................................................................................................................................19
6.3
Storage .............................................................................................................................................................................20
6.3.1
STORAGE OF THE UPS .........................................................................................................................................20
6.3.2
STORAGE OF BATTERY ......................................................................................................................................20
6.4
Site & Environment Consideration .........................................................................................................................21
6.5
Unpacking .......................................................................................................................................................................23
6.6
Cable Selection ..............................................................................................................................................................24
6.6.1
CURRENT RATING FOR INPUT.........................................................................................................................24
6.6.2
CABLE SIZE FOR INPUT & OUTPUT ...............................................................................................................24
6.6.3
FUSE RATING & CABLE SIZE FOR BATTERY BANKS ............................................................................28
6.7
Terminal Connection...................................................................................................................................................29
7
FRONT PANEL...........................................................................................................................31
8
OPERATION...............................................................................................................................37
9
8.1
Switch On Procedure (Authorized
personnel ONLY) ............................................................................37
8.2
Shutdown Procedure....................................................................................................................................................38
8.3
From Inverter To Manual Bypass Procedure.......................................................................................................39
8.4
From Manual Bypass To Inverter Procedure.......................................................................................................40
THE LCD DISPLAY ....................................................................................................................41
9.1
Menu 0 – Main Menu ..................................................................................................................................................41
9.2
Menu 1 – Select Menu .................................................................................................................................................42
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11
12
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9.3
Menu 2 – Status Warning Menu...............................................................................................................................43
9.4
Menu 3 – Real Time Data Menu...............................................................................................................................44
9.5
Menu 4 – Historical Event Menu..............................................................................................................................45
9.6
Menu 5 – Parameter Setting Menu ..........................................................................................................................46
9.7
Menu 6 – Rectifier Data Menu..................................................................................................................................47
9.8
Menu 7 – Reserve Data Menu ...................................................................................................................................47
9.9
Menu 8 – Output Data Menu ....................................................................................................................................48
9.10
Menu 9 – Other Data Menu .......................................................................................................................................48
9.11
Menu 10 – Boost Charge Setting Menu..................................................................................................................49
9.12
Menu 11 – Data Time Setting Menu........................................................................................................................51
9.13
Menu 12 – Other Setting Menu.................................................................................................................................51
INTERFACE CONNECTIONS....................................................................................................52
10.1
Dry Contacts ..................................................................................................................................................................52
10.2
Software for PC Monitoring ......................................................................................................................................53
10.3
Emergency Power Off Connection...........................................................................................................................53
10.4
DB9 Connectors ............................................................................................................................................................53
OPTIONS....................................................................................................................................54
11.1
Battery Cabinet.............................................................................................................................................................54
11.2
Battery Runtime Charts .............................................................................................................................................55
11.3
Emergency Stop Switch ..............................................................................................................................................57
11.4
Remote Display Panel..................................................................................................................................................57
11.5
Isolated Parallel Redundant Operation (IPRO) ..................................................................................................57
11.6
Web Monitoring Module (SNMP Module)............................................................................................................57
11.7
12-Pulse Rectifier..........................................................................................................................................................57
11.8
5 th Harmonic Filter.......................................................................................................................................................57
11.9
External Wrap Around Bypass ................................................................................................................................57
TECHNICAL SPECIFICATION..................................................................................................59
12.1
NX Series – 10kVA to 60kVA UPS 3Ø Input - 3Ø Output ...............................................................................59
12.2
NX Series – 80kVA To 160kVA UPS 3Ø Input 3Ø Output.............................................................................62
12.3
NX Series – 200kVA To 320kVA UPS 3Ø Input 3 Ø Output ...........................................................................64
PREVENTATIVE MAINTENANCE FORM ................................................................................65
13.1
Maintenance Measurement Form............................................................................................................................75
13.1.1
Initial Start Up (no load connected)...................................................................................................................75
13.2
Maintenance Measurement Form cont’ .................................................................................................................77
13.2.1
Normal Service Measurements (normal loads connected and operating)...................................................77
14
13.3
Front Panel Status Report Log .................................................................................................................................79
13.4
Front Panel Readings ..................................................................................................................................................81
13.5
Battery Maintenance Form........................................................................................................................................83
CONTACT INFORMATION........................................................................................................84
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1
IMPORTANT SAFETY INSTRUCTIONS
Save These Instructions.
This manual contains important safety instructions that should be followed during installation and
maintenance of the NX Series UPS system and optional packages. Before the installation process
begins, we recommend that the installer read through the safety precautions, operators manual and
the option installation instructions, taking all necessary safety precautions to protect themselves and
the equipment being installed.
GENERAL
Move the UPS in an upright position, in its original packaging, to its final destination.
To lift the cabinets, use a forklift or lifting belts with spreader bars.
- Check for sufficient floor and elevator loading capacity.
- Check the integrity of the UPS equipment carefully.
If visible damage is evident, do not attempt to install or start the UPS. Contact the transport
delivery company, immediately file a claim with the transport company and inform Always
“On” directly.
- WARNING! RISK OF ELECTRICAL SHOCK: use extreme caution when removing covers.
- All maintenance and service work should be performed by qualified and trained service
personnel. The UPS contains its own energy source, (batteries) which can be dangerous to the
untrained person. This UPS contains potentially hazardous voltages
- The field-wiring terminals may be electrically live, even when the UPS is not connected to the
utility.
- Dangerous voltages may be present during battery operation. The batteries must be disconnected
during maintenance or service work. (Open battery breaker of fuses)
- Be aware that the inverter can restart automatically after the utility voltage is restored.
INSTALLATION
-
This UPS is intended for use in a controlled indoor environment free of conductive
contaminants and protected against any type of intrusion.
Do not install the UPS in an excessively humid environment or near water.
Avoid spilling liquids and/or dropping any foreign object(s) onto the UPS.
The unit must be placed in a sufficiently ventilated area; the ambient temperature should not
exceed 35°C (95°F).
Optimal battery life is obtained if the ambient temperature does not exceed 25°C (77°F).
HIGH GROUND LEAKAGE CURRENT: ground connection completed before connecting the
AC voltage wires on the input!
Switching OFF the UPS does not isolate the UPS from the utility as the utility supply is still
HOT at the input terminal strip. Supply breaker needs to be opened.
It is important that air can move freely around and through the unit. Do not block the air vents.
Avoid locations in direct sunlight or near heat sources.
STORAGE
-
Store the UPS in a dry location free of contaminants;
Storage temperature must be within -25°C (-13°F) to 55°C (131°F).
If the unit is stored for a period exceeding 3 months, the batteries must be recharged periodically
(time depending on storage temperature).
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WARNING!
LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT IS
APPARENTLY NOT OPERATING. OBSERVE ALL CAUTIONS AND WARNINGS IN
THIS MANUAL. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR
DEATH. REFER UNIT TO QUALIFIED SERVICE PERSONNEL IF MAINTENANCE IS
REQUIRED. NO ONE SHOULD WORK ON THIS EQUIPMENT UNLESS THEY ARE
FULLY QUALIFIED TO DO SO. AN INSTALLER SHOULD NEVER WORK ALONE.
WARNING!
WHEN REMOVING POWER FROM THE UPS, ALLOW FIVE MINUTES FOR
CAPACITORS TO DISCHARGE BEFORE WORKING ON THE EQUIPMENT.
CAUTION!
This equipment complies with the requirements in Part 15 of FCC rules for a Class A
computing device. Operation of this equipment in a residential area may cause interference to
radio and TV reception, requiring the operator to take whatever steps necessary to correct the
interference.
CAUTION!
Do not put option control wiring in the same conduit as the UPS input or output power cables.
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2
2.1
INTRODUCTION
System Description
The NX Series (UPS) continually monitors and provides conditioning to the incoming electrical
power removing surges, spikes, sags, over-voltages, and other irregularities that are inherent in
commercial utility power. This UPS system supplies clean, consistent power at the rated voltage
with low wave distortion to your sensitive electronic equipment. Blackouts, brownouts and
other power interruptions regardless of duration can be protected against with additional
optional battery cabinets to provide the necessary emergency power to safeguard your operation.
Always “On” UPS Systems Inc. believes that product reliability is first and foremost in
acquiring the confidence of the industry. Our Quality Control Standards ensures that testing at
the component level, board level, function level and completed stage level as specified by our
ISO9001 Certification allows us to gain this confidence and sets us apart as one of the leading
UPS manufacturers in this industry.
Always “On” maintains reliability by incorporating conservatively rated components
minimizing transfers to bypass, which eliminates over working many components. Always “On”
provides a truly isolated output (no common neutral from input to output) to eliminate all types
of power aberrations as well as Common and Normal Mode noise increasing the reliability and
life of the loads connected.
2.2
Definitions
UPS Module: That portion of the UPS system which contains the rectifier/charger, inverter,
static bypass switch, maintenance bypass switch, controls, monitoring, and indicators.
Rectifier/Charger: That portion of the UPS module, which converts the normal source AC input
power to DC power for the inverter input and for charging the battery.
Inverter: That portion of the UPS module, which converts DC bus power to regulated and filter
AC power that is then supplied to the critical loads.
Static Bypass Switch: That portion of the UPS module which automatically transfers the critical
loads, without interruption, from the inverter output to the bypass AC power source in the event
of an overload or degradation of the inverter’s performance.
Maintenance Bypass Switch: That portion of the UPS module which is used to connect the
bypass AC power source to the critical loads while electrically isolating the static bypass switch,
rectifier/charger and inverter for maintenance purposes.
Battery: The battery system provides DC power to the inverter input when the normal AC input
power to the UPS fails or in the event that the rectifier/charger failure.
Critical Loads: These are loads that require clean, regulated and continuous AC power and
which are connected to the output of the UPS module.
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Key features:
Ø 0.9 power factor, the Always “On” NX Series delivers more real power than other
manufactured UPS’s. With today’s trend toward power factor corrected loads, the NX
Series can support more total load than any other UPS, of similar size, allowing you
to support a greater number of today’s Power Factor Corrected (PFC) equipment.
Ø Isolated Parallel Redundancy Operation (IPRO) is exclusive Always “On”
technology. With IPRO the NX Series UPS’s are controlled in a true peer-to-peer
configuration where all critical elements and functions (including bypass) being
redundant. The NX Series is designed to be the most reliable power protection system
available on the market today.
Ø IGBT technology and new triggering technology allows the NX Series to offer
efficiencies up to 94%.
Ø Digital Signal Processor (DSP), Flash memory and user compatibility are the
technology corner stones of our New Age of power quality and reliability.
Ø Custom made power protection and tailored to meet your individual requirements, the
NX Series offers user selectable options. I.e. Input harmonic filters, comprehensive
shutdown software suite for mission control and data protection needed to facilitate
all your needs.
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3
3.1
THEORY OF OPERATION
General Topology
Figure 3.1.1
General Block Diagram
UPS Module Components: The UPS module consists of the following major components:
- Input, Reserve and Bypass circuit breakers
- Rectifier / Charger
- Inverter
- Microprocessor controlled logic and control panel with alarm indicators and digital
metering display
- External battery connection
- Static bypass
- Full maintenance bypass
- Emergency power off (EPO) connection
- Communications interface
- Input power walk-in
- Front cable connections
- Output isolation transformer
- Optional Features:
- 5th harmonic filter to reduce input harmonic content.
- SNMP Adapter for network communications and monitoring
- Additional battery modules for extended runtime
- Top cable entry
- Remote display panel
- Emergency power off switch
- External maintenance bypass cabinet
- Isolated parallel redundant operation (IPRO)
Generally, there are four modes of operation for a UPS system, NORMAL MODE, BACK-UP
(BATTERY) MODE, RESERVE MODE and MAINTENANCE BYPASS MODE.
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3.2
Normal Operation Mode
Figure 3.2.1
Normal Mode Operation
The rectifier/charger converts the supplied AC power into DC (bus) power, which is then
supplied to the inverter and the battery charger. The DC to AC inverter then supplies
continuous, noise free AC power to the critical loads. The inverter output is synchronized with
the bypass AC power source provided that the bypass AC power source is within the specified
frequency range.
3.3
Back-Up Mode:
Figure 3.3.1
Back-up Mode Operation
As the batteries are connected to the DC bus they supply energy to the inverter via this DC bus,
the AC power will remain constant and continuous without interruption to the loads when the
AC fails or falls out side of the operating parameters. Upon return of the supplied AC input
power the UPS the rectifier will automatically assume the DC load (charger, inverter) from the
batteries. The UPS will simultaneously supply power to the inverter and the battery charger to
replenish the batteries.
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3.4
Reserve Mode:
Figure 3.4.1
Reserve Mode Operation
If the inverter is placed into an abnormal condition, such as over temperature, short circuit,
abnormal output voltage or is overloaded for a period which exceeds the inverter’s limits, the
inverter will automatically shutdown in order to protect itself. If the AC utility power is within
the normal parameters, the static switch will automatically transfer the load to the reserve
(utility) source without interruption of the AC output.
3.5
Maintenance Bypass Mode:
Figure 3.5.1
Maintenance (Manual) Bypass Mode Operation
During UPS maintenance procedures or battery replacement, the loads cannot be interrupted,
and as such the technician needs to turn off the inverter switch, close the bypass breaker and
then open the rectifier and reserve (utility) breakers. The UPS is now running in Maintenance
By-pass mode supplying utility AC to the loads. The AC output will not be interrupted during
the manual bypass transfer procedure because the maintenance bypass switch is designed to
supply continuous power to the loads.
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3.6
Features and Advantages
a. Reliable input protection: Circuit breakers are in each input loop to ensure power can
continue through the other loops in the event of a breaker trip caused by abnormal conditions in
either the rectifier or the load.
b. Input surge protection: Input surge protection is added at the input to provide enhanced
protection to both the UPS and the load and also protects against lightning effects and/or surges
caused by large cycling loads or those that are being turned on and/or off.
c. EMI suppression: An EMI filter is added to meet the international EMC limits to ensure that
No noise will effect or interfere with other equipment connected to the same AC source.
d. Ruggedness: The rectifier employs phase control technology to regulate the DC bus voltage
allowing the batteries to be charged while supplying DC power to the inverter. This has been
proven to be the most efficient method to control and regulate the charge on the batteries. The
SCR technology and PFC circuit also assist in maintaining the input waveform.
e. High frequency design: The inverter design incorporates high frequency, highly efficiency
Insulated Gate Bi-polar Transistors (IGBT). A PWM wave, synchronized to the bypass input,
triggers the IGBT’s, which invert the DC into AC power required by the loads. This design
decreases the number of required components, increases reliability and performance while
decreasing acoustic noise, size and weight.
f. True galvanic isolation: The isolation transformer addresses ground differentials between the
input and output, and prevents ground leakage current problems, common mode and normal
mode noise. This transformer is located on the output side of the UPS system providing
isolation under every mode of operation.
g. PNP modular design: The circuit boards are designed into several modules, which are
plugged into slots in the UPS. These plug-able modules allow for easy replacement in the field
when necessary and eliminate field diagnostics.
h. Cold start function: The UPS can be started without the utility AC supply being activated.
Or present at the input terminal strip because our designed system is designed with current
limiting circuitry, which allows Startup of the UPS on battery DC power.
i. Multi-CPU design: Several CPU’s are designed into the control circuit. These critical
functions are designed with multi-level redundancy increasing reliability and up-times by
eliminating field problems.
j. Protection against possible operator error: The UPS is designed with breaker on/off
sensors and power supply sensors. These sensors prevent potential operational mistakes from
interfering with the start –up operation causing possible damage.
k. Wide input range: The components are overrated by designed to handle high input voltages
and currents without harm to the system, ensuring that Always “On” UPS’s remain one of the
most reliable UPS Systems available in today’s market.
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l. Harsh environment: Each component of the UPS is chosen with the highest degree of safety
margins allowing for wider environmental parameters and specifications related to temperature,
humidity, altitude, surge or noise.
m. Intelligent charger: The UPS will automatically recharge (boost charge) the batteries when
the battery voltage level decreases to approximately 2V/Cell or to a user specified level. To
prevent the over-charging of the battery, the boost charge will stop when batteries achieve a
90% charged level or the ambient temperature reaches 35o C (95o F) at which point the float
charging begins.
n. Intelligent battery test: The batteries are tested after every boost charge whether the charge
has been initiated by a battery discharge state (2V/Cell) or by the regular battery test preformed
by the UPS (monthly test). When an abnormal condition (low charge rating, or bad battery) is
found the user will be informed immediately through alarms on the UPS system.
o. Charging rate: The charging rate is selectable (L/M/H) according to Ah ratings of the
batteries. The charger is designed to charge the larger battery banks without adding an
additional charger (up to 8hr. back-up).
p. MTBF of cooling fans : Long cycling fans will operate at variable speeds necessary which is
dependent on the ambient temperature of the UPS system increasing the life expectancy of the
fan motors.
q. Redundant power supply: Redundant power supplies have been installed to allow for worry
free operation of the system.
r. Intelligent interface: One remote control panel (or one PC) can monitor and control up to
ninety-nine UPS’s. The communication allows for N+1 redundancy, whereby if one system
encounters an emergency or fault condition, it will warn the user immediately and the load is
automatically transferred to the other UPS systems. The UPS status, data or commands are
transmitted to external modules through four RS-485 ports.
s. Data log capability: All abnormal conditions will be stored within the UPS control interface
board for further reference by the user. Each abnormal condition is time and date stamped (realtime clock) as the event occurs. This history is stored and cannot be removed even if or when
the UPS is turned off for servicing.
t. Convenient front panel design: The LCD display and control switches are accessible
through the up, down, and enter switches below the front panel window. All the viewable
parameters can be read without opening the front door. The inverter on/off switch is protected
from accidental operation by being located behind the locked front door although the inverter
can still be switched on and off via the control switches on the front panel but this feature is
password protected.
u. Emergency stop: In the event of an emergency the UPS can be shutdown (no AC at the
output) either through a switch (optional) or through a smoke detector signal (optional).
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3.7
Rectifier
The main function of a rectifier is to convert the AC input power to DC power. The DC power is
then used to charge the batteries, supply the DC bus, which in turn supplies the inverter.
The rectifier design used in the 10kVA to 60kVA UPS’s include a 6-pulse full controlled
rectifier. Power Factor Correction (PFC) has been added to maintain a high input power factor,
independent of the load power factor. This 6 pulse rectifier smoothes the current waveform and
reduces the harmonic content reflected back to the utility. The control circuit regulates the DC
bus to within 1% of the nominal voltage. Soft walk-in circuitry (approximately 20 seconds) and
current limiting circuitry are used to prevent over current or surge currents from affecting any
part of the UPS system.
Additionally, over and under-voltage protection is added to improve reliability and to shutdown
the rectifier in the event of abnormal conditions. The DC bus is adjustable to allow for different
types and capacities of batteries. The power components used within the rectifier are specially
designed and selected to handle extreme ranges of high voltage and high current (–25% to
+25%).
In order to further improve the power factor and reduce harmonic current drawn by the rectifier,
Always “On” UPS’s above 80kVA incorporate a 12-pulse full controlled rectifier (also available
as an option on the 10 to 60kVA UPS’s) to reduce the total harmonic current to less than 12%. A
phase shift transformer is added with input inductors to achieve this higher level of performance
while maintaining our high input power factor. An optional 5th harmonic filter can be added to
further reduce the total harmonic distortion current to less than 9%.
The total harmonic current can be decreased to less than 7% with the inclusion of the 18-pulse
full controlled rectifier. This option is recommended for the larger (80kVA and up) UPS
systems.
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3.8
Inverter
Figure 3.8.1
Inverter Layout
The inverter is composed of IGBT’s, inductors, capacitors, highly efficient filters, control
circuitry and protection circuitry. This inverter inverts the DC power received on the DC bus to
isolated, noise-free AC power, which is then supplied to the critical loads. Our PWM wave
generator is switching at a higher frequency well above the human audible range.
The Voltage regulating circuitry limits the output voltage variation to within 1% of the nominal
voltage and special compensation circuitry has been added to eliminate output distortion. Every
component is oversized to accept a wide DC input range (from 285 to 420VDC), allowing the
output waveform to remain sinusoidal throughout the entire range. With the aid of dynamic
feedback loop circuits the inverter maintains a true sine wave output, even if non-linear loads
are connected.
The system is designed and incorporates an independent inverter per phase. These inverters are
totally independent of each other preventing the possibility of cascading failures while allowing
the user to connect loads to adjacent inverters without affecting the other inverters. This
connectivity provides high-end voltage regulation under a 100% unbalanced load situation.
The IGBT is operated in its optimal condition to obtain maximum efficiency, keeping electrical
costs to a minimum.
Usually, most UPS failures are a result of inverter failures. To prevent this occurrence, Always
“On” has included redundant protection circuitry to protect the inverter and increase its
reliability. To enhance this protection we have also added a high efficiency filter designed to
suppress the spikes and noise that can be reflected from the attached loads back into the UPS
system. Specifying oversized and high quality components, additional semi-conductor fuses and
allowing for good ventilation systems within further increase reliability.
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3.9
Static Switch
Figure 3.9.1
Static Bypass
The static switch is composed of two pairs of back to back naturally commutated SCR’s, which
moves the load from inverter to reserve (utility) or from reserve to inverter without interruption
of power to the load.
Detection circuitry is included in the control circuit to achieve “0” dead time transfer.
Additional detection is employed to control the static switch transfer.
Dead Short: If a dead short circuit was to occur under normal mode operation, the UPS would
detect the short circuit and immediately stop the inverter until the problem has been rectified.
Due to the large amount of current a dead short requires, the static switch will not transfer to
reserve preventing the tripping of the reserve breaker.
Overload condition: The UPS will transfer the load to reserve (utility) path. The static switch is
designed to handle 110% of the capacity of the system but will switch to the reserve path if the
overload continues for any length of time. The load will still be operational, but the load system
will not be protected from a utility failure, as it has no battery capability until the overload is
removed.
The static switch will only be activated if the input levels are within parameters to ensure the
load is only supplied with acceptable power to protect against damage that may be caused to the
critical load. The system performs numerous checks on the transfer from inverter to bypass and
visa versa to ensure the exchange is smooth.
3.10
Maintenance Bypass Switch
The maintenance bypass switch is a function of Always “On” UPS’s, which is open under
normal operation, and closed for maintenance service. All power supplied to the UPS should be
disconnected before service begins. The maintenance bypass is switched seamlessly to supply
utility AC power to the loads during UPS maintenance and servicing. If the bypass breaker is
closed (by mistake) under normal operations, the inverter will stop and the load will be
transferred to reserve (utility) power.
The inverter cannot be turned on when the maintenance bypass breaker is in the closed position.
(The operation of the maintenance bypass breaker is explained later in this manual)
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4
INTER-PCB DIAGRAM
12 Pulse Rectifier
Rectifier
Driver
Rectifier
Control
Rectifier
Driver
Rectifier
Control
Batt
Relay
R Phase
Inverter
Driver
S Phase
Inverter
Driver
T Phase
Inverter
Driver
Controller
6 Pulse Rectifier
LCD
Call
Service
Switch
SS Drive
Power Supply
Remote Control
Panel
PC
Communications
Display
LED
Dry
Contact
SNMP (Web)
Monitoring
Battery Monitoring
Optional Communication
Features
Figure 4.1
Block Diagram For Component And Feature Layout
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DIMENSIONS & DRAWINGS
92mm (3.6in)
1,600mm (63.0in)
5
800mm (31.5in)
550mm (21.7in)
Figure 5.1
10kVA to 60kVA Dimensional Drawing
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F R O M
I N V E R T E R
T O
B Y P A S S
P R O C E D U R E :
Figure 5.2
10kVA to 60kVA Interior Layout
Table 5.1 Weight, Dimensions and Loading of the 10 to 60kVA UPS systems.
UPS Rating
(kVA)
10
20
30
40
50
60
W (Width)
500mm (20.0")
500mm (20.0")
500mm (20.0")
500mm (20.0")
500mm (20.0")
500mm (20.0")
Dimensions
D (Depth)
800mm (32.0")
800mm (32.0")
800mm (32.0")
800mm (32.0")
800mm (32.0")
800mm (32.0")
H (Height)
1,600mm (64.0")
1,600mm (64.0")
1,600mm (64.0")
1,600mm (64.0")
1,600mm (64.0")
1,600mm (64.0")
UPS
250kg (550lbs)
300kg (660lbs)
400kg (880lbs)
480kg (1,056lbs)
550kg (1,210lbs)
680kg (1,496lbs)
Weight
Floor Loading
625kg/sq.m (124lbs/sq.ft.)
750kg/sq.m (149lbs/sq.ft)
1,000kg/sq.m (198lbs/sq.ft.)
1,200kg/sq.m (238lbs/sq.ft.)
1,375kg/sq.m (273lbs/sq.ft)
1,700kg/sq.m (337lbs/sq.ft.)
16
Always On UPS Systems Inc
Figure 5.3
80kVA to 160kVA Dimensional Drawing
17
Always On UPS Systems Inc
WARNING
INVERTERON
R E S E R V E
ACFAIL
INVERTERSS
RECTACFAIL
R E S E R V E
FREQFAIL
SHORTCIRCUIT
B A T T E R Y L O W
RESERVEFAIL
FUSE/OVER
B A T T E R Y
T E M P S D
S H U T D O W N
INVERTERFAIL
RECTACFAIL
B A T L O W
L O W
S H U T D O W N
FUSE/TEMP
B Y P A S S O N
ROTATION
S H U T D O W N
E R R O R
HIGH DC
S H U T D O W N
S H U T D O W N
O V E R L O A D
S H U T D O W N
HIGHDC
7 0% L O A D
B O O S T
C H A R G E
1 1 0% L O A D
B A T T E R Y
T E S T
1 2 5% L O A D
E M E R G E N T
S T O P
1 5 0% L O A D
DATALINE
RECTIFIER
~
~
B A T L O W S T O P
O V E R L O A D
~
F A U L T
INVERTER
~
~
/
~
~
/
ON
O F F
L C D
TRUE GALVANIC ISOLATED UPS
U P
START
1.
2 .
3 .
PROCEDURE:
CLOSE
THE
C L O S E
PUSH
6 .
T H E
7 .
L O C K
T H E
F O R
O F
L O A D
O N
1 .
B R E A K E R .
A F T E R
2 .
B Y P A S S
CLOSE
O P E N
T O
3 .
W A I T
C L O S E
P U S H
7 .
T H E
8 .
L O C K
T H E
T H E
5.
O P E N
I N V E R T E R
&
T H E
O P E N
O F F
M I D D L E
O F
B A T T E R Y
T H E
W A I T
S W I T C H
I N V E R T E R
B R E A K E R .
R E C T I F I E R
5 m i n
F O R
D C
B R E A K E R .
C A P A C I T O R
I N S I D E
D I S C H A R G E .
OPEN
L O C K
F R O M
RECTIFIER
F O R
O F
L O A D
I N V E R T E R
T H E
BREAKER.
D C
O N
THE
RESERVE
T H E
D O O R .
I N V E R T E R
BREAKER.
V O L T A G E
D O O R .
A F T E R
T H E
T O
BREAKER.
B Y P A S S
T O
7 s e c .
I N V E R T E R
&
O F F
M I D D L E
O F
S W I T C H
I N V E R T E R
S W I T C H ) .
R I S E2 . U OP P. E N
( L E F T
3 .
&
4 .
S W I T C H ) .
T R A N S F E R
O U T P U T
P U S H
( R I G H T
B R E A K E R .
S W I T C H
I N V E R T E R
W I L L
1 .
B R E A K E R .
B A T T E R Y
I N V E R T E R
M I D D L E
P R O C E D U R E :
T H E
U P S. W I T C H ) .
T O
I N V E R T E R
RESERVE
B Y P A S S
3 0 s e c
5 .
6 .
4 .
6 .
E N T E R
P R O C E D U R E :
THE
T H E
C L O S E
4 .
&
3 .
T O
7 s e c .
D O O R .
P R O C E D U R E :
1.
2 .
P U S H
( R I G H T
R I S E
( L E F T
S W I T C H ) .
T R A N S F E R
O U T P U T
T H E
V O L T A G E
B R E A K E R .
S W I T C H
I N V E R T E R
W I L L
I N V E R T E R
F R O M
D C
B A T T E R Y
INVERT E R
M I D D L E
BREAKER.
R E C T I F I E R
3 0 s e c
C L O S E
5.
S H U T D O W N
RESERVE
T H E
W A I T
4 .
D O W N
T H E
O P E N
L O C K
B R E A K E R .
R E C T I F I E R
5 m i n
F O R
D C
B R E A K E R .
C A P A C I T O R
I N S I D E
D I S C H A R G E .
C L O S E
OPEN
B A T T E R Y
T H E
W A I T
T O
5 .
6.
7 .
T H E
THE
T H E
B Y P A S S
RESERVE
BREAKER.
BREAKER.
D O O R .
Figure 5.4
80kVA to 160kVA Interior Layout
Table 5.2 Weight, Dimensions and Loading of the 80 to 160kVA UPS systems
UPS Rating
(kVA)
80
100
120
160
W (Width)
1,100mm (44.0")
Dimensions
D (Depth)
800mm (32.0")
H (Height)
1,600mm (64.0")
1,100mm (44.0")
1,100mm (44.0")
1,100mm (44.0")
800mm (32.0")
800mm (32.0")
800mm (32.0")
1,600mm (64.0") 950kg (2,090lbs) 1,080kg/sq.m (214lbs/sq.ft.)
1,600mm (64.0") 1,180kg (2,596lbs) 1,340kg/sq.m (266lbs/sq.ft.)
1,600mm (64.0") 1,450kg (3,190lbs) 1,648kg/sq.m (327lbs/sq.ft.)
UPS
820kg (1,804lbs)
Weight
Floor Loading
932kg/sq.m (185lbs.sq.ft.)
18
Always On UPS Systems Inc
6
6.1
INSTALLATION
Transport
The UPS is packaged on a pallet, suitable for handling with a forklift.
Pay strict attention to the center of gravity. The UPS must be moved in upright position. Do not tilt
cabinets more than +/- 10° during handling.
Move the UPS in its original package to the final destination site.
Do not stack other packages on top.
If the UPS must be lifted by crane, use suitable lifting straps and spreader bars.
6.2
Delivery
Upon receiving the UPS system, inspect the packaging integrity and the physical condition of the
cabinets carefully.
In the event that physical damage is visible, the carrier must be informed immediately and a claim
filed with them. Inform Always “On” as soon as the claim has been filed and a copy of claim should
be faxed to Always “On” at (250) 491-9775.
A detailed report of the damage is necessary for carrier insurance claim.
WARNING
A damaged UPS system must never be installed or connected to the utility or batteries without
written instruction from Always “On” Engineering.
19
Always On UPS Systems Inc
6.3
Storage
6.3.1
STORAGE OF THE UPS
The UPS is carefully packed for transport and storage.
Never leave a UPS outside the building exposed to the elements and do not place
other packages on the top of the UPS.
Storing: It is recommended to store the UPS in its original package in a dry, dust-free
room, away from chemical substances, and with a temperature range of -25°C (13°F) to 55°C (131°F). Exceeding this temperature range may cause damage.
Important functions of the UPS, are defined by parameters stored in a RAM memory.
The RAM is supplied by a small backup battery located on the Controller board. If
the storage time of the UPS exceeds 1 year, these functions should be verified by an
Always “On” Service Center before putting the UPS into operation.
6.3.2
STORAGE OF BATTERY
Although this system includes maintenance free batteries, keep in mind that they are
subject to self-discharge and therefore must be recharged.
The storage time without battery recharge depends on the temperature of the storage
site. The optimal temperature for battery storage is 20°C (68°F) to 25°C (77°F).
Recharge of the stored maintenance free battery every:
6 months when the ambient storage temperature is 20°C (68°F)
3 months when the ambient storage temperature is 30°C (86°F)
2 months when the ambient storage temperature is 35°C (95°F)
20
Always On UPS Systems Inc
6.4
Site & Environment Consideration
The designed function of the UPS is to provide a safe, clean and independent electrical supply
free from random variations, disturbances or interruptions of the utility mains. The UPS will
provide a constant power source, which is regulated in both voltage and frequency. When the
utility mains are not available, the UPS will provide optimal back-up time depending on the
capacity connected battery bank.
Usually the life expectancy of the UPS is 8 to 10 years. The optimal life expectancy of the UPS
can be achieved by careful consideration of the site and environment.
The following precautions and recommendations should be checked when considering the site
and environment for the UPS:
a. The UPS should be located in a place with adequate ventilation (refer to the specification of
the heat dissipation of the UPS). Should the UPS be installed in a sealed room, care must be
taken to ensure adequate heat evacuation is provided.
b. Void space is not required on all sides of the UPS system, but adequate space, a minimum of
1m (3’), should be allowed for the door to open. Adequate space, a minimum of 60cm (2’)
[recommended 1m (3’)], should also be allowed at the top of the UPS system to allow for
proper heat dissipation and ventilated through the top openings (optional ventilation booth is
available upon request).
c. The battery banks require access to front and both sides. A minimum of 60cm (2’)
[recommended 1m (3’)] should be allowed at the front and both sides to allow for the door
to open and removal of the side panels for operation or maintenance purposes.
Figure 6.4.1
Minimum Spacing Requirements
21
Always On UPS Systems Inc
d. Do not place any objects on the top of the UPS that might obscure the ventilation. Do not
place the UPS near any heat source, or machinery, which may produce metallic particles,
dust or powder. Do not place the UPS near equipment that will produce corrosive
substances or vapor.
e. Do not place the UPS below the shower of a fire extinguishing system (optional drip shield
available). Abnormal conditions of the UPS should be protected by a cutoff from the power
supply.
e. The user is required to guarantee the temperature and humidity values of the site into which
the UPS will be installed meet the required and published manufacturer specifications. The
UPS should be installed within the range allowed by these specifications. The UPS is
capable of continuous normal operation within a temperature range of 0°C (32°F) to 40°C
(104°F). For optimal performance and reliability the recommended environment
temperature is best at 25°C, with humidity < 80% non-condensing.
f. The floor loading capacity should be sufficient to endure the weight of the UPS. Four rightangled steel feet attached restrainers are included with the UPS system, which should be
inserted into the floor for securing the UPS system, when the location has the potential to
experience vibrations. (e.g.: earthquake, moving vehicles, or tanker.) The locations and
layout of the restrainers are shown below.
Figure 6.4.1
Layout Of Securing Tab Locations
h. Walls, ceilings, floors or anything near to the UPS should be constructed of noncombustible materials. A portable fire extinguisher should be accessible nearby.
i. Avoid accumulating litter or trash of any sort in or around the UPS system. The floor area
surrounding the UPS should be kept clean, free from metallic powder and/or filings.
22
Always On UPS Systems Inc
j. Access to the UPS room should be limited to operation and maintenance personnel. The
doors should be kept locked and the keys should be available only to authorized personnel.
k. Personnel who operate or maintain the UPS system should be proficient in normal and
emergency operational procedures. New personnel should be trained and qualified prior to
operation of the equipment.
l. Although the UPS has passed the international EMC tests, it is not recommended to install
the UPS near to any equipment that is susceptible to electro-magnetic interference, such as
computer systems, monitors, radios etc.
6.5
Unpacking
Carefully remove all the packaging material of the UPS, then carefully place the UPS at the
final destination site.
This UPS system has passed all stages of production testing and final stage QC testing prior to
shipment from the factory (report enclosed). The UPS should be in full operating condition
upon receipt. Upon receiving visually check the UPS for any physical damage that may have
occurred during transport. If damage is notice file a damage report immediately with the
transport company and inform Always “On”.
Also check to ensure all of the accessories/options ordered are received.
•
•
•
DOOR KEY
OPERATOR’S MANUAL
BATTERY FUSE (FOR BATTERY CABINET ONLY)
Check and verify the specifications of the UPS are identical to the specifications of the system
ordered. The key items in the specifications you must check are:
•
•
•
•
RATED POWER OF THE UPS
INPUT VOLTAGE & FREQUENCY
OUTPUT VOLTAGE & FREQUENCY
BATTERY RUNTIME
Check that the necessary documentation located inside the front door of the UPS, is included:
•
•
•
OPERATORS MANUAL
TEST AND WARRANTY INFORMATION
SERVICE MANUAL (If purchased)
23
Always On UPS Systems Inc
6.6
Cable Selection
The cabling of the UPS system has to be sized according to the UPS power rating.
Sizing of circuit breakers, fuses and cables for input utility, output load and battery must meet the
requirements of local and national electrical codes.
The following tables list the information between kVA of the UPS and the current requirements
of the systems.
WARNING
Inadequate cable size and over sized breakers can increase the risk of fire or damage connection
cables and internal components.
The following tables can be used to determine the input circuit breaker rating and the size of
cable for input, output and battery connections. This data is for reference only as final
installation must meet the requirements of local and national electrical codes.
6.6.1
CURRENT RATING FOR INPUT
Table 6.6.1.1 Maximum Input current ratings
Imax(A)
Imax(A)
Imax(A)
KVA
Minimum
Minimum
Minimum
120/208VAC
277/480VAC
347/600VAC
Rating
Breaker/Fuse
Breaker/Fuse
Breaker/Fuse
3Ø
3Ø
3Ø
10
45
50
20
20
16
20
15
63
70
27
30
22
30
20
83
90
36
40
30
30
30
125
125
55
60
45
50
40
160
175
70
70
56
60
50
200
200
90
90
70
70
60
250
250
110
110
90
90
80
330
350
145
150
115
125
100
415
450
180
200
145
150
120
500
500
220
225
175
175
160
660
700
290
300
230
250
When choosing a non-fused breaker (NFB) for the UPS, always choose the NFB that is closest,
but not below the maximum rated input current.
6.6.2
CABLE SIZE FOR INPUT & OUTPUT
NEC SECTION 210-20 (a)
Table 8.3.2 (next page) shows the allowable amperage of insulated conductors rated 0 through 2000
Volts, 60°C through 90°C (140°F through 194°F) not more than three current-carrying conductors
in a raceway, cable, or earth (directly buried), based on ambient temperature of 30°C (86°F).
24
Always On UPS Systems Inc
Table 2
(See rules 4-004, 8-104, 12-012, 12-2212, 26-000, 26-742, 42-008, and 42-016 and Tables 5A, 5C, 19, and D3)
Allowable Ampacities for Not More Than 3 Copper Conductors in Raceway or Cable
Based on Ambient Temperature of 30°C
Allowable Ampacity
60°C
75°
85-90°C
110°
125°
Size
AWG
kcmil
Types
TW
Types
RW75
TW75
Types
R90, RW90
T90 NYLON
Paper
See
Note
(1)
See
Note
(1)
200°
See
Note
(1)
Mineral-Insulated
Cable**
COPPER
14
15
15
15
30
30
30
12
20
20
20
35
40
40
10
30
30
30
45
50
55
8
40
45
45
60
65
70
6
55
65
65
80
85
95
4
70
85
85
105
115
120
3
80
100
105
120
130
145
2
100
115
120
135
145
165
1
110
130
140
160
170
190
0
125
150
155
190
200
225
00
145
175
185
215
230
250
000
165
200
210
245
265
285
0000
195
230
235
275
310
340
250
215
255
265
315
335
300
240
285
295
345
380
350
260
310
325
390
420
400
280
335
345
420
450
500
320
380
395
470
500
600
355
420
455
525
545
700
385
460
490
560
600
750
400
475
500
580
620
800
410
490
515
600
640
900
435
520
555
1000
455
545
585
680
730
1250
495
590
645
1500
520
625
700
785
1750
545
650
735
2000
560
665
775
840
Col.1
Col.2
Col.3
Col.4
Col.5
Col.6
Col.7
CORRECTION FACTORS
Ambient Temp. For ambient temperatures other than 30°C (86°F), multiply the allowable amperage shown above by the
(°C)
appropriate factor below
21 - 25
1.08
1.05
1.04
1.08
1.05
1.04
26 - 30
1.00
1.00
1.00
1.00
1.00
1.00
31 - 35
0.91
0.94
0.96
0.91
0.94
0.96
36 - 40
0.82
0.88
0.91
0.82
0.88
0.91
41 - 45
0.71
0.82
0.87
0.71
0.82
0.87
46 - 50
0.58
0.75
0.82
0.58
0.75
0.82
51 - 55
0.41
0.67
0.76
0.41
0.67
0.76
25
Always On UPS Systems Inc
Table 4
(See rules 4-004, 8-104, 12-2212, 26-000, 26-742, 42-008, and 42-016 and Tables 5A, 5C, and D3)
Allowable Ampacities for Not More Than 3 Aluminum Conductors in Raceway or Cable
Based on Ambient Temperature of 30°C
Allowable Ampacity
60°C
75°
85-90°C
110°
125°
Size
AWG
kcmil
Types
TW
Types
RW75
TW75
Types
See
R90,RW90
Note
T90 NYLON
Paper
COPPER
15
25
25
35
30
45
55
60
65
80
75
95
95
105
105
125
120
150
145
170
165
195
185
215
215
250
12
10
8
6
4
3
2
1
0
0
0
0
250
15
25
30
40
55
65
75
85
100
115
130
155
170
15
25
30
50
65
75
90
100
120
135
155
180
205
300
190
230
240
275
305
350
210
250
260
310
335
400
225
270
290
335
360
500
260
310
330
380
405
600
285
340
370
425
440
700
310
375
395
455
485
750
320
385
405
470
500
800
330
395
415
485
520
900
355
425
455
1000
375
445
480
560
600
1250
405
485
530
1500
435
520
580
1750
455
545
615
2000
Col.1
470
Col.2
560
Col.3
650
Col.4
200°
See
Note
See
Note
30
40
50
65
90
100
115
135
160
180
210
245
270
30
45
55
75
95
115
130
150
180
200
225
270
650
705
Col.5
Col.6
Col.7
26
Always On UPS Systems Inc
Table 5A
(See rules 4-004(8), 12-2212, and Tables 1,2,3,4,57,58, and D3)
Correction Factors Applying to Tables 1,2,3, and 4
Ampacity Correction Factors for Ambient Temperatures Above 30°C
(These correction factors apply, column for column, to Tables 1,2,3, and 4. The correction factors in column 2 also
apply to Table 57.)
Ambient
Temperature °C
40
45
50
55
60
70
75
80
90
100
120
140
Col.1
60°C
75°
60°C
Types
TW
75°C
Types
RW75
TW75
0.82
0.71
0.58
0.41
0.88
0.82
0.75
0.65
0.58
0.35
Col.2
Col.3
Correction Factor
85-90°C
110°
125°
200°
85-90°C
Types
R90,RW90
T90 NYLON
Paper
0.90
0.85
0.80
0.74
0.67
0.52
0.43
0.30
110°C
See
Note(2)
125°C
See
Note(2)
200°C
See
Note(2)
0.94
0.90
0.87
0.83
0.79
0.71
0.66
0.61
0.50
0.95
0.92
0.89
0.86
0.83
0.76
0.72
0.69
0.61
0.51
Col.4
Col.5
Col.6
1.00
1.00
1.00
1.00
0.91
0.87
0.86
0.84
0.80
0.77
0.69
0.59
Col.7
NOTES:
(1) The ampacity of a given conductor type at these higher ambient
temperatures is obtained by multiplying the appropriate value from Table 1,2,3,
or 4 by the correction factor for that higher temperature.
(2) These ampacities are only applicable under special circumstances where the use
of insulated conductors having this temperature rating are acceptable.
27
Always On UPS Systems Inc
6.6.3
FUSE RATING & CABLE SIZE FOR BATTERY BANKS
Table 6.6.3.1 Recommended Fuse and Cable Size for the Battery Banks
KVA Rating
Imax(A)
FUSE(A)
CABLE(mm²)
10
60
70
22
15
60
70
22
20
60
70
22
30
90
100
38
40
120
125
38
50
150
175
50
60
180
200
80
80
240
125*2
38*2
100
300
175*2
50*2
120
360
200*2
80*2
160
480
200*2
80*2
240
720
200*4
80*4
320
960
200*4
80*4
*THE BATTERY VOLTAGE IS 295 – 410V
**LEAD ACID BATTERY – 174 CELLS
CABLE (AWG)
#6
#6
#6
#3
#2
0
00
#2
0
00
00
00
00
28
Always On UPS Systems Inc
6.7
Terminal Connection
Different models of UPS’s may have different cable connection terminals.
terminal configurations fall into one of the following types:
RR
RS
RT
IN
RESERVE
INPUT
IR
IS
IT
OR
RECTIFIER
INPUT
OS
OT
ON
UPS
OUTPUT
UPS connection
B+
B-
BATTERY
INPUT
3 PHASE INPUT / 3 PHASE OUTPUT
TERMINAL WITH TWO SOURCE
IN
IR
IS
IT
RECTIFIER & RESERVE
INPUT
OR
OS
OT
ON
UPS
OUTPUT
B+
B-
BATTERY
INPUT
3 PHASE INPUT / 3 PHASE OUTPUT
TERMINAL WITH SINGLE SOURCE
Figure 6.7.1
Terminal Strip Layout for Dual in Single input UPS systems
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7
FRONT PANEL
A
B
C
R
Q
P
D
E F
G
H
I
J K L
M
N
O
Figure 7.1
Front Panel Display
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The front panel is located behind the glass window on the front of the UPS system. It displays
the real time information and status of the UPS and battery system. It also provides for user
interface for controlling and setting the UPS operating status. This panel also allows the user to
operate and monitor the system with ease. The panel is explained below:
A: LCD display- Real time status, data and historical events are displayed on the LCD. The
UPS parameters, real time clock, inverter, and buzzer can also be set through
this LCD. The LCD is back lit by LED’s for a sharper display, but in order to
lengthen the LED’s life time, the LED will automatically shut off 3 minutes
after a key has been pressed, and will light up again when one of the
up/down/enter keys are pushed.
B: Warning LED’s-When an abnormal condition occurs, these LED’s will illuminate allowing
the user to identify the fault. This will also allow the service personnel the
ability to troubleshoot the system. These LED’s are described below:
•
•
•
•
•
•
•
•
RECT AC FAIL – when the supply to the rectifier is outside of the operating
parameters. This not only applies to voltage range but also when phase
rotation is incorrect or the rectifier has been shutdown (refer to C: Status
LED’s).
RESERVE FAIL – supply to the reserve is outside of the operating
parameters. Supply voltage or frequency out of range (refer to C: Status
LED’s).
FUSE/TEMP – inverter has shutdown due to inverter fuse open or heat sink
temperature above operating parameters.
OVERLOAD – an overload condition has occurred on the output.
HIGH DC – this LED will be lit as long as the DC voltage exceeds
430VDC.
BAT LOW – this LED will be lit as long as the DC voltage is lower than
320VDC.
BAT LOW STOP – the LED will be lit as long as the DC voltage is lower
than 295VDC. The inverter will not activate until the DC voltage is above
this level.
FAULT – the inverter has shutdown because an abnormal condition has
occurred. Possible conditions include overload, short circuit, high DC
shutdown, fuse/over temperature, bypass breaker on or emergency stop (refer
to C: Status LED’s).
C: Status LED’s- 24 LED’s represent the real-time information regarding the status of the UPS
system. These LED’s will aid in diagnosing and trouble shooting abnormal
conditions. The 24 LED’s represent the following:
•
•
•
•
INVERTER ON – inverter is running.
INVERTER SS – inverter static switch is active.
SHORT CIRCUIT – UPS output is in a short circuit state.
FUSE/OVER TEMP SD – inverter has shutdown due to inverter fuse open
or heat sink temperature above operating parameters.
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•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
INVERTER FAIL SHUTDOWN – inverter has shutdown due to inverter
output voltage below tolerances.
BYPASS ON SHUTDOWN – inverter has shutdown because the bypass
breaker has been activated while the inverter is supplying power to the load.
HIGH DC SHUTDOWN – inverter has shutdown because the DC Bus
voltage is outside of operating parameters while the inverter is operating.
OVERLOAD SHUTDOWN – inverter has shutdown because an overload
condition has been detected on the output. The inverter will automatically
restart after the condition has been removed for a period of seven seconds.
70% LOAD – load connected to the output is over 70% of the UPS rating.
110% LOAD - load connected to the output is over 110% of the UPS rating.
125% LOAD - load connected to the output is over 125% of the UPS rating.
150% LOAD - load connected to the output is over 150% of the UPS rating.
RESERVE AC FAIL – supply voltage to the Reserve is outside of operating
window.
RESERVE FREQ FAIL – supply frequency to the Reserve is outside of
operating window.
BATTERY LOW – the DC bus (or battery) voltage is lower than 320VDC.
Low battery shutdown is approaching.
BATTERY LOW SHUTDOWN – the inverter has shutdown because the
DC bus (or battery) voltage is below operating level (lower than 295VDC).
RECT AC FAIL – supply to rectifier is outside of operating window.
ROTATION ERROR – supply phase rotation is outside of operating
window.
RECTIFIER SHUTDOWN – the rectifier has shutdown because the DC
bus voltage has exceeded maximum operating level (over 445VDC). The
rectifier will automatically restart 30 seconds this abnormal condition has
been cleared.
HIGH DC – the DC voltage has exceeded maximum operating level (over
430VDC). The bus voltage is limited to this voltage.
BOOST CHARGE – the batteries are being boost charged by the rectifier.
BATTERY TEST – batteries are being tested.
EMERGENCY STOP – the inverter has shutdown because the emergency
stop switch has been activated.
DATA LINE – blinks when data is being transmitted or received via the
communication port.
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D: Buzzer outlet: There is a buzzer located behind the LCD Display. The buzzer will allow for
audile notification during an abnormal condition. The buzzer will be
activated under one of the following conditions: (The frequency of the
buzzer is also described for your reference.)
•
INVERTER IS OVERLOADED
•
BACK-UP
seconds
•
•
•
•
•
•
INVERTER IS SHORT CIRCUITED
FUSE BROKEN
HEAT SINK OVER TEMPERATURE
HIGH DC SHUTDOWN
BYPASS ON STOP
EMERGENCY STOP
>110%, beep once / 3 seconds
>125%, beep once / second
>150%, beep twice / second
>320VDC, beep once/ 3
<320VDC, beep twice / second
<295VDC, no beeping
beep continuously
beep continuously
beep continuously
beep continuously
beep continuously
beep continuously
The buzzer will beep once every time the inverter is switched on or off. This
will allow for the user to be sure the operation was preformed correctly.
E. Bypass LED: This LED is lit when the maintenance bypass breaker is closed leaving the
inverter in the off mode. If the inverter is active when the bypass breaker is
closed the inverter will shutdown immediately.
F. Reserve LED: This LED is lit when the reserve breaker is closed, and the supply is within
operating parameters.
G. Rectifier LED: This LED is lit when the rectifier is operating, the supply is within operating
parameters, the rectifier breaker is closed and the DC bus voltage is within
operating parameters.
H. Back-up LED: This LED is lit while the UPS is in back-up mode. This LED also indicates
the results of battery test. If the battery pack does not pass the test, this LED
will flash prompting the user to change the battery pack.
I. Inverter LED: This LED is lit when the inverter is supplying power to the load.
J. Inverter SS LED: This LED is lit when the inverter static switch is operating and the reserve
static switch is turned off. When this LED is on, the load is supplied from the
inverter. Usually this LED will stay lit for 7sec. after the inverter is switched
on.
K. Reserve SS LED: This LED is lit when the reserve static switch is operating and the inverter
static switch is turned off. When this LED is on, the load is being supplied
by the reserve. Since the reserve static switch and inverter static switch will
never operate simultaneously, the Inverter SS LED and the Reserve SS LED
will never be lit at the same time.
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L. Output LED: This LED is lit when there is AC power present at the output terminals.
M. Up key:
This is an LCD control key. It moves the cursor one field upward when items
are being selected or changes the number/character forward when data or
parameters of the UPS are being set.
N. Down key:
This is an LCD control key. It moves the cursor one field downward when
items are being selected or changes the number/character backward when
data or parameters of the UPS are being set.
O. Enter key:
This is an LCD control key. It returns to the previous page, and also confirms
the number/character/item selected.
P. Inverter “On“ switch: This is an inverter control switch. When this switch is pushed
simultaneously with the control key, the inverter will switch on.
Q. Inverter “Control” switch:
This is an inverter control switch. When this switch is
pushed in conjunction with the inverter “On” switch the inverter will
activate. Similarly, when this switch is pushed with the inverter “Off” switch
the inverter will shutdown. This switch acts as a safety switch to prevent
accidental operation of the inverter.
R. Inverter Off switch: This is an inverter control switch. When this switch is pushed
simultaneously with the control switch the inverter will be turned off.
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8
OPERATION
After all the cables have been connected and power is present at the input terminal, the UPS is
ready to operate. Before initial start-up, re-check the following:
a.
b.
c.
d.
e.
8.1
Make certain there is no foreign material left on, inside or around the UPS
Ensure all breakers and the battery disconnect switches are opened
Ensure all loads are switched off.
Check that the input frequency matches the UPS’s rated input frequency
Check that the input voltage matches the UPS’s rated input voltage
Switch On Procedure (Authorized Trained Personnel ONLY)
These start-up procedures can be preformed with the AC utility source connected to or with
only the batteries connected.
a. Close the reserve breaker – The reserve and output LED on the status panel will light up,
indicating the reserve static switch loop is energized and there is power on the output
terminals. The power supplies within the UPS will energize and the internal fans will rotate.
b. Close the rectifier breaker - The rectifier will automatically start if the AC utility power
connected is within operating parameters. The DC voltage will slowly rise (15 – 30 sec.)
until the designated voltage is reached. The DC voltage is now ready for the inverter and
battery bank.
c. Close the battery fuse holder - A fuse holder between the battery to the DC bus is used for
safety purposes. The batteries will start charging once the fuse door or breaker is closed.
This fuse holder can be located within the UPS system or within the battery cabinets
depending on rating.
d. Push inverter on switch – To turn on the inverter simultaneously press the inverter on switch
(?) and the control switch (? ? ). The inverter will begin to function with inverter output
within 4 sec. The load will automatically transfer to the inverter 3 sec. later. The UPS is now
operating in normal mode.
e. Check the status panel for correctness as shown in the diagram on the next page. All
warning LED’s on the right hand side are off, two LED’s: ‘INVERTER ON’ and
‘INVERTER SS’ on the left hand side should be lit, and the LED’s circle should also be lit.
If the load is over 70%, the ‘70% LOAD’ LED will also be lit.
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Figure 8.1.1
Status Panel Display Under Normal Operation
Circles represent LED’s that are on.
8.2
Shutdown Procedure
To completely shutdown the UPS, please follow the following steps.
a. Switch off the inverter – The inverter can be switched off by simultaneously pressing the
inverter off switch (O) and the inverter control switch (? ? ). The load will be automatically
transferred to reserve without interruption.
b. Open the battery fuse holder – This will disconnect the batteries from the DC bus and the
UPS no longer has back up available. This fuse holder can be located within the UPS system
or within the battery cabinets.
c. Open the rectifier breaker – Opening the rectifier breaker will remove the power source
from the DC bus. The DC bus will start to drop slowly until it reaches a save level of
approximately 20VDC.
WARNING!
Completing the next step will turn off the power to the loads.
Make sure all loads have been turned off before proceeding or the external wrap-around
bypass has been initiated.
d. Open the reserve breaker – Before opening the reserve breaker you must make sure there is
no critical load connected to the UPS that requires power. NO OUTPUT POWER WILL BE
SUPPLIED FROM THE UPS ONCE THE RESERVE (UTILITY) BREAKER IS
OPENED.
e. Now that all power has been cut off within the UPS system. All LED’s, displays and fans
should be off.
CAUTION!
Terminal strip and breakers may still be energized if the main input breaker feeding the UPS
system is not turned off or open.
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8.3
From Inverter To Manual (Maintenance) Bypass Procedure
The following procedures will allow the service personnel to switch the UPS system to
maintenance bypass mode without interrupting the output power to the loads.
a. Switch off the inverter – The inverter can be switched off by simultaneously pressing the
inverter off switch (O) and the inverter control switch (? ? ). The load will be automatically
transferred to reserve (utility) supply without interruption.
b. Open the battery fuse holder – This will disconnect the batteries from the DC bus and the
UPS no longer has back up available. This fuse holder can be located within the UPS system
or within the battery cabinets.
c. Open the rectifier breaker – Opening the rectifier breaker will take the power source away
from the DC bus, therefore, the DC bus will start to drop slowly. After 5 min., the DC bus
will drop to a safe level (approx. 20VDC).
d. Close the bypass breaker – The reserve breaker and reserve static switch are still
conducting. When the maintenance bypass breaker is closed, power will flow through the
bypass loop instead of the reserve loop because the impedance of the bypass loop is lower.
e. Open the reserve breaker – You can now open the reserve breaker to cut off any power
within the UPS electronics.
The system is now in Maintenance Bypass mode. Power will be present at the input terminal
and extreme caution must be used.
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8.4
From Manual Bypass To Inverter Procedure
After the maintenance procedures and testing are complete you will need to restore the UPS
back to its normal mode of operation without interrupting the power to the loads.
The following procedures need to be followed.
a. Close the reserve breaker – The reserve and output LED on the status panel will light up,
indicating the reserve static switch loop is energized and there is power on the output
terminals. The power supplies within the UPS will also energized and the internal fans will
rotate.
b. Open the bypass breaker – The inverter cannot be switched on when the maintenance
bypass breaker is closed (because the CPU will sense the breaker and prevent the inverter
from connecting directly to the AC source). The reserve breaker is already closed so power
goes through the reserve loop if the bypass breaker is open. AC power at the output will not
be interrupted.
c. Close the rectifier breaker - The rectifier initiates automatically if the AC utility power
connected is with in operating parameters. The DC voltage will slowly rise (15 – 30 sec.)
until the designated voltage is reached. The DC voltage is now ready for the inverter and
battery cabinets.
f. Close the battery fuse holder - A fuse holder is employed from the battery to the DC bus for
safety purposes. The batteries will start charging once the fuse door or breaker is closed.
This fuse holder can be located within the UPS system or within the battery cabinets.
g. Push inverter on switch – To turn on the inverter simultaneously press the inverter on switch
(?) and the control switch (? ? ). The inverter will start working and the inverter output will
be established in 4 sec. The load will automatically transfer to the inverter 3 sec. later. The
UPS is now operating in normal mode.
d. Check the status panel is correct, as shown in the diagram on the previous page. All warning
LED’s on the right hand side are off, two LED’s: ‘INVERTER ON’ and ‘INVERTER SS’ on
the left hand side should be lit, and the LED’s circle should also be lit. If the load is over
70%, the ‘70% LOAD’ LED will also be lit.
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Always On UPS Systems Inc
9
THE LCD DISPLAY
The LCD displays Real Time information as to the status and operation characteristics of the
UPS system and battery banks. In order to make the display sharp and readable, the LCD is
back-lit by LED’s. To prolong the life of the LED, the CPU will cut off the power of the LED 3
minutes after the last key has been pressed. The backlight will illuminate whenever a key has
been pressed. This screen will pop up once the system power is enabled (i.e. the default screen).
9.1
Menu 0 – Main Menu
WE L C O M E T O A L W A Y S O N U P S S Y S T E M S I N C
MO DE L : NX - S E RI E S S / N: 3 4 5 6 7 8 9 0 I D: 0 1
5 0 K V A I : 1 2 0 2 0 8 V 6 0 H Z O: 1 2 0 2 0 8 V 6 0 H Z
20 02 02 0 1
TUE
08 : 0 0 AM
Figure 9.1.1
Main Menu Display
The first row will display the greeting content set by the factory. The model no. (MODEL),
serial no. (S/N), and the identification no. (ID) are displayed in the second row. The third row
will display the kVA rating, input rating and output rating of the UPS.
The serial no. is set by the factory for the convenience of maintenance personnel who may need
to refer to the serial number for the correct spare parts and testing procedures. The identification
no. is set only when multiple UPS systems are connected in parallel. Each UPS must have a
unique number to identify itself, and will be set by a factory trained technician after installation.
The YEAR/MONTH/DATE, DAY OF THE WEEK, HOUR, MINUTE and AM/PM from the
real time clock inside the UPS are displayed in the fourth row for user’s reference and for
stamping the date and time in the historical data when an abnormal conditions occurs. By
pressing one of the UP(↑), DOWN(↓) or ENTER(↵) keys, the LCD will change to another
screen.
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9.2
Menu 1 – Select Menu
S E L E C T
S T A T U S
R E A L
WA R N I N G
T I ME
H I S T O R I C A L
F A U L T
ME N U
P A R A ME T E R
S E T
D A T A
D A T A
E X I T
Figure 9.2.1
Select Menu Display
MENU 1 is reached by pressing any button on the opening screen and is also the default menu.
From this menu the personnel can select STATUS WARNING FAULT (MENU 2 – Section 10.3),
REAL TIME DATA (MENU 3 – Section 10.4), HISTORICAL DATA (MENU 4 – Section 10.5)
and PARAMETER SET (MENU 5 – Section 10.6). To select an option move the cursor (→) by
pressing the UP (↑) key, or the DOWN(↓) key. Selections are confirmed by pressing the ENTER
(↵) key. The user will be sent to the menu the cursor is pointing to. If the item ‘PARAMETER
SET’ is selected, the LCD will jump into a screen that will prompt the user for a password. See the
figure below.
P A S S WO R D : 1 2 3 4
Figure 9.2.1
Password Menu Display
The numbers are changed by pressing the UP (↑) or the DOWN(↓) key respectively and is
confirmed by the ENTER(↵) key. When the four-digit password has been entered successfully
you will proceed to the selected area. If the password has been entered incorrectly three times
the display will revert to the default menu (MENU 0).
The password for entering the < PARAMETER SET > menu is 1-2-3-4. To change the
password, please review MENU 12 (Section 10.13).
To return to MENU 0 select the ‘EXIT’ option (blinking instead of pointed by cursor).
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9.3
Menu 2 – Status Warning Menu
S T A T US
WA R N I N G
R E CT I F I E R = O N
I N V E RT E R= ON
L O A D
O N
I NV E RT E R
Figure 9.3.1
Status Warning Menu Display
The Status/Warning menu is accessed through MENU 1 by selecting STATUS WARNING
FAULT. The left-hand side of this menu shows the real time status of the rectifier, inverter and
static switch, while the right hand side shows the warning or fault condition if any. Under
normal condition, the LCD display should be exactly the same as the figure shown above. When
abnormal conditions occur it will be shown under the title < WARNING >, but this will be
overridden by a “fault” message if more serious abnormal conditions occur and the title <
WARNING > will then change to < FAULT >.
For example, if a short circuit has occurred, this screen will display as follows:
S T A T U S
R E C T I F I E R = O N
F A U L T
S H O R T
C I R C U I T
I N V E R T E R = O F F
L OA D
O N
I N V E R T E R
Figure 9.3.2
Warning Status Display with Fault Condition
The inverter will automatically shut off under a short circuit fault. The CPU is designed to
detect short circuits and in order to avoid unnecessary tripping of the reserve (utility supply)
breaker, the static switch will remain open or inactive. (There will be no output power present)
Listed below are all the warning conditions that can be displayed (they are arranged in order of
priority, starting with the highest priority):
1st row:
BYPASS ON – Output is being supplied by the reserve
RECT AC FAIL – AC utility source failure
RECTIFIER PHASE ERROR – AC utility phase loss or one phase out of operating
parameters
RESERVE FREQ. ERROR – AC utility frequency is out of parameters and reserve
has been disabled until error is corrected
2nd row:
170% OVERLOAD – over 170% maximum capacity for the UPS system.
150% OVERLOAD – over 150% maximum capacity for the UPS system.
125% OVERLOAD – over 125% maximum capacity for the UPS system.
110% OVERLOAD – over 110% maximum capacity for the UPS system.
3rd row:
BATTERY LOW STOP – Battery have been exhausted.
BATTERY LOW – Batteries have passed the low voltage level and will soon be
exhausted.
BATTERY BAD – One or more cells have tested faulty.
BATTERY GND FAULT – Battery cabinet not grounded properly.
BATTERY TESTING – performing test on the batteries.
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Listed below are all the fault conditions that can be displayed:
1st row:
HIGH DC SHUTDOWN – DC Bus voltage out of operating range.
2nd row:
SHORT CIRCUIT! – a short circuit condition has occurred on the output.
FUSE/OVERHEAT – a fuse has blown or the system has shutdown due to
overheating.
OVERLOAD SHUTDOWN – system has exceeded the overload limit beyond the
operating window.
EMERGENCY STOP – user has activated the emergency stop feature.
INVERTER ABNORMAL – inverter is not operating within specified parameters.
3rd row:
BYPASS ON SHUTDOWN – inverter failure, system operating in bypass mode.
The UP (↑) or DOWN (↓) key has no function in this menu. The screen will go back to MENU
1, when ENTER(↵) is pressed.
9.4
Menu 3 – Real Time Data Menu
RE A L
R E CT I F I E R
R E S E RV E
O U T P UT
D A T A
T I ME
DA T A
O T HE R
D A T A
D A T A
DA T A
E X I T
Figure 9.4.1
Real Time Data Menu Display
MENU 3 is reached by selecting REAL TIME DATA on MENU 1. The cursor(? ) is used to select
what type of real time data the user would like to view, RECTIFIER DATA (MENU 6 – Section
10.7), RESERVE DATA (MENU 7 – Section 10.8), OUTPUT DATA (MENU 8 – Section 10.9)
and OTHER DATA (MENU 9 – Section 10.10). To select one of the different menu options move
the cursor(→) until it is pointing at the correct selection, by press the UP (↑) key or the DOWN (↓)
key. To confirm and select the menu option press the ENTER (↵) key.
Selecting the ‘EXIT’ option (blinking instead of pointed by cursor) will return you to MENU 1.
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9.5
Menu 4 – Historical Event Menu
DAT
20 0 2\ 03
20 0 2\ 11
20 0 3\ 03
E T I ME E
\ 29
09 :
\ 01
22 :
\ 10
15 :
VE NT S
32
15
47
>
R U N : 2 1 Y R 0 3 MO
Figure 9.5.1
Historical Event Menu Display
MENU 4 is reached by selecting HISTORICAL DATA on MENU 1. All abnormal events are
stored on the EEPROM and viewed through this menu based on the time each event occurred.
The record display starts with the date and time stamp allowing the user or maintenance
personnel to trace back that occurrence. A maximum of 77 records can be stored in one
EEPROM. This can be increased to 154 records with the addition of a second EEPROM. These
records are hard coded onto the EEPROM and will not be erased by cutting off the power
supply or during a complete shutdown of the UPS, i.e. they will be kept in the EEPROM
forever until they’re overwritten by the 78th (or the 155th ) events.
The three most recent records are displayed at one time on the view screen. The displayed
records will move one record upward when the UP (↑) key is pressed, and move one record
downward when the DOWN (↓) key is pressed.
Below is a list of the abnormal conditions that are stored and can be displayed:
HIGH DC SHUTDOWN / SHORT CIRCUIT! / FUSE/OVERHEAT / OVERLOAD SHUTDOWN
/ EMERGENCY STOP / INVERTER ABNORMAL / BYPASS ON SHUTDOWN
The display in the top right corner of the screen is the UPS installation time displayed in
year/month. This information is provided to allow the user or the maintenance personnel to have
a reference point to schedule the next preventative maintenance visit.
To return to MENU 1 press the ENTER (↵) key.
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Always On UPS Systems Inc
9.6
Menu 5 – Parameter Setting Menu
P A R A ME T E R
I N V E R T E R = ON / OF F
S E T T I N G
D A T E
T I ME
B U Z Z E R = O N / O F F
B O OS T
C H A R G E
E X I T
Figure 9.6.1
Parameter Setting Menu Display
MENU 5 is reached by selecting PARAMETER SET on MENU 1 and access is only allowed if
the correct password is entered. The cursor (→) is used to select which parameter the user
would like to edit, such as INVERTER ON/OFF, BUZZER ON/OFF, BOOST CHARGE,
DATE/TIME. To select one of the different menu options move the cursor(→) until it is
pointing at the correct selection, by press the UP (↑) key or the DOWN (↓) key. To confirm and
select the menu option press the ENTER (↵) key.
The INVERTER ON/OFF option allows the user to activate or deactivate the inverter. When
selected the blinking display (ON or OFF) indicates the current status of the inverter. To change
the state of the inverter press the UP (↑) or the DOWN (↓) key and confirm selection by
pressing the ENTER (↵) key. ‘INVERTER = ON’ will be displayed if ‘ON’ is selected or
‘INVERTER = OFF’ will be displayed if ‘OFF’ is selected.
To control the state of the buzzer select the BUZZER ON/OFF option. Again the current status
of the buzzer is indicated by the blinking ON or OFF. To change the state of the buzzer press the
UP (↑) or the DOWN (↓) key and confirm selection by pressing the ENTER (↵) key. ‘BUZZER
= ON’ will be displayed if ‘ON’ is selected or ‘BUZZER = OFF’ will be displayed if ‘OFF’ is
selected.
Selecting the BOOST CHARGE option will bring you to MENU 10 (Section 10.11).
Selecting the DATE/TIME option will bring you to MENU 11 (Section 10.12).
Selecting the ‘EXIT’ option (blinking instead of pointed by cursor) will return you to MENU 1.
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Always On UPS Systems Inc
RE CT I F I E R
R E CT I F I E R
R - N= X X X
V a c
DA T A
>
F R E Q UE N CY = X X
S - N = X X X
V a c
H Z
T - N = X X X
V a c
Figure 9.7.1
Rectifier Data Menu Display
9.7
Menu 6 – Rectifier Data Menu
MENU 6 is reached by selecting RECTIFIER DATA on MENU 3. The information provided on
this menu is the real time readings of the rectifier input; RECTIFIER FREQUENCY, R-N/SN/T-N VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R VOLTAGE on delta (? )
configured systems.
The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3
when the ENTER (↵) key is pressed.
9.8
Menu 7 – Reserve Data Menu
<
RE S E R V E
R- N = X X X
V a c
RE S E R V E
D A T A
F R E Q U E N C Y = X X
S - N = X X X
V a c
>
H Z
T - N = X X X
V a c
Figure 9.8.1
Reserve Data Menu Display
MENU 7 is reached by selecting RESERVE DATA on MENU 3. The information provided on
this menu is the real time readings of the reserve input; RESERVE FREQUENCY, R-N/S-N/TN VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R VOLTAGE on delta (? )
configured systems.
The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3
when the ENTER (↵) key is pressed.
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Always On UPS Systems Inc
9.9
Menu 8 – Output Data Menu
O UT P UT
O UT P UT
L O A D : R = X X X
R - N= X X X
V a c
D A T A
F R E Q UE N CY = X X
%
S = X X X
S - N = X X X
%
V a c
H Z
T = X X X
%
T - N = X X X
V a c
Figure 9.9.1
Output Data Menu Display
MENU 8 is reached by selecting OUTPUT DATA on MENU 3. The information provided on
this menu is the real time readings of the inverter or reserve output (depending on what mode
the system is in); OUTPUT FREQUENCY, LOAD % OF R/S/T, OUTPUT R-N/S-N/T-N
VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R VOLTAGE on delta (? )
configured systems.
The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3
when the ENTER (↵) key is pressed.
9.10
Menu 9 – Other Data Menu
O T H E R
D A T A
T E MP E R A T U R E = X X
C
D C
V d c
V O L T A GE = X X X
C H A R G E
C U R R E N T = X X X A
Figure 9.10.1
Other Data Menu Display
MENU 9 is reached by selecting OTHER DATA on MENU 3. The information provided on this
menu is the real time readings of the UPS system; TEMPERATURE, DC VOLTAGE,
CHARGE OR DISCHARGE CURRENT.
When the UPS system is operating in normal mode the last line on MENU 9 will read
CHARGE CURRENT and will represent the amount of current being supplied to the batteries.
When the system changes to back-up mode the last line will change to DISCHARGE
CURRENT displaying how much current is being supplied to the inverter from the batteries
(figure below).
O T H E R
D A T A
T E MP E R A T U R E = X X
C
D C
V d c
V O L T A GE = X X X
D I S C H A R G E
C U R R E N T = X X X A
Figure 9.10.2
Other Data Menu Display when system in Back-up
Mode
The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3
when the ENTER (↵) key is pressed.
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Always On UPS Systems Inc
9.11
Menu 10 – Boost Charge Setting Menu
Warning!
These settings have been preset by the factory to optimize the battery bank requirements. Do
not change settings unless factory or factory trained service personnel have been consulted.
B O O S T
C H A R GE
S E T T I NG
A U T O - B O OS T ( MON T H ) = 0 4
A U T O - B O OS T ( B A T T
C H A R GE
L O W) = 0 8
CU RR E NT = L O
E X I T
Figure 9.11.1
Boost Charge Setting Menu Display
MENU 10 is reached by selecting BOOST CHARGE on MENU 5. This option allows the
maintenance personnel to select the amount of boost charge required to maintain the batteries at
their optimal performance.
Move the cursor (→) up or down (UP (↑) and DOWN (↓) key respectively) and select the option by
pressing the ENTER (↵) key.
B O OS T
C H A R G E
A U T O - B OO S T ( MO N T H ) = 0 4
A U T O - B OO S T ( B A T T
C H A R GE
S E T T I N G
0 8
1 2
1 6
2 0
2 4
L O W) = 0 4
C U R R E N T = L O
E X I T
Figure 9.11.2
Boost Charge Setting Menu Display Program Settings
AUTO-BOOST (MONTH) controls the number of hours that the system will be boost charged
every month. This boost charging conditions the batteries and increases the life expectancy of
the batteries.
Warning!
These are preset options by the factory. DO NOT CHANGE without consulting factory.
AUTO-BOOST (BATT LOW) controls the number of hours that the system will be boost
charged after the system has reached a low battery condition. This boost charging recharges the
batteries at a faster rate and will improve the conditioning of the batteries.
Both of the above AUTO-BOOST selections have six options for recharge rate (04, 08, 12, 16,
20 and 24) the numbers represent the number of hours the system will perform the boost charge
for. The option is selected by the number of battery bank, the number of cells per battery bank
and the type of batteries used within the battery bank. The factory set value will be display or
will flash if the option has been selected. To select a different option use the UP (↑) or the
DOWN (↓) key to select the time and press the ENTER (↵) key to confirm.
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Always On UPS Systems Inc
B O O S T
C H A R G E
S E T T I N G
A U T O - B O O S T ( MO N T H ) = 0 4
A U T O - B O O S T ( B A T T
C H A R G E
L O W) = 0 4
0 8
1 2
1 6
2 0
C U R R E N T = L O
2 4
E X I T
Figure 9.11.3
Boost Charge Setting Menu Display Program Settings
CHARGE CURRENT increases the amount of charge current the rectifier/charge supplies the
battery bank. There are three possible options (LO/ME/HI). The factory will set the system at the
optimal charge level for the battery bank provided. To change the level of charge select the
CHARGE CURRENT option then select the level of charge via the UP (↑) and DOWN (↓) keys.
Once the level of charge has been selected confirm with the ENTER (↵) key.
The CHARGE CURRENT can be roughly selected by the simple rule listed below:
CHARGE CURRENT SETTING
10 – 30 min battery back-up
LOW
30 min – 1 hour battery back-up
MEDIUM
> 1 hour battery back-up
HIGH
Selecting the ‘EXIT’ option (blinking instead of pointed by cursor) will return you to MENU 5.
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9.12
Menu 11 – Data Time Setting Menu
D A T E
T I ME
S E T T I N G
Y E A R =X X X X
H O U R ( 2 4 H ) = X X
MON T H = X X
MI N U T E = X X
D A Y = X X
D A Y
O F
T H E
WE E K = M O N
E X I T
Figure 9.12.1
Data Time Setting Menu Display
MENU 11 is reached by selecting DATE/TIME on MENU 5.
This menu allows the user to set the YEAR, MONTH, DAY, HOUR, MINUTE and DAY OF THE
WEEK of the real time clock. The display upon selection is the current time and day (factory
preset). To change any to the variables move the cursor (→) to the correct variable by pressing the
UP (↑) and DOWN (↓) key, the ENTER (↵) key will confirm the selection.
Below is a list of the available variables:
•
•
•
•
•
•
YEAR : 1998 – 2097
MONTH : 01-12
DAY : 01 – 31(internal calendar will correct it if 31 is entered to a 30day month)
HOUR : 0 – 23
MINUTE : 0 - 59
DAY OF THE WEEK : MON, TUE, WED, THU, FRI, SAT, SUN
The values (selected value is flashing) are increased by the UP (↑) key, and can be decreased by
the DOWN (↓) key and confirmed by the ENTER (↵) key.
If ‘EXIT’ is selected (blinking instead of pointed by cursor), the screen will go back to the
MENU 5- the PARAMETER SETTING menu.
9.13
Menu 12 – Other Setting Menu
OT HE R
SET T I NG
TI TL E:
A L WA Y S
O N UP S S Y S T E MS GE S - x x x N X 3 3
MO D E L : 5 0 3 3 A
SI N: 1 2 3 4 5 6 7 8 9 0 I D: 0 0
Figure 9.13.1
Other Setting Menu Display
This menu is for factory use only and is password protected.
EXI T
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10
INTERFACE CONNECTIONS
All user interfaces are connected to or from PCB 3R, see the figure below.
Figure 10.1.1
3R PCB Layout
10.1
Dry Contacts
Eight, normally open, dry contact terminals are provided. Maximum rating is 16A/250VAC or
16A/30VDC.
Definitions:
•
INVON – Short whenever inverter is on, open when inverter is off.
•
OVL – Short whenever UPS is overloaded.
•
FAULT – Short when UPS encounters a fault condition such as high DC shutdown, short
circuit, fuse/overheat, overload shutdown, emergency stop, inverter abnormal, and bypass
on shutdown. The contact is latched until it is manually reset (off switch) or the fault has
been cleared for 30 seconds.
•
SS – Short when the inverter is supplying output power, open when reserve is supplying
output power (The two output will never conduct simultaneously).
•
BYPASS – Short when the maintenance bypass breaker is closed, open when the breaker is
opened.
•
BACK-UP – Short when the UPS system is in back-up mode (batteries supplying DC Bus).
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•
BATL – Short when low battery condition occurs and the batteries are about to be
exhausted.
•
COM – This contact is the OR result of the signals described above. That is, if any other
contact closes, this contact will close too. The signal to be read is selectable through SWR2.
See the figure below.
Figure 10.1.2
Dry Contact Layout
10.2
Software for PC Monitoring
The monitoring software allows for a server or workstation to monitor the UPS operation. When the
software is installed on a PC it can monitor 1-99 UPS’s connected in series via a DB9 connection.
The connector on the UPS side is RS-485 (for long distance transmission) therefore a RS-485 ó
RS-232 adapter (hardware) is required to modify the signal (not included with UPS system).
10.3
Emergency Power Off Connection
Two pairs of terminals (CNR 3) are provided to allow the user to shutdown the UPS system in
an emergency situation (e.g. fire, short circuit, etc.). A minimum of 10mA is needed for activate
the photo-coupler.
10.4
DB9 Connectors
Four RS-485 and one RS-232 are provided to communicate with more sophisticated optional
communication modules. Each connector is dedicated to one type of external module.
Below is a list of some of the optional features available:
Software for PC monitoring or SNMP (web monitoring) card
Battery Monitoring Module
Remote Control Panel
Transferring RS-485 into RS-232
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11
OPTIONS
This section provides a brief introduction to some of the options available for our NX Series
UPS system.
Warning!
Similar products from other manufacturers will not fit into our UPS systems.
The installation of any option requires professional settings and should only be preformed by
the factory or factory trained representatives.
11.1
Battery Cabinet
The battery cabinet is designed with the same size and look as the UPS for convenience of
installation and cosmetic value. Structural strength is enhanced to endure transportation.
Figure 11.1.1
Battery Cabinet Layout
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11.2
Battery Runtime Charts
Table 11.1.1 Battery Chart for 10 to 40kVA UPS Systems
Battery Runtime Chart
Model #
GES-103NX33
GES-203NX33
GES-303NX33
GES-403NX33
kVA
10
20
30
40
Runtime (hrs:min)
Full Load Half Load
Runtime (hrs:min)
Full Load
Half Load
Runtime (hrs:min)
Full Load
Half Load
Runtime (hrs:min)
Full Load
Half Load
Battery Cabinet
Dimensions (mm)
Weight (kg)
Order Code
Order Code
Order Code
Order Code
A cabinet
29 x 26ah
WxDxH
550 x 800 x 1600
420
B cabinet
58 x 26ah
550 x 800 x 1600
689
C cabinet
29 x 75ah
550 x 800 x 1600
906
E cabinet
29 x 100ah
550 x 800 x 1600
1,167
2* C cabinet
2 x (29 x 75ah)
2 * 550 x 800 x 1600
1,812
1:00
1:43
825433 67000
2:26
2:43
825433 67010
3:42
4:17
825433 67020
4:49
6:19
825433 67030
X
X
2* E cabinet
2 x (29 x 100ah)
2 * 550 x 800 x 1600
2,334
0:22
0:34
825433 67100
1:12
1:20
825433 67110
1:43
2:18
825433 67120
2:05
3:38
825433 67130
3:42
4:36
825433 67140
4:27
7:35
825433 67145
0:13
0:16
825433 67150
0:36
0:43
825433 67160
0:47
1:25
825433 67170
1:24
1:48
825433 67180
2:07
2:45
825433 67190
2:53
4:36
825433 67195
0:07
0:13
825433 67200
0:23
0:23
825433 67210
0:36
0:52
825433 67220
0:51
1:20
825433 67230
1:37
2:08
825433 67240
2:02
4:01
825433 67245
X
X
Note: X marks where the battery bank not recommended being connected to the UPS.
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Always On UPS Systems Inc
Table 11.1.2 Battery Chart for 50 to 120kVA UPS Systems
Model #
kVA
GES-503NX33
GES-603NX33
GES-803NX33
GES-1003NX33
GES-1203NX33
50
60
80
100
120
Battery Runtime Chart
Runtime (hrs:min)
Runtime (hrs:min)
Runtime (hrs:min)
Runtime (hrs:min)
Runtime (hrs:min)
Full Load Half Load Full Load Half Load Full Load Half Load Full Load Half Load Full Load Half Load
Battery Cabinet
Dimensions (mm) Weight (kg)
Order Code
Order Code
Order Code
Order Code
Order Code
WxDxH
B Cabinet
58 x 26ah
550 x 800 x 1600
689
0:13
0:16
0:07
0:09
0:04
0:09
X
0:07
X
X
825433 67250
825433 67300
825433 67350
C Cabinet
29 x 75ah
550 x 800 x 1600
906
0:27
0:39
0:18
0:27
0:13
0:16
0:07
0:11
0:05
0:12
825433 67260
825433 67310
825433 67360
825433 67400
825433 67450
E Cabinet
29 x 100ah
550 x 800 x 1600
1,167
0:39
0:57
0:28
0:46
0:18
0:34
0:13
0:23
0:09
0:16
825433 67270
825433 67320
825433 67370
825433 67410
825433 67460
2* C Cabinets 2 x (29 x 75ah) 2 * 550 x 800 x 1600
1,812
1:16
1:36
0:52
1:25
0:41
0:55
0:24
0:39
0:18
0:27
825433 67280
825433 67330
825433 67380
825433 67420
825433 67470
2* E Cabinets 2 x (29 x 100ah) 2 * 550 x 800 x 1600
2,334
1:43
2:18
1:05
1:45
0:56
1:32
0:37
0:57
0:28
0:46
825433 67290
825433 67340
825433 67390
825433 67430
825433 67480
Note: X marks where the battery bank not recommended being connected to the UPS.
Table 11.1.3 Battery Chart for 160kVA UPS System
Battery Runtime Chart
Battery Cabinet
Model #
kVA
GES-1603NX33
160
Runtime (hrs:min)
Full Load Half Load
Weight (kg)
Order Code
C Cabinet
29 x 75ah
Dimensions (mm)
WxDxH
550 x 800 x 1600
E Cabinet
29 x 100ah
550 x 800 x 1600
1,167
2* C Cabinets
2 x (29 x 75ah)
2 * 550 x 800 x 1600
1,812
2* E Cabinets 2 x (29 x 100ah) 2 * 550 x 800 x 1600
2,334
906
X
0:07
0:06
0:15
825433 67500
0:13
0:16
825433 67510
0:23
0:34
825433 67520
Note: X marks where the battery bank not recommended being connected to the UPS.
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Always On UPS Systems Inc
11.3
Emergency Stop Switch
This switch is used to immediately remove power from the load in the event of an emergency condition
e.g. electrical shock, burning of the load or water located around the UPS. When the emergency stop
button is pushed, the inverter will stop running immediately and the static switch does not activate.
There will be no AC supply at the output.
This shutdown condition is latched until a manual reset has been preformed. Manual reset is preformed
by pressing the inverter off switch (O) and the inverter control switch (tu) simultaneously. Once the
system is reset follow the Start-up procedure discussed earlier to turn the system back on.
11.4
Remote Display Panel
The remote panel is a display module with LCD and LED’s that can monitor 1 – 99 UPS’s via a DB9
connected in series from distance < 1000m. It allows for remote monitoring of the UPS status and
alarms .
11.5
Isolated Parallel Redundant Operation (IPRO)
Two or more UPS systems can be paralle led to improve the overall reliability of an UPS system. The outputs
of parallel units are connected to a common power bus, and in normal operation the units connected on the
parallel bus share the load equally. The modular design of NX Series allows parallel operation, without using
paralleling switchgear, external bypass circuits or common control circuitry.
The output power rating of the redundant paralleled systems must be equal to or greater than the power
required by the load in order to function properly. The output power will be equally divided among the
paralleled UPS system connected. Should one of the paralleled systems be shutdown or shutdown
unexpectedly, the remaining system will automatically assume the load, maintaining conditioned and
backed-up power to the critical load. This results in higher reliability, security of the loads, and a
substantially increased MTBF (Mean Time Between Failures).
11.6
Web Monitoring Module (SNMP Module)
Simple Network Management Protocol. The SNMP Card is an Interface to the Ethernet network, and
provides UPS information via the standard SNMP protocol. The UPS can therefore be managed via an
internet browser. This information can be used to determine the state of the UPS and guarantee safe and
orderly shutdown of servers and workstations when needed.
11.7
12-Pulse Rectifier
Located inside the UPS system cabinet. The 12-pulse rectifier is a standard feature for UPS systems
80kVA and above, but is optional for systems smaller than 80kVA. The 12-pulse rectifier is designed to
reduce the input harmonic distortion to less than 12%.
11.8
5th Harmonic Filter
Located inside the UPS system cabinet. This filter is designed to reduce the input harmonics from 12% to
9%. This will allow for less reflected harmonics from the UPS system to the utility.
11.9
External Wrap Around Bypass
A separate cabinet that allows for complete removal of the UPS system from the load, while still
supplying the load with conditioned power. Systems can include isolation transformer for different
voltage configurations, distribution panels and Kirk-Key interlock protection to ensure proper operation.
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12
TECHNICAL SPECIFICATION
12.1
NX Series – 10kVA to 60kVA UPS 3Ø Input - 3Ø Output
kVA Rating
RECTIFIER
Input Voltage
10
15
20
40
50
180-750V
Input Frequency
50 / 60 Hz +/- 7%
>1
33
42
66
99
132
165
198
45
62
83
125
160
200
250
6 PULSE : 30% ; 12 PULSE :15%
12 PULSE WITH FILTER : 9%
Current THD
Power Walk In (adjustable)
0% - 100% : 20 sec
Efficiency
99%
Voltage Regulation
1%
Ripple Voltage
0.5%
BATTERY
Battery Type
Maintenance free Sealed Lead Acid
No. Of Cells
174
Voltage Range
Maximum Charge
Current (ADC)
Battery Low
Voltage
Battery Low Stop
Voltage
60
208V/480V/600V 3 phase 3 and 4 wire + G
Input Range
Input Power Factor
Normal Input
Current(A) (Based on 208VAC)
Maximum Input
Current(A) (Based on 208VAC)
30
295 – 410VDC
10
15
20
25
30
320VDC
295VDC
Boost Charge
410VDC
Float Charge
396VDC
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Always On UPS Systems Inc
kVA Rating
10
15
20
INVERTER
DC Input Range
30
60
Sinusoidal
120/208V 277/480V 347/600V 3 Phase
4 Wire + G
3:1
0.8
Output Voltage (Adjustable)
Crest Factor
Output Power Factor
Voltage Regulation 100% Unbalance
Load
Frequency Lock Range
Output Frequency (Free Running)
Static
Load step 0% - 100% Output
0%
Voltage
Load step 0% - 50% Tolerance 0%
100% unbalanced load
(Ph-N)
Phase Shift Under 100% Unbalance
Load
+/-1%
45 – 55 Hz / 55 – 65 Hz
50 / 60 Hz + / - 0.1 Hz
+/- 1%
+/- 3%, recovering to within +/- 1% in 1 cycle
+/- 2%, recovering to within +/- 1% in 1 cycle
+/- 2.5%
120° + / - 0.5
THD (Linear Load)
<2%
- <110%
CONTINUOUS
- 110 – 125%
15 min
- 125 – 150%
10 min
- > 150%
60 sec
Efficiency (100% Load)
Maximum Output Wattage (kW)
STATIC SWITCH
Voltage Range
Frequency Range
Efficiency
- Mains -> Inverter
- Inverter -> Mains
- 100%
Overload
- 300%
Isolation With Output
Transfer Time
50
285 – 415VDC
Wave Form
Overload
40
93%
93%
93%
93%
93.5%
93.5%
94%
8
12
16
24
32
40
48
+- 20% of input voltage (Line to Neutral)
45 – 55 Hz / 55 – 65 Hz
99.5%
0 ms
0 ms
30 sec
1 sec
YES
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Always On UPS Systems Inc
kVA Rating
OVERALL CHARACTERISTICS
Overall Efficiency
10
15
20
30
40
50
60
91%
91%
91%
91%
91.5%
92%
92%
Operating Environment:
- Temperature
0 – 40°C (32 – 104°F)
- Humidity
0% - 90% (non–condensing)
- Altitude
<1500 m above sea level
Maximum Heat Dissipation(kW)
1.2
1.3
1.9
2.6
3
3.5
Weight(kg)
250
300
400
480
550
680
Dimension:
- HEIGHT(mm)
1600
- WIDTH(mm)
550
- DEPTH(mm)
800
- Audible Noise
< 65 dBA (AT 1 m)
Standards:
- cUL/UL
Yes
- CE
Yes
- EN50091-1,-2
Yes
- FCC Class A
Yes
Protections:
- Short Circuit
- Lightning
- EMC Filter
- Galvanic Isolation
Data Display By LCD
Rectifier, Reserve, Bypass NFB
MOV
Input & Output
Between Input & Output
Yes
Indications & Alarms:
- LED, LCD, Buzzer
Yes
Dry Contact
Yes
Battery Start
Yes
All specifications mentioned above are subject to change without prior notice.
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12.2
NX Series – 80kVA to 160kVA UPS 3Ø Input 3Ø Output
kVA Rating
80
100
120
160
RECTIFIER
Input Voltage
208V/480V/600V 3 phase 3 and 4 wire + G
Input Range
180-750V
Input Frequency
Input Power Factor
Normal Input Current(A)
Maximum Input Current(A)
50 / 60 Hz +/- 7%
>1
263
330
Current THD
Power Walk In (adjustable)
329
395
415
500
6 PULSE : 30% ; 12 PULSE :15%
12 PULSE WITH FILTER : 9%
0% - 100% : 20 sec
Efficiency
99%
Voltage Regulation
1%
Ripple Voltage
0.5%
BATTERY
Battery Type
Maintenance Free Sealed Lead Acid
No. Of Cells
174
Voltage Range
295 – 410VDC
Maximum Charge Current (ADC)
526
660
40
50
60
Battery Low Voltage
320VDC
Battery Low Stop Voltage
295VDC
Boost Charge
410VDC
Float Charge
396VDC
80
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Always On UPS Systems Inc
kVA Rating
80
INVERTER
DC Input Range
Output Voltage (adjustable)
Output Power Factor
Crest Factor
Voltage Regulation 100% Unbalance Load
Frequency Lock Range
Output Frequency (Free Running)
Phase Shift Under 100% Unbalance Load
Static
Output
Load step 0% - 100% - 0%
Voltage
Load step 0% - 50% - 0%
Tolerance
100% unbalanced load (Ph-N)
THD (Linear Load)
Continuous
- 110 – 125%
15 min
- 125 – 150%
5 min
- > 150%
30 sec
Efficiency (100% Load)
Maximum Output Wattage (kW)
STATIC SWITCH
Voltage Range
94.5%
64
94.5%
80
95%
96
95%
128
+/- 20% of input voltage (Line To Neutral)
Frequency Range
45 – 55 Hz / 55 – 65 Hz
Efficiency
Overload
160
Sinusoidal
120/208V, 277/480V or 347/600V
3 PHASE 4 WIRE + G
0.8
3:1
+/-1%
45 – 55 Hz / 55 – 65 Hz
50 / 60 Hz + / - 0.1 Hz
120° + / - 0.5°
+/- 1%
+/- 3%, recovering to within +/- 1% in 1 cycle
+/- 2%, recovering to within +/- 1% in 1 cycle
+/- 2.5%
<2%
- <110%
Transfer Time
120
285 - 415VDC
Waveform
Overload
100
99.5%
- Mains -> Inverter
0 ms
- Inverter -> Mains
0 ms
- 100%
30 sec
- 300%
1 sec
Isolation With Output
YES
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Always On UPS Systems Inc
kVA Rating
OVERALL CHARACTERISTICS
Overall Efficiency
80
100
120
160
92.5%
92.5%
93%
93%
Operating Environment:
- Temperature
0 - 40°C ( 32 - 96°F )
- Humidity
0% - 90% (non–condensing)
- Altitude
<1500 m above sea level
Maximum Heat Dissipation(kW)
4.6
5.4
6.5
8.7
Weight(kg)
820
950
1180
1450
Dimension:
- HEIGHT (mm)
1600
- WIDTH (mm)
1100
- DEPTH (mm)
800
- Audible Noise
< 65 dBA (AT 1 m)
Standards:
- cUL/UL
Yes
- CE
Yes
- EN50091-1,-2
Yes
- FCC Class A
Yes
Protections:
- Short Circuit
- Lightning
Rectifier, Reserve, Bypass NFB
MOV
- EMC Filter
- Galvanic Isolation
Data Display By LCD
Input & Output
Between Input & Output
Yes
Indications & Alarms:
- LED, LCD, Buzzer
Yes
- Dry Contact
Yes
- Battery Start
Yes
*All specifications mentioned above are subject to change without prior notice.
12.3
NX Series – 200kVA to 320kVA UPS 3Ø Input 3Ø Output
*NOTE: We are currently engineering the 200kVA to 320kVA series. They will be available
the first quarter of 2004.
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13
PREVENTATIVE MAINTENANCE FORM
Date of Installation:
Customer Name:
Company Name:
Address:
UPS Identification:
Model:
Serial Number:
UPS Rating:
Options:
Input Voltage:
Output Voltage:
Prepared By:
Date:
ATTENTION:
Before performing maintenance on the UPS system, record and complete the Front Panel
Status Report Log and Front Panel Meter Readings Forms.
Includes the following:
1. Maintenance Measurement Form
2. Front Panel Status Report Log
3. Front Panel Readings
4. Battery Maintenance Form
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13.1
Front Panel Status Report Log
Please complete this form during Preventative Maintenance Checks and any Fault Condition
periods.
Date:
Model:
Time:
Customer:
Serial Number:
Circle all LED’s that are illuminated before powering the unit down.
Warning Messages on LCD: (Record the past five events displayed on the LCD).
Complete Front Panel Reading Form.
Please have these forms available when consulting the factories Service Center.
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13.2
Front Panel Readings
Date:
Model:
Time:
Customer:
Serial Number:
Remarks:
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Rectifier Data
Frequency: ______Hz
R_______ S________ T_______VAC
Reserve Data
Frequency: __________Hz
R ________ S________ T________VAC
Output Data
Frequency: ______Hz
Load: R ______ S______ T_____%
Voltage: R ______ S_______ T_______VAC
Other Data
Temperature: ________o C
DC Voltage: ________ Battery ________%
Charge/Discharge Current ________A
Historical Data
Date
_____________________
_____________________
_____________________
_____________________
Time
Event
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Parameter Setting
Inverter= __________
Auto-Start= ___________
Boost Charge= __________
Auto-Boost (Month)= __________
Auto-Boost (Bat Low)= __________
Charge Current= ________
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13.3
1)
NX Series UPS Preventative Maintenance Checklist
The Following Battery Maintenance Procedures Preformed:
a) Measure and record charging voltages of each battery onto Battery Maintenance Form.
b) Inspect for leaks, swelling, corroded cables and connectors.
c) Annually, re-torque all battery connections to their proper specifications.
d) Clean exposed surfaces of batteries and enclosures.
2)
Perform the Following UPS Maintenance Procedures:
a) Clean interior and exterior of UPS and battery cabinets with vacuum cleaner .(non-metal ends)
b) Check and clean air filter and replace if necessary.
c) Inspect all ribbon cables and connectors.
d) Check DC capacitors for swelling, leaking and extruded vents.
e) Check for burned or heated wires and connections.
f) Check for proper operation of cooling fans and blowers.
3)
Complete the Maintenance Measurement Form.
4)
Complete the Front Panel Status Report Log Form.
5)
Complete the Front Panel Meter Readings Form.
6)
Complete the Battery Maintenance Form.
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Requires Action and Comments:
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13.4
Maintenance Measurement Form
Measure and Record the following Voltages and Currents
13.4.1 Initial Start Up (no load connected)
a) Static Mode
{Utility Power applied; Input Breaker Closed; Bypass, Reserve, Rectifier, Battery Breakers Open}
{Inverter Off}
IP Vac
IP Iac
1-2
1-N
1
V
V
A
2-3
2-N
2
V
V
A
3-1
3-N
3
V
V
A
N
A
b) Maintenance Bypass/Ext Bypass Phase Check
{Utility Power applied; Input, Bypass Breakers Closed; Reserve, Rectifier, Battery Breakers Open}
{Inverter Off}
Diff. Vac IR-OR
V IS-OS
V IT-OT
V
c) Static Bypass Mode
{Utility Power applied; Input, Reserve, Battery Breakers Closed; Bypass, Rectifier Breaker Open}
{Inverter Off}
OP Vac
1-2
1-N
V
V
2-3
2-N
V
V
3-1
3-N
V
V
d) Rectifier ON
{Utility Power applied; Input, Reserve, Rectifier, Battery Breakers Closed; Bypass Breaker Open}
{Inverter Off}
IP Iac
BVdc
BIdc
1
V
A
A
BVac
BIac
2
V
A
A 3
A N
A
e) Inverter ON
{Utility Power applied; Input, Reserve, Rectifier Breakers Closed; Bypass Breaker Open}
{Inverter On}
OP Vac 1-2
1-N
IP Iac
1
V
V
A
2-3
2-N
2
V
V
A
3-1
3-N
3
V
V
A
N
A
f) Backup Mode
{Utility Power applied; Reserve, Rectifier Breakers Closed; Input, Bypass Breaker Open}
{Inverter On}
OP Vac
1-2
1-N
BVdc
V
V
V
2-3
2-N
BIdc
V
V
A
3-1
3-N
V
V
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13.5
Maintenance Measurement Form cont’
13.5.1 Normal Service Measurements (normal loads connected and operating)
Normal On-line Mode Loads connected
IP Vac
IP Iac
OP Vac
OP Iac
1-2
1-N
1
V
V
A
2-3
2-N
2
V
V
A
3-1
3-N
3
V
V
A
N
A
1-2
1-N
1
V
V
A
2-3
2-N
2
V
V
A
3-1
3-N
3
V
V
A
N
A
BVdc
BIdc
V
A
BVac
BIac
V
A
3. Record Final Front Panel Meter Readings (attach sheet)
4. Attach Battery Maintenance Sheet
Requires Action:
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13.6
Front Panel Status Report Log
Please complete this form during Preventative Maintenance Checks and any Fault Condition
periods.
Date:
Model:
Time:
Customer:
Serial Number:
Circle all LED’s that are illuminated before powering the unit down.
Warning Messages on LCD: (Record the past five events displayed on the LCD).
Complete Front Panel Reading Form.
Please have these forms available when consulting the factories Service Center.
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13.7
Front Panel Readings
Date:
Model:
Time:
Customer:
Serial Number:
Remarks:
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Rectifier Data
Frequency: ______Hz
R_______ S________ T_______VAC
Reserve Data
Frequency: __________Hz
R ________ S________ T________VAC
Output Data
Frequency: ______Hz
Load: R ______ S______ T_____%
Voltage: R ______ S_______ T_______VAC
Other Data
Temperature: ________o C
DC Voltage: ________ Battery ________%
Charge/Discharge Current ________A
Historical Data
Date
_____________________
_____________________
_____________________
_____________________
Time
Event
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Parameter Setting
Inverter= __________
Auto-Start= ___________
Boost Charge= __________
Auto-Boost (Month)= __________
Auto-Boost (Bat Low)= __________
Charge Current= ________
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13.8
Battery Maintenance Form
BATTERY TYPE: __________________________
NO. OF BATTERIES : ________________ AMPERE-HOUR:_______________
BRAND NAME OF BATTERY: _____________________________
S/N : __________________ PURCHASE DATE:______________________
DATA:
CHARGER VOLTAGE:_______________ CHARGE CURRENT: ____________
Record Voltages:
Cabinet #1
Cabinet #2
Bat.No.
Static
Float
Discharge
Bat.No.
Static
Float
1(NEG)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29(POS)
Discharge
1(NEG)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29(POS)
AMBIENT TEMPERATURE: _______o C / _________ o F
CHECK BY: _________ COMPANY:__________________ DATE:______________
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14
CONTACT INFORMATION
QA / Warranty Questions
Always “On” UPS Systems Inc.
Bldg 1 – 150 Campion Road,
Kelowna, BC, Canada, V1X 7S8
Phone: (250) 491-9777 Ext 209
Fax: (250) 491-9775
Email: [email protected]
Website: www.alwaysonups.com
Software Questions
Always “On” UPS Systems Inc.
Bldg 1 – 150 Campion Road,
Kelowna, BC, Canada, V1X 7S8
Phone: (250) 491-9777 Ext 204
Fax: (250) 491-9775
Email: [email protected]
Website: www.alwaysonups.com
Additional Purchases or Upgrades
Always “On” UPS Systems Inc.
Bldg 1 – 150 Campion Road,
Kelowna, BC, Canada, V1X 7S8
Phone: (250) 491-9777 Ext 451
Fax: (250) 491-9775
Email: [email protected]
Website: www.alwaysonups.com
85
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