HP-300 SERIES
UNINTERRUPTIBLE POWER SUPPLIES
HP-340P
HP-350P
HP-360P
HP-380P
HP-3100P
HP-3120P
HP-3150P
HP-3160P
HP-3200P
40 kVA
50 kVA
60 kVA
80 kVA
100 kVA
120 kVA
150 kVA
160 kVA
200 kVA
USER MANUAL
CONTENTS
YSAFET1
I.
GENERAL DESCRIPTION.................................................................................................................... 2
1.1 Introduction .................................................................................................................................... 2
1.2 Design Concept.............................................................................................................................. 3
1.2.1 The Operating Modes of UPS .............................................................................................. 4
1.2.2 The Power Configuration of UPS ......................................................................................... 4
1.3 Technical Specifications ................................................................................................................ 9
II.
FRONT PANEL ..................................................................................................................................... 10
2.1 Introduction .................................................................................................................................... 10
2.2 Alarms And Status Messages ........................................................................................................ 10
2.3 Menu Description ........................................................................................................................... 13
2.4 MAIN Menu .................................................................................................................................... 15
2.5 MEASURES Menu Items .............................................................................................................. 15
2.6 ALARMS Menu Items ..................................................................................................................... 15
2.7 INFORMATION Menu Items ........................................................................................................ 16
2.8 SETTINGS Menu Items................................................................................................................. 16
2.9 COMMAND Menu Items................................................................................................................ 17
2.10 TIME Menu Items ....................................................................................................................... 18
2.11 PASSWORD Menu Items ........................................................................................................... 18
III.
PARALLEL OPERATION ..................................................................................................................... 19
3.1 Introduction .................................................................................................................................... 19
3.1.1 Security ................................................................................................................................ 19
3.1.2 Redundancy ......................................................................................................................... 19
3.1.3 Power Increase .................................................................................................................... 19
3.2 Parallel Operation Modes ............................................................................................................... 19
3.2.1 Symmetric Parallel Mode ..................................................................................................... 19
3.2.2 Redundant Parallel Mode................................................................................................... 20
3.2.3 Hot Standby Mode ............................................................................................................... 21
3.3 Parallel Operation Mode Fault Codes ............................................................................................ 21
3.4 Parallel System Accessories .......................................................................................................... 21
IV. OPERATING INSTRUCTIONS.............................................................................................................. 23
4.1 Introduction .................................................................................................................................... 23
4.2 OPERATING INSTRUCTIONS FOR A SINGLE UPS UNIT. (ONLINE OPERATION) .................. 23
4.2.1 Procedure For Switching The UPS To Power The Load From a Power-Off Condition ........ 23
4.2.2 Procedure For Switching The UPS Into a Maintenance Bypass From ................................ 23
Normal Operation ................................................................................................................. 24
4.2.3 Procedure For Switching The UPS ON From a Maintenance By-Pass Power
Down Condition .................................................................................................................... 24
4.2.4 Procedure For Switching The UPS From Manual By-Pass
To Inverter (Normal Operation) ........................................................................................... 24
4.2.5 Procedure For Completely Powering Down The UPS .......................................................... 25
4.2.6 When Utility Power Is Interrupted ......................................................................................... 25
4.3 OPERATING INSTRUCTIONS FOR PARALLEL CONNECTED UPS’s ................................... 25
4.3.1 Procedure For Switching The UPS To Power The Load From a Power-Off Condition ........ 25
4.3.2 Procedure For Switching The UPS’s Into a Maintenance By-Pass From
Normal Operation ................................................................................................................. 26
4.3.3 Procedure For Switching The UPS-ON For Normal Operation From a
Maintenance By-Pass Power Down Condition .................................................................... 27
IV. INSTALLATION PROCEDURE ............................................................................................................ 28
5.1 Introduction .................................................................................................................................... 28
5.2 Unpacking ...................................................................................................................................... 28
5.3 Equipment Positioning ................................................................................................................... 28
5.4 Connecting The UPS Power Cables .............................................................................................. 29
5.4.1 Safety Earth ......................................................................................................................... 30
5.4.2 Cable Connections ............................................................................................................... 30
5.4.3 Battery Installation................................................................................................................ 38
5.4.4 The Communication (UPS-Server)....................................................................................... 41
VI. CUSTOMER SERVICE ......................................................................................................................... 42
6.1 Maintenance................................................................................................................................... 42
6.2 Troubleshooting ............................................................................................................................. 42
6.3 Storage........................................................................................................................................... 42
VII. REMOTE MONITORING AND CONTROL.......................................................................................... 43
7.1 Using Serial Port ............................................................................................................................ 43
7.2 Serial Communication Cable .......................................................................................................... 43
7.3 Modem Connection ....................................................................................................................... 44
7.3.1 Hardware Configuration ....................................................................................................... 44
7.3.2 Functioning Principle ............................................................................................................ 44
7.3.3 SMART Modem Programming (PC modem) ........................................................................ 44
7.3.4 DUMB Modem Programming ............................................................................................... 44
7.3.5 DUMB Modem –UPS Connection Cable .............................................................................. 45
7.5 Dry Contact (Interface) Connection ............................................................................................... 45
7.6 Remote Monitoring Panel ............................................................................................................... 45
VIII. LIMITED WARRANTY.......................................................................................................................... 46
SAFETY
This manual contains important instructions for HP-300 series UPS that should be followed during installation
and maintenance.
IMPORTANT NOTICES
1.
2.
3.
4.
5.
6.
7.
Read instructions carefully before operating the UPS
All warnings in the manual should be adhered to.
All operating instructions should be followed.
The unit should be supplied by a grounded outlet. Do not operate the unit without ground source.
Power cord of the UPS should be routed carefully so that they are not to be walked on.
Please save this manual.
Please save or recycle the packaging materials.
WARNING !
Do not insert any object into ventilation holes or other openings.
To reduce the risk of fire or electric shock, install in temperature and humidity controlled indoor area free of
conductive contaminants.
To reduce the risk of fire, replace fuses with the same type and rating when necessary.
CAUTION !
Only qualified personnel should install or service UPS/batteries.
Risk of electric shock, do not remove cover. No user serviceable parts inside, refer servicing to
qualified service personnel.
The output may be energized when the unit is not connected to a mains supply.
Risk of electric shock hazardous live parts inside this unit are energized from the battery supply
even when the input AC power is connected.
Turn OFF the UPS before installing a computer interface signal cable. Reconnect the power cord only after
signaling interconnections have been made.
ABOUT THE BATTERY
A battery can present a risk of electric shock or burn from high short circuit currents. The following precaution
should be observed when working on batteries :
* Remove watches, rings or other metal objects.
* Use tools with insulated handles.
The batteries in this UPS are recyclable. Batteries must be disposed of according to local environmental
laws. The batteries contain lead and pose a hazard to the environment and human health if not disposed of
properly.
Do not dispose of batteries in a fire. The batteries will explode. Do not open or mutilate the batteries. They
contain an electrolyte which is toxic and harmful to the skin and eyes. If electrolyte comes into contact with
the skin the affected area should be washed immediately.
The energy source (the battery) cannot be de-energized by the user.
1
I. GENERAL DESCRIPTION
1.1 Introduction
HP-300 Uninterruptible Power Supplies, are On-Line UPS’s, being manufactured with the state-of-the art PWM
and IGBT technology, produce microprocessor controlled pure sine wave output to critical loads. HP-300 series
UPS’s install between the critical load and the mains.
The advantages of using UPS:
Power blackout protection:
If the mains power fails, the UPS continues to power the critical load from its battery source, leaving the load
immune from power disturbances.
Increased power quality:
The UPS has its own internal voltage and frequency regulator circuits, which ensure that its output is
maintained within close tolerances independent of voltage and frequency variations on the mains power lines.
Increased noise rejection:
By rectifying the input AC power to DC power, and then converting it back to AC, any electrical noise present
on the input mains supply line is effectively isolated from the UPS output, therefore the critical load sees only
clean power.
Features :
Parallel mode operation (optional) up to 2 UPS. (1 redundant)
On-line technology with pure sine wave output.
PWM and IGBT technology.
3 Microprocessors at each UPS
Microprocessor controlled main controller board.
Microprocessor controlled rectifier board.
Microprocessor controlled parallel control board.
Static (STS) and maintenance by-pass.
LCD (Liquid Crystal Display) display.
Alarm history (Memory for max. 64 alarms.)
High quality maintenance-free lead-acid type batteries.
High nonlinear load capacity, special for computers.
Automatic and Manual Battery Test System:
After all the pre conditions ensured, the battery test is made periodically by itself.
Interactive battery management system (optional)
Nonlinear loads driving capability.
Facility of connection with the PC:
In case of failure, alarms of the UPS (Battery low, mains control or general) is shown by the dry relay contacts
and RS232, to the user. The relay interfaces are specially produced for the server systems (IBM AS400 and
Microsoft Windows NT).
Accessories:
o Optional UPS monitoring software ( RUPS , RUPSII , UPSILON ) SNMP devices, compatible to
any operating system.
o Remote Monitoring Panel (RMP) available: You can observe the UPS status and parameters without
using a computer at a remote location up to 200 meters away (via RS485 interface). Up to 5 remote
monitoring panel connection is possible.
o UPS Port Sharer up to 24 server is available
2
1.2 Design Concept
Mechanic Transfer Switch
Maintenance By-pass
S3
Static Transfer Switch
Static By-pass
S2
3 Phase
Line
Input
S4
S1
Rectifier
3 Phase
Load
Output
Inverter
S5
Battery Group
Figure 1-1 Block Diagram
S1
S2
S3
S4
S5
S6
: Inverter input power switch
: Static by-pass input power switch
: Maintenance by-pass power switch
: UPS power out switch
: Battery circuit breaker (optional)
: Static By-Pass control switch (Figure 1.3.a-b-c)
RECTIFIER: The first conversion stage (from AC to DC) uses a 3 phase, fully controlled rectifier to convert the
incoming mains supply into a regulated DC BUS BAR. The DC BUS BAR produced by the rectifier provides
both battery charging power and power to the inverter section.
BATTERY GROUP: It keeps as an reserve DC power supply, for the inverter in case of mains failure.
INVERTER: It is made by utilizing the latest technology of power transistor (IGBT) and pulse width modulation
(PWM). Inverter converts dc bus voltage into (second conversion) an alternative voltage like line voltage. And
provides this voltage and frequency being fixed.
STATIC TRANSFER SWITCH (STATIC BY-PASS): Two types of bypass circuitry is available for HP-300 series
UPS
Full static switch for parallel systems
Half static switch for normal UPS
The circuit block annotated contains an electronically controlled switching circuit, which enables the critical
load to be connected either to inverter output or to a by-pass power source via the” static by-pass line”.
Normally at standart models, the load is connected to the inverter via a contactor K1 (controlled by the static
switch circuits); but in the event of a UPS overload, or inverter failure, it is automatically transferred to the
static by-pass line.
In parallel systems the second static switch is builded ,from inverter output ,to load.
3
MECHANIC TRANSFER SWITCH (MAINTENANCE BY-PASS): A second, manually controlled, ”maintenance
by-pass” supply is also incorporated into the UPS design. Its purpose is to enable the critical load to be
powered from the mains (by-pass) supply while the UPS is shut down for maintenance or troubleshooting.
The load is unprotected against mains power supply aberrations or failure when it is connected to either the
static by-pass or maintenance by-pass supply.
BATTERY CIRCUIT BREAKER: There is a fuse loadbreak switch (externally mounted ) between the UPS and
the batteries. The battery is connected to the DC BUS BAR through a fuse loadbreak switch . This switch has
two built-in fuses (one for battery plus, and one for battery minus). This circuit breaker is closed manually.
Also electronic controlled battery circuit breaker (optional) available. This circuit breaker is closed manually
but it contains an under voltage release coil which enables it to be tripped from the UPS control electronics
following certain detected faults. It also has a magnetic trip facility for overload protection.
BATTERY GROUP (CABINET): The batteries associated with the UPS are generally housed in a purpose-built
cabinet located along-side the main UPS equipment. For a long-term efficiency from the batteries, keep them in
room temperature (20 C).
1.2.1 The Operating Modes of UPS
A. Normal Operation (If there is a mains supply) : All relevant power isolators and circuit Breakers
Closed (except mechanical bypass circuit breaker), the load is powered by the UPS. Also during the
normal operation battery charges. This is made by the UPS’s rectifier.
B. Battery operation:
During this operation Inverter part of the UPS is converting DC power (from battery group) to AC
power ,and feeding the load. Critical load works till the batteries are being empty. At the end of
discharge UPS gives ”A7 BATTERY LOW” alarm.If the batteries are fully discharged UPS gives
“A5 BAT.AUT END” message and shutdown. When the mains is restored the UPS returns back to
normal operation.
NOTE: The battery circuit breaker must be turn to “1” position when the mains is restored. If not in a
second main failure the critical load will be without Voltage.
C. On maintenance by-pass: UPS shutdown but the load connected to the unprotected mains
via the maintenance by-pass supply line.
D. Parallel operation : (optional, need special hardware) At least 2 UPS’s are installed to system
for increasing security and redundancy, they operates together and interactive.
1.2.2 The Power Configuration of UPS
The power switch location of the HP-300 series UPS’s are shown in the figures 1.1-2-3 In the figure 1.2 external
(split) by-pass block diagram is given. Optionally the static and mechanic by-pass line can be connect to a
different 3 phase AC source ( other UPS etc.),and the rectifier input is connected to generator or mains voltage.
If there is no other power supply static and mechanic by-pass line input (S2) and the rectifier input connections
will be connect to each other. (See figure 1.1)
During the normal operation except the maintenance by-pass switch, all the Switches will be at “1-On” position.
4
Mechanic transfer switch
Maintenance Bypass
S3
3 Phase
By-Pass
Supply
Input
3 Phase
Line
Input
Static Transfer Switch
Static By-Pass
S2
S4
S1
Inverter
Rectifier
S5
Battery group
Figure 1.2 UPS Split (external) By-Pass Block Diagram
5
3 phase
load
output
Battery Circuit Emergency
Breaker Input
Stop
Line Failure
Relay
Battery Low
Relay
By-Pass
Relay
Dry Relay Output Contacts
RS232 – SNMP
Communication
Select Switch
RS232
Communication
Port
(DB9 Female)
Parallel System
Data Socket
(DB25 Female)
(optional)
Static By-Pass
Control Switch
(optional)
Parallel System
Analog Signals
Socket
(DB15 Female)
(optional)
SNMP Socket
(optional)
Figure 1.3.a
40-50-60 kVA Power Switch Locations
6
Battery Circuit Emergency
Breaker Input
Stop
Line Failure
Relay
Battery Low
Relay
By-Pass
Relay
Parallel System
Data Socket
(DB25 Female)
(optional)
Dry Relay Output Contacts
Static By-Pass
Control Switch
(optional)
Figure 1.3.b
RS232 Communication
Port (DB9 Female)
80 kVA Power Switch Locations
7
Parallel System
Analog Signals
Socket
(DB15 Female)
(optional)
S4
S3
RS232
Communication
Port
(DB9 Female)
S2
S6
S1
Parallel System
Analog Signals
Socket
(DB15 Female)
(optional)
Battery Circuit Emergency
Breaker Input
Stop
Line Failure
Relay
Battery Low
Relay
By-Pass
Relay
Dry Relay Output Contacts
Figure 1.3.c 100-120-150-160-200 kVA Power Switch Locations
8
Parallel System
Data Socket
(DB25 Female)
(optional)
Static By-Pass
Control Switch
(optional)
1.3 Technical Specifications
GENERAL SPECIFICATIONS
Output kVA
Output kW
Output Power factor
Parallel Operation
Hot Stand-by Operation
Battery charging
temperature compensation
Emergency shutdown
INPUT
Number of phase
Input voltage
Voltage tolerance
By-pass voltage
Input frequency
RFI Level
Split bypass connection
OUTPUT
Number of phase
Nominal Output voltage
Voltage regulation tolerance
Nominal Output frequency
(line syncron)
Output frequency
tolerance
(free running)
Efficiency 100% Load
Load Crest Factor
Total Harmonic Distortion (THD)
Overload
BATTERY
Number of
Run time
Float charge voltage
End of charge voltage
Boost charge
Battery Test
Charge time
Battery trip
INTERFACE
Communication
Remote control
SNMP capability
Modem connection
OTHER
Maximum temperature
Audible noise
Humidity
Dimensions (HxWxD) (mm)
40
40
32
50
50
40
60
60
48
80
80
64
100
100
80
120
120
96
150
150
120
160
160
128
200
200
160
0,8
Up to 2 UPS (1 Redundant) (optional)
Up to 2 UPS (1 Redundant) (optional)
Optional
Available
3 phase
220/380 Vac or 230/ 400 Vac 3 phase ,N
+15% , -15%
220/380 Vac or 230/ 400 Vac 3 phase, N
50 Hz. 5%
EN 50091
Available
3 phase
220/380 Vac or 230/ 400 Vac 3 phase ,N
1%
50 Hz
2%
0,2%
90%
3:1
<3%
125% load 10 min.150% load 1 min.
30
Optional
405 Vdc
300 Vdc
Available
1 time in 1 week (manuel test available)
<5 hours at full load
Available
RS232(standart) RS485 (optional)
Up to 5 remote monitoring panel
Dry contact Line failure,battery low,bypass,
EPO ,battery trip in/out
Optional SNMP adapter
Available
0-40 C
<60 dBA
1360x550x855
<64 dBA
%10-%90
1730x1195x870
1450x720x800 1600x1100x800
9
II. FRONT PANEL
2.1 Introduction
The front panel of UPS, consisting of a 2 lines alphanumeric display ,6 status lamps,plus 5 function keys, allows
the complete monitoring of the UPS status. The mimic flow diagram helps to comprehend the operating status
of the UPS. By using the function keys operator can moves on menus and change some parameters.
ENTER
L4
L1
L5
L2
L3
L6
L7
Figure 2-1 Operator control and indicator panel
L1
L2
L3
L4
L5
L6
L7
:
:
:
:
:
:
:
If lamp is lit mains is okay
If lamp is lit the rectifier is operating
If lamp is lit UPS is operating on batteries
If lamp is lit static bypass is active and load is connected to mains voltage
If lamp is lit mechanical bypass switch is on
If lamp is lit inverter feeds the load
If lamp is lit S4 power output switch “1” on position. (Not exist in 40-50-60 kVA)
There are 5 function keys on front panel these are ENTER ,UP ,DOWN ,PLUS and MINUS.
UP and DOWN keys help moving on menus , PLUS and MINUS keys select options , ENTER key means the
selected option or menu is valid.
NOTE : ALL MESSAGES SHOWN IN THIS CHAPTER IS VALID FOR MC VERSION OF UPS
CONTROL SOFTWARE.
2.2 Alarms And Status Messages
Totally 64 alarm and status messages are used in UPS which helps the user. Messages are coded for easy
dialog with service organization,all messages contains numbers A1-A2-A3….An. Messages and events in UPS
are recorded to a log file with event time and date
ALARM
A1 BYPASS FAILURE
Possible Causes:
A2 INVERTER FAILURE
Possible Causes:
A3 3 OVERTEMP
Possible Causes:
DESCRIPTION
Bypass system failure
1) Maybe bypass parts are defective call service
Inverter digital start system is failed
Internal failure. Call service.
Overload in UPS repeated at 3 times in 30 min.
1) Overload
2) Fan failure or durty air inlets,outlets
3) Bad UPS settling
10
ALARM
A4 OUT FAILURE
A5 BATT AUT END
A6 CHARGER FAULT
A7 BATTERY LOW
Possible Causes:
A8 OUTPUT HIGH
Possible Causes:
A9 OVERLOAD
Possible Causes:
A10 LINE FAILURE
Possible Causes:
A11 HIGH TEMPER
Possible Causes:
A12 IGBT FAILURE
Possible Causes:
A13 OUTPUT LOW
A14 BATTERY HIGH
A15 FUSE FAILURE
A16 BYP INPUT BAD
A17 BATT CB OPEN
A18 BATT.CAPA.LOW
A19 BATT FAULT
Possible Causes:
A20 BOOST CHARGE
A21 ROTATE PHASE
A23 MODE FAILURE
A24 P.FAILURE 17
A25 P.FAILURE 18
A26 P.FAILURE 19
A27 P.FAILURE 20
DESCRIPTION
UPS output voltage is out of tolerance at 3 times in 30 min.
Internal failure. Call service.
Batteries empty at last of line out. Wait to return of electric.
Rectifier is not to produce DC bus voltage.
Batteries are low.
1) UPS wrought long time when line out
2) Charger system failure
Inverter output voltage is over than max. tolerance voltage value.
Inverter is stopped.
1) Inverter failure
UPS loaded over than max. %100 load level.
Load on the UPS output is over than max. Load capacity. This state is maybe
continous or short time. When this alarm is continous to check loads.
Line failure.
1) Maybe line out
2) There is a problem on the UPS ınput board. Please Check.
3) UPS input fuses blowned.
Over temperature. (inverter or rectifier section)
1) Overload for inverter
2) Over temperature
3) Fan failure or durty air inlets
4) Bad UPS settling. There is not vantilation area.
Inverter output system failure.
1) Overload.
2) Short circuit.
3) UPS is out of order. Call service.
Inverter output voltage is under than min. tolerance voltage value.
Inverter is stopped.
Battery voltage is over than max. tolerance.
Fuse blowned. (not used at this power range)
During transfer to bypass ,Voltage or frequency value of bypass source is incorrect
and the UPS turn off the load power.
During normal (inverter) operation some times you can see this message.
During bypass if the bypass protection option is on and if the bypass source is
tolerant out UPS switch off the static bypass for load protection.
Battery circuit breaker is off ,batteries are not connected to UPS
At start up If the mains is okay you can start operation but this message is active
At start up During Line failure UPS waits for turn on battery CB and then it starts
If the battery charge is low this message indicates that charge period is not
completed. If mains failure occurs during this message battery operating time is
not valid.
UPS gives beep sound whitin 15 sec
Battery test aborted. And batteries are not OKAY
UPS gives beep sound whitin 15 sec
You can clear this message by pressing 3 seconds to ENTER key
1) Rectifier fault
2) Battery cells damaged
3) PURE battery connection
Boost charge is active for 10 hours. At the end of this time UPS stops the boost
charge.
UPS gives beep sound whitin 15 sec
Phase sequence is changed on the UPS input. Please change.
In parallel system, the operation mode of 1 UPS is differenf from the other
Parallel controller board failure
Parallel controller board failure
Parallel controller board failure
Parallel controller board failure
11
ALARM
A28
A29
A30
A31
DESCRIPTION
P.FAILURE 21
P.TEST MODE
P FAILURE 23
DUBL UPS NR.
Possible Causes:
Parallel controller board failure
Paralel controller is in test mode
Parallel controller board failure
Same UPS number is used in parallel system.
1) Change from settings menu
Power supply is not functioning possibly because either of a wrong phase
A39 PSP FAILURE
sequence or rectifier fault.
One of parallel modes is selected but there is no parallel control board on UPS
A40 CANT FIND PR
Change mode from settings menu
A41 P.BAL.FAILURE
In parallel operation current sharing is not okay
A42 BATTERY TEST
Performing battery test
A43 P.SYNC.FAIL
In parallel system SLAVE UPS is not synchronized to MASTER UPS
A44 BT.OPERATION
UPS is operating from batteries
Possible Causes: 1) Central system is black-out
2) Distribution problems upfront of the UPS
After mains failure, mains voltage restored again. This message appears on
A45 MAINS OK
screen for 15 seconds after mains restored.
A46 BOOST CH.END
Boost charge mode is finished, normal charge is valid.
A47 CANNOT START
Analog start system in UPS is failed.
Status messages:
This message group simply shows the UPS STATUS at the upper line of LCD PANEL.
RECTIFIER START !
INVERTER START !
MAINT SWITCH ON !
MANUEL BYPASS !
STATUS ALARM !
STATUS NORMAL !
EMERGENCY STOP !
WAITING SYNC !
STATUS FAULT !
CLOSE BATT.CB !
STATUS WARNING !
:
:
:
:
:
:
:
:
:
:
:
UPS started the rectifier
UPS started the inverter
Maintenance bypass switch is on
Load is transferred to mains manually
Alarm status
UPS is operating
External emergency signal is detected.
Inverter started waiting for syncronization
Fault status
UPS is waiting for battery CB close
Warning message is valid on LCD panel
RECTIFIER START :
At start up the UPS controller board check for input voltage, frequency, battery voltage for starting, if these
parameters normal UPS starts.
INVERTER START :
If the inverter stops controller board tries to start again, during inverter start this message appears on first line of
LCD PANEL.
MAINT SWITCH ON:
Maintenance bypass switch is connected from input to the output of UPS directly, controller stops inverter for
accidental short circuits between mains voltage and inverter output. If the user turn off maintenance switch
inverter starts again.
EMERGENCY STOP :
If an external EPO switch is installed to system (connected to interface board) ,to stop all UPS parts (rectifier
,static bypass ,inverter ,etc….) is possible . After pressing EPO switch all parts of the UPS stops ,for restart turn
off S1 (inverter input) switch and turn on again.
12
FAULT STATUS :
In some cases controller checks events but can not find solutions, in this case controller decide to stop system
,for restart user must be turn off S1 (inverter input) switch and turn on again.
WARNING STATUS :
Some events recorded to log event file stays on LCD PANEL but UPS continues to work, these messages
named as warning messages, user can clear this messages by pressing ENTER key for 3 seconds.
These are:
A20 Boost charge alert
A6 Charger fault
A18 Batt capacity low
Shutdown Messages :
HP-300 series UPS’s can operate interactive with operating system, by using some softwares you can send
commands to UPS from operating system .UPS takes this commands and produces some messages these are:
WAITING SHUTDOWN : Shutdown command is performed from operating system and UPS is waiting for
a certain delay for shutdown.
UPS SHUTDOWN
: UPS is in shutdown status
WAITING RESTART
: UPS is shutdown but it is waiting for a certain delay for restart
PAR.SHUTDOWN
: In parallel system the other UPS send shutdown command and UPS is in
shutdown status.
CANCEL SHUTDOWN : Shutdown command is canceled.
Only operating system or a PC computer can send this commands.
If the shutdown command is performed during line failure UPS shutdowns and is the mains is okay UPS starts
again automaticly.
2.3 Menu Description
By using UP and DOWN function keys on front panel you can move on main menu functions ,when main menu
appears on LCD panel if you press ENTER key you can go to submenu item.
In submenu you can move by UP and DOWN keys ,if there is option on submenu item ,you can change options
by pressing PLUS and MINUS keys. If you press ENTER ket the option is valid.
MEASURES submenu
LD% (output load percentage)
OPV (output voltages)
FREQU (output frequency)
IPV (input voltages)
BYP (bypass source voltages)
BATT (battery voltage and current)
...... etc
SAMPLE menu selection:
If you want to go measures menu use UPS and DOWN keys find MEASURES MENU, press ENTER key ,now
you can move on measures menu subitems by UP and DOWN keys.
At the end of sub menus ENTER EXIT is located, during this message if you press ENTER key you can go back
main menu.
At ALARMS MENU you can see LOG HISTORY, log events are recorded with event time and date.
PASSWORD Menu is located for service purposes. This menu is developed for only adjustment.
13
Menu and submenu items
MAIN MENU
MEASURES MENU
ALARMS MENU
INFORMATION MENU
PASSWORD MENU
SETTINGS MENU
COMMAND MENU
TIME MENU
SUBMENU
MEANING
LD%: 050 030 060
OPV: 220 221 219 V
FREQU: 50.0 Hz
IPV: 240 230 226 V
BYP: 225 221 219 V
IPI: 031 040 020 A
BATT: 432 V 06.7A
TEMP: 24 C
CHARGE LEVEL: 60%
ENTER EXIT
UPS STATUS
000>DATE AND ALARM
ENTER CLEAR LOG
PARR.ERR.NR
ENTER EXIT
SYNC :OK COMM :OK
POWER: 20000 VA
VERSION : MC1XX
FREQUENCY : PLL/XTAL
ENTER EXIT
(password required )
ENTER EXIT
MODE:
UPS No :
REMOTE :ENABLE
RESTART:ON/OFF
BYP.PROTECT ON
ENTER EXIT
SOUND : ON/OFF
ENTER B.TEST>432
ENTER <BYPASS>
ENTER:MODEM INIT
ENTER <BOOST>
SIMULATION OFF
ENTER EXIT
TIME : 23 :15
DATE : 11-10-2001
SET HOURS: 11
SET MINS : 38
SET DAY : 21
SET MONTH : 06
SET YEAR : 2001
ENTER <UPDATE>
ENTER EXIT
Output load
Output voltage
Output frequency
Input voltages
Bypass source voltages
Ginput currents
Battery voltage and charge current
Cabinet inside heat
Battery charge level
Exit from submenu
Valid alarm
Recorded log events
Clearing log records
Parallel control board error nr.
Exit from submenu
Syncronization and comminication
Output power of the UPS
Version of UPS
Frequency generation mode
Exit from submenu
System settings
Exit from submenu
Operation mode selection
UPS number selection
Remote access on/off
Mains restored setting
Bypass load protection
Exit from submenu
Sound alert on/off
Manuel battery test
Manuel bypass
Modem settings
Boost charge on/off
Simülation mode selection
Exit from submenu
time
date
Adjust hours
Adjust minutes
Adjust day
Adjust month
Adjust year
Write new time and date
Exit from submenu
14
2.4
MAIN Menu
The main menu items is given at the following table you can move on main menu items by using UP and DOWN
keys.
Main Menu item
STATUS MENU
MEASURES MENU
ALARMS
INFORMATION MENU
PASSWORD MENU
SETTINGS MENU
COMMAND MENU
TIME MENU
Go to STATUS MENU
Function
The status message which shows the UPS status
Enter
"go to Meausures submenu"
Enter
"go to Alarms submenu"
Enter
"go to İnformation submenu"
Enter
"go to password submenu"
Enter
"go to Settings submenu"
Enter
"go to Command submenu"
Enter
"go to Time and date submenu"
2.5 MEASURES Menu Items
At this menu you can see all measured values, use UP and DOWN keys for moving on submenu items.
Submenu item
LD%: 060 074 080
OPV: 220 221 220
FREQU: 50.0 Hz
IPV: 240 235 220
BYP: 230 232 231
IPI: 022 010 030
BATT: 430 V 22.1 A
TEMP: 030 c
CHARGE LEVEL :%100
9
BATT.CAPACI:068%
10 ENTER EXIT
Goto first submenu item
1
2
3
4
5
6
7
8
Function
Output load percentage (capacity %)
Output voltages
Output frequency
Input voltages
Bypass source voltages
Input currents (amperes)
Battery voltage and charge current
Cabinet inside temperature
Battery charge level
Remaining battery capacity when operationing on battery
Enter
( ) exit from menu
2.6 ALARMS Menu Items
At this menu you can see recorded log events and valid alarms
1
Submenu item
UPS STATUS
2
000>311201 23:15
3
ENTER CLEAR LOG
4
PARR.ERR.NR : 017
5
ENTER EXIT
Goto first submenu item
Function
Valid alarm is on LCD PANEL
See recorded log events :
At the first line the first 3 numbers shows the event number. 000 numbered
event is the last event. Date ddmmyy time:hh:mm
At the second line of LCD PANEL you can see al recorded alarms.
Use PLUS and MINUS keys for moving on events.
Enter
( ) clear log event records
After you cleared events you see EMPTY LOG message at lines
Parallel control board fault number. (use if the parallel board is installed)
0 means that there is no error on parallel board
Enter
( ) exit from submenu
15
2.7 INFORMATION Menu Items
This menu gives some information about UPS.
Submenu item
1
SYNC :OK COMM :OK
2
3
POWER: 20000 VA
VERSION : MC1xx
4
FREQUENCY : PLL
5
ENTER EXIT
Goto first submenu item
Function
If the UPS is operating syncron to mains SYNC:OK ,if not syncron SYNC:-If communication is active COMM:OK ,if not active COMM:-The maximum power rating of the UPS
Shows the UPS version
Frequency generation mode
PLL :phase locked loop is generating the frequency
XTAL : XTAL oscillator is generating the frequency
SLAVE : in parallel system master is generating the frequency
Enter
( ) exit from submenu
2.8 SETTINGS Menu Items
From this menu user can set some important options.
Submenu item
1
MODE: ONLINE
2
UPS No : 001
3
REMOTE :ENABLE
4
RESTART:ON/OFF
5
BYP.PROTECT ON
6
ENTER EXIT
Goto first submenu item
Function
By using PLUS and MINUS keys you can move on 4 operation mode
options
ONLINE : stand alone mode
PARALLEL : 2 UPS in symmetric parallel operation
HOT STANDBY : 1 UPS main the other UPS spare mode
REDUNDANT : 2 UPS in redundant parallel mode.
press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change number 0 to 3.
In parallel operation select different number for each UPS. If you select the
same number DUBL UPS NUMBER message tells the fault.
press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change enable and disable
options.
enable : remote battery test, shutdown and bypass function is enabled
disable : these functions are disabled
press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change on and off options.
ON : during mains failure at the and of battery discharge UPS shutdowns
,after mains restored UPS startes again.
(battery trip out is on every time)
OFF: during mains restore UPS don’t start again.
(battery trip out is off)
press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change on and off options.
ON: if the bypass source is out of tolerant UPS turn off load power.
OFF : UPS turn off load power only during bypass moves. If bypass period is
completed UPS continues to feed load.
Enter
( ) exit from submenu
16
2.9 COMMAND Menu Items
You can give immediate commands to ups by using this menu.
Submenu items
1
SOUND : ON/OFF
2
ENTER B.TEST>432
3
ENTER <BYPASS>
Function
Use for turn on/off beep alert sound.
If you press ENTER key the option will change ,one press ON ,one press
OFF.
If the OFF option is used sound alert is turn off but if a new different
alarm is valid UPS changes de option to ON state.
If you press enter for 3 seconds battery test starts for 15 seconds.
If battery test failes A6 BATT FAULT message is on panel and this
message stays until you press ENTER key for 3 seconds.
Numbers at the right shows the battery voltage.
Starting of battery test time is recorded to log event menu if the test is
successful you can see only BATTERY TEST message on log records..
If you press ENTER key for 3 seconds UPS transfers load to bypass.
If the load is on bypass in this submenu you see ENTER<INVERTER>
message at this position if you press ENTER key for 3 seconds UPS
transfers the load on inverter.
In parallel modes this function disables and you see
BYP.FUNC.DISABLE message on this submenu item.
ENTER:MODEM INIT
If you press ENTER key the connected modem of RS232 port is installed
UPS sends AT command set to modem for installation.
If the function is completed you must hear a beep sound.
At the and of this function modem is ready to answer dial up connection.
ENTER <BOOST>
If you press ENTER key for 3 seconds boost charge starts. The given
time for boost charge is 10 hours. At the end of this time UPS stops the
boost charge.
If the boost charge is active this submenu item changes to STOP
BOOST> 005H message the 005H shows that boost charge is started
before 5 hours.
If the number is 10 boost charge stops. If you press ENTER key bosst
charge stops immediately.
Boost charge starting and boost charge end time is recorded to log event
menu.
If boost is active UPS beeps in each 15 seconds
6
SIMULATION OFF
The purpose of this submenu to check dry contact connections. Normally
to check line failure contact you must turn off mains power. This is not
necessary with this utility. 3 options are avalible.
SIMULATION OFF simulaion mode is off
SIM:LINE FAILURE if you press ENTER key for 3 seconds line failure
lamp on interface board lits
SIM:LIN.F+BT.LOW if you press enter key for 3 seconds line failure and
battery low lamp on interface board lits
SIM:BYPASS if you press ENTER key for 3 seconds bypass (aux) lamp
on interface board lits.
So you can check the connections
7
ENTER EXIT
Goto first submenu item
4
5
Enter
( ) exit from submenu
17
2.10 TIME Menu Items
You can see date and time of RTC (real time clock) on UPS. And you can adjust date and time.
1
2
3
4
5
6
7
8
9
Submenu item
TIME : 23 :15
DATE : 11-10-2001
SET HOURS: 11
SET MINS : 38
SET DAY : 21
SET MONTH : 06
SET YEAR : 2001
ENTER <UPDATE>
ENTER EXIT
Goto first submenu item
Function
time
date
(+) and (-) adjust hours (0-23)
(+) and (-) adjust minutes (0-59)
(+) and (-) adjust day (1-31)
(+) and (-) adjust month(1-12)
(+) and (-) adjust year (2000-2099)
Enter update new date and time
Enter
( ) exit from submenu
2.11 PASSWORD Menu Items
Only service personnel can use this menu ,the incorrect use of this menu can cause to damage the UPS.
Submenu item
1
PASSWORD : XXX
2
ENTER EXIT
Goto first submenu item
Function
Service password input
(-) key 100 ,
UP key 10,
(+) key 1 changes
after you write the password on screen press ENTER key ,if the
password is wrong the is no action.
If the password is okay a beep sounds and you see ADJUST MODE at
the second line.
Enter
( ) exit from submenu
18
III. PARALLEL OPERATION
3.1 Introduction
Two of HP-300 UPS can be used in parallel mode ,the purpose of parallel use:
Increasing security
Redundancy
Power increment purpose
3.1.1 Security
At stand alone UPS systems mains voltage is spare energy in case of UPS failure, but some critical loads don’t
works with mains tolerances. Cause of this a second spare UPS is a better solution.
3.1.2 Redundancy
UPS designs are perfect but they takes all mains risks ,sometimes some failures is possible ,the lifetime of
batteries and some parts are limited. In such a case the second UPS installed on system will be working on.
3.1.3 Power Increase
Some load systems always develop and the power need increases, the cheapest solution is to install one more
UPS to the system.
3.2 Parallel Operation Modes
NOTE: Parallel control board and some accessories are not installed in a standard HP-300 series UPS, but
parallel operation option is available for these models.
Parallel operation is possible in one of the three modes:
SYMMETRIC PARALLEL operation
REDUNDANT parallel operation
HOT STANDBY operation
User can select one of the operation modes according to purpose. If parallel control board is installed in your
UPS, you can select operation mode from SETTINGS MENU. In this chapter you can find parallel operation
mode information.
CAUTION !!!
You must not set the operation modes of the parallel connected UPS’s to
“ONLINE”, otherwise serious damage may occur in UPS’s.
3.4.1
Symmetric Parallel Mode
On UPS panel, shortly “PARALLEL MODE” word is used. This mode is useful for increasing power capacity.
Mains power is used as the spare energy supply. In case of an Inverter failure in one of the UPS’s, the static
bypass system of all UPS’s go to bypass together. If everything returns to normal, than the inverters resume the
load together. If current sharing is active, current is shared 50%-50% by two UPS’s. During bypass, the UPS’s
also share the load.
If this mode is active, on the LCD panel of one UPS, you will see “PARALLEL MODE/SL”, and on the LCD panel
of the other UPS, you will see “PARALLEL MODE/MS” : (SL means SLAVE, MS means MASTER)
19
The general diagram of parallel connection is shown below :
MB1
S3
UPS1
SB1
S2
CB1
SB2
CB2
BATT.1
S1
S4
INVERTER 1
AC/DC -1
OUTPUT
LINE
MB2
S3
UPS2
SB3
S2
CB3
SB4
BATT.2
S1
CB4
S4
AC/DC -2
Figure 3-1
INVERTER 2
Parallel connected UPS’s
The inputs of two UPS’s are connected to mains, outputs of two UPS’s are connected to each other. There are
two battery groups.
SB1 and SB3 static bypass switches work always together. They turn on/off together. If these static switches
are conducting the load is connected to mains directly.
SB2 and SB4 static switches work always together. If these static switches are conducting, the load is
connected to inverter. In this position current sharing is active.
If a failure occurs in one UPS, bypass system transfers the load to bypass .
At this mode, power capacity is higher than only one UPS.
3.4.2
Redundant Parallel Mode
At this mode if one of the UPS’s fails the other UPS continues to supply the load.
Assume that UPS1 on figure 3-1 is failed ,SB1 and SB2 static switches will turn off and the UPS 1 is isolated
from load. The SB4 static switch of the UPS 2 will stay in conducted position and it continues to supply the load.
If UPS 1 is okay after a delay this UPS will join the system.
If two UPS’s are in failure SB1 and SB3 static switches will turn on and load is transferred to bypass
This is a 3 level redundancy UPS1+UPS2 ,UPS2 ,mains
Current sharing is active in this mode.
In this mode the power of load must be lower than 1 UPS power.
In this mode, on the LCD panel of both UPS’s you will see the message “REDUNDANT MODE”.
20
3.2.3 Hot Standby Mode
If current sharing is active, two UPS’s are operating continuously and lifetime of some parts will be shorten. Hot
standby mode is a solution for increased UPS lifetime.
In this mode, UPS 1 supplies the load and the UPS 2 waits as spare. It is in standby mode but it is ready to
work.
If a failure occurs in UPS 1, static switch system will isolate UPS 1 from the load and activates the UPS 2. This
is a very fast response, the load doesn’t understand the replacement.
Current sharing is not active in this mode.
In this mode, on the LCD panel of both UPS’s you will see the message “HOT STANDBY”.
3.3 Parallel Operation Mode Fault Codes
FAULT
A23 MODE FAILURE
A24
A25
A26
A27
A28
P.FAILURE 17
P.FAILURE 18
P.FAILURE 19
P.FAILURE 20
P.FAILURE 21
A29 P.TEST MODE
A30 P FAILURE 23
A31 DUBL UPS NR.
A40 CANT FIND PR
DESCRIPTION
SLAVE ups search for the same operating mode with MASTER ups ,if they are different
this message locates on LCD panel.
Change the operation mode of SLAVE ups from SETTINGS MENU.
Don’t forget to press ENTER key for 3 seconds
Turn off the SLAVE ups and turn on again.
Parallel Controller Board Failure
Parallel Controller Board Failure
Parallel Controller Board Failure
Parallel Controller Board Failure
Parallel Controller Board Failure
Parallel control board is in test position
Parallel Controller Board Failure
The same UPS number is selected for SLAVE ups ,you must give separate ups number
to each ups in parallel system.
Goto SETTINGS MENU and change UPS number.
Don’t forget to press ENTER key for 3 seconds.
Turn off the SLAVE ups and turn on again.
Parallel mode is selected but main controller could not find parallel control board.
Select ONLINE mode from SETTING MENU.
Turn off the ups and turn on again.
A41 P.BAL.FAILURE Current sharing failed in parallel operation after a delay sharing will try again
A43 P.SYNC.FAIL
In parallel system SLAVE UPS is not synchronized to MASTER UPS
After a delay SLAVE ups will try to syncron again.
A48 STATIC BYP
In parallel system static bypass switch (S6) is in “ON” position.
3.4 Parallel System Accessories
At standart HP-300 series there is no installed parallel components but they can install. For parallel operation
the following parts are necessary:
Parallel control board
Current transformers
Digital connection cable
Analog connection cable
Fully static bypass system
During order, the customer should give information about any options and accessories, to factory.
21
IMPORTANT NOTE: Parallel system installation is much more complex from stand alone UPS installation, it
needs qualified service personnel.
You have to keep 80 cm distance between two UPS’s for service purposes.
Add 20% tolerance to cable sizes, fuses and circuit breakers in parallel connection.
In figure 3-2 ,the connections of 2 parallel UPS’s and load distribution panel are shown.
L1 (U3)
L2 (V3)
L3 (W3)
NEUTRAL (N3)
U3 V3 W3 N3
U3 V3 W3 N3
AC INPUT
(+)
UPS1
BATTERY
INPUT
(- )
AC OUTPUT
AC INPUT
(+)
BATTERY
INPUT
UPS2
(- )
AC OUTPUT
U2 V2 W2 N2
U2 V2 W2 N2
CB1
CB2
Figure 3-2 Parallel UPS Connection
22
IV. OPERATING INSTRUCTIONS
4.1 Introduction
The Operating instructions will be considered in two parts:
1. The operating instructions for a single UPS (ONLINE OPERATION)
2. The operating instructions for two UPS’s which are connected in parallel.
4.1 OPERATING INSTRUCTIONS FOR A SINGLE UPS UNIT. (ONLINE OPERATION)
4.2.1
Procedure For Switching The UPS To Power The Load From a Power-Off Condition :
By applying this procedure UPS returns to normal operation, when it is completely off.
ATTENTION !!! The following action will apply power to the load equipment.
1) Make sure that all the switches and fuses (S1, S2, S3, S4 and S5) are in “OFF” position and S6 is in
“NORMAL” position.
NOTE THAT S6 SHOULD ALWAYS BE IN “NORMAL” POSITION FOR ONLINE OPERATION
2) Turn S2 switch (static bypass) into “1” (ON) position.
3) Turn on S4 (output switch), now the load is connected to bypass supply.
4) Turn on the S1 switch (inverter input), into ”1” position. By turning on S1, all lights on the front panel
will be lit for 4 secs (lamp test) and then, the following messages will appear on LCD.
“RECTIFIER START”
“INVERTER START”
“STATUS NORMAL”
: Rectifier is operating and static bypass continues to supply the load.
: Inverter is operating and static bypass continues to supply the load.
: The UPS is operating normally and the inverter is supplying the load.
ATTENTION : AC output voltage is applied to the load at this step.
5) Turn on the S5 (The battery circuit breaker) into “1” position or insert the battery fuse. By this way,
the battery group is connected to the UPS.
6) Once you see the green inverter led on the front panel then the UPS system is now ready for use.
You can start up your PC, printer and other critical loads.
ATTENTION : For using as a single unit, the UPS must be operated in “ONLINE” mode. And the
mode selection can be mode as follows :
Using the UP-DOWN buttons on the front panel, select “SETTINGS MENU” on
LCD and press “ENTER”. When you see “MODE” display, using “+” and “-“ buttons
select “ONLINE” mode.
After selecting ONLINE mode press “ENTER” until the beep sound stops.
Turn off S1 and after a few seconds, turn it on again. You will see “INVERTER
START” and than “STATUS NORMAL” messages on the LCD.
23
4.2.2
Procedure For Switching The UPS Into a Maintenance Bypass From Normal Operation :
This procedure should be followed when turning from normal operation to maintenance bypass. This
procedure can be used for supplying temporary mains voltage to the system during the maintenance of
the UPS or in case of failure.
1. Press on the UP or DOWN button when there is “COMMAND MENU” message on the front panel of
the UPS. Then press “ENTER” button.
2. Press on the UP or DOWN button when there is “ENTER <BYPASS>” message on the front panel of
the UPS. Then press “ENTER” button for 3 seconds. L4 static by-pass led lit and L6 inverter led off.
Now your load is supplied by the Static By-pass.
NOTE : Using the procedure in 4.2.2.1 and 4.2.2.2 you can switch the load to by-pass
manually. (MANUAL BY-PASS)
3. Take out the lock from the S3 (maintenance bypass) switch.
4. Turn on (into “1” position) the S3 (maintenance bypass) switch.
5. Turn off all the following switches into “0” position.
S1 (inverter input)
S2 (static bypass)
S4 (UPS output)
S5 (Battery circuit breaker or battery fuse)
WARNING!!!
Inside the UPS the following points will be on operation:
* By-pass AC input mains terminals
* Maintenance by-pass switch
* UPS output terminals
Now your load is completely supplied by the maintenance by-pass supply and the
UPS is not operating.
WARNING!!!
During the maintenance or static by-pass the connected loads at the UPS output
can not being protected against the mains (by-pass source) failure.
4.2.3 Procedure For Switching The UPS ON From a Maintenance By-Pass Power Down
Condition :
1. While the S3 switch in closed position”1” (ON) ;
turn on (into “1” position) the S2 (static bypass) and S4 UPS output) Switch.
2. Turn on (into “1” position) the S1 (inverter input) switch.
3. When “MAINT SWITCH ON!” message appears on the front panel, turn off (into “0” position)
the S3 (maintenance by-pass) switch. By this way the load will be fed from the static by-pass.
4. See “STATUS NORMAL!” message on the front panel and the green inverter led lit.
5. Turn on the battery circuit breaker into “1” (ON) position (or insert the battery fuse).
Now the UPS system is in normal operation. You can start-up your PC, printer etc.
4.2.4 Procedure For Switching The UPS From Manual By-Pass To Inverter (Normal Operation)
1. Press on the UP or DOWN button when there is “COMMAND MENU” message on the front panel of
the UPS. Then press “ENTER” button.
2. Press on the UP or DOWN button when there is “ENTER <INVERTER>” message on the front panel
of the UPS. Then press “ENTER” button for 3 seconds. L4 static bypass led off and L6 inverter led
on. Now your load is supplied by the inverter.
3. See “STATUS NORMAL!” message on the front panel. Now the UPS system is on normal operation.
You can start-up your PC, printer etc.
24
4.2.5 Procedure For Completely Powering Down The UPS :
TURNING OFF THE UPS
All the power switches, isolators and circuit breakers should be turned off, with the following sequence.
(Turn off into “0” (OFF) position). There will be no voltage on the load.
WARNING!!!
S4
S2
S1
S5
4.2.6
This procedure will cut the energy of all the equipments, which are
connected to UPS output.
(UPS output)
(static by-pass)
(inverter input)
(Battery circuit breaker or battery fuse)
When Utility Power Is Interrupted
When there is a utility power interrupted, the L6 inverter led continuously lit also L3 battery and on the LCD
“A10 LINE FAILURE” message appears. And also an audible alarm sounds. Your UPS continues to convert
the battery voltage to AC voltage and protect against loss of data and failure. The autonomy can be increased
by disconnecting relatively unimportant loads. But do not connect this load again while the autonomy. When the
utility power is restored the UPS will return to normal operation and on the front panel of the UPS “A45 MAINS
OK” mesage appears.
When there is a “A7 BATTERY LOW” message appears and audible alarm sounds shut down your PC. If not all
the batteries will be discharge in a few minutes.
After you shut down the critical load (computer system). Apply the completely powering down the UPS.
Apply the normal operation procedure to start up the UPS again after a long time later.
NOTE:
4.3
4.3.1
Do not forget to turn on the battery circuit breaker into “1” (ON) position when there is a mains
voltage return. If not, in case of a second power cut there will be no voltage for the critical load.
If you have a reserve generator, you can use it to feed the UPS’s input and the batteries starts to
charge. By using UPS and the generator at the same time ensures to charge the batteries faster.
OPERATING INSTRUCTIONS FOR PARALLEL CONNECTED UPS’s
Procedure For Switching The UPS To Power The Load From a Power-Off Condition :
With all the switches and fuses (S1,S2, S3, S4 and S5) in “OFF” “0” position and with S6 in “NORMAL”
position.
Turn on the parallel connected UPS’s, UPS1 and UPS2 separately as follows:
1. Make sure that the two UPS’s are properly connected for parallel operation in accordance with the
diagrams given in “INSTALLATION PROCEDURES” section. ( Section V.)
2. Turn on the S1 switch (inverter input) into “1” position. By turning on S1 you will see the following
messages on the LCD panel,
a. “RECTIFIER START”
b. “INVERTER START”
c. “STATUS NORMAL”
After these messages the UPS will start running and the green INVERTER LED on the front panel
will be turned on.
25
3. Using the UP-DOWN buttons on the front panel select “SETTINGS MENU” on LCD and press
“ENTER”.
When you see “MODE” display, using “+” and “-“ buttons select either one of the following operation
modes which is suitable for your needs.
OPERATION MODES:
1. ON-LINE
2. PARALLEL
3. HOT-STANDBY
4. REDUNDANT
4. After selecting one of the above modes, press “ENTER” until the beep sound stops.
5. Turn off S1 (inverter input) and after a few seconds, turn it on again. Now the inverter is ready to
operate in the selected mode.
Perform the same procedure given above for both UPS’s (UPS1 and UPS2). Make sure that you
select the same mode for both UPS’s. If you select different modes, then a fault signal will be
generated.
After selecting the operation modes for both devices then perform the following procedure:
6. Turn on the Battery Circuit Breaker S5 (Optional) or insert the battery fuse, to connect the battery
group to the UPS for uninterrupted operation.
7. Turn on S2 switches (static by-pass) of both UPS’s.
8. When you restart UPS’s again, make sure that the CB1 and CB2 switches on the AC distribution
panel are in “OFF” position. Then turn on S4 (output) switches of both inverters.
ATTENTION : VOLTAGE AT THE OUTPUT !!!
9. Before going any further, measure the voltage (using an AC voltmeter) between the corresponding
phase outputs of UPS’s at the CB1 and CB2 contacts on the distribution panel. Only after you are
sure that there is no voltage difference between the corresponding contacts, turn on CB1 and CB2
on the AC distribution panel.
Now the outputs of the UPS’s are connected in parallel and the parallel system is ready for use with
AC loads.
4.3.2 Procedure For Switching The UPS’s Into a Maintenance By-Pass From Normal
Operation :
1) Bring S6 (static by-pass) of either one of the UPS’s into “STATIC BYPASS” position.
2) See that the red coloured by-pass leds on the front panels of both UPS’s are lit. (Static bypass
operation)
3) Turn on S3 switches (maintenance bypass) of both UPS’s.
4) Turn off S4 switches (AC output) of both UPS’s.
5) Turn off S1 switches of both UPS’s.
6) Turn off S2 switches (AC output) of both UPS’s.
7) Turn off S5 (optional battery circuit breaker ) or remove battery fuses of both UPS’s.
Now, the UPS’s are completely turned off but the load is supplied by the AC-input via the
Maintenance By-Pass switch.
WARNING!!!
Inside the UPS’s the following points will be on operation:
* By-pass AC input mains terminals
* Maintenance by-pass switch
* UPS’s output terminals
Now your load is completely supplied by the maintenance by-pass supply and the
UPS’s is not operating.
WARNING!!!
During the maintenance or static by-pass the connected loads at the UPS output
can not being protected against the mains (by-pass source) failure.
26
4.3.3 Procedure For Switching The UPS-ON For Normal Operation From a Maintenance
By-Pass Power Down Condition :
With the S6 switches (static bypass) of the inverters (at least one of them) in “STATIC BYPASS”
position, turn on the parallel connected UPS’s UPS1 and UPS2 as follows:
1) Turn on the S2 switches (static bypass) of both UPS’s.
2) Turn on S4 switches (AC output) of both UPS’s.
3) Turn on S1 switches (inverter input) of both UPS’s.
4) Turn on the Battery Circuit Breakers S5 (optional) or insert the battery fuses of both UPS’s to
connect the battery groups to the UPS’s for uninterrupted operation.
5) When “MAINT SWITCH ON!” message appears on LCD, turn off S3 switches (maintenance bypass)
of both UPS’s.
6) Bring S6 switches (static bypass) of both UPS’s to “NORMAL” position.
27
V. INSTALLATION PROCEDURE
5.1 Introduction
WARNING!!!
Do not apply electrical power to the UPS equipment before the arrival of authorized service personnel.
The UPS equipment should be installed by a qualified service personnel.
The connection of the batteries and the maintenance should be done by the qualified service personnel.
Do not make short- circuit to the batteries poles. Because of the high short-circuit current, it has the danger
of electrical shock or burn.
Eye protection should be worn to prevent injury from accidental electrical arcs. Remove rings, watches and
all metal objects. Only use tools with insulated handles. Wear rubber gloves.
This chapter contains location installation information of the UPS and the batteries. All the establishments have
their own specialties and needs. So in this part the installation procedure is not being explain step by step.
Instead general procedure and the applications are explained for the technical personnel.
5.2 Unpacking
The UPS is packed and enclosed in a structural cardboard carton to protect it from damage.
1. Inspect for damage that may have occurred during the shipment If any damage is noted, call the shipper
immediately and retain the shipping carton and the UPS.
2. Carefully open the carton and take the UPS out.
3. Retain the carton and packing material for future use.
Unit package contents :
User Manual
Guarantee Certificate
Battery cabinet and/or shelf
Battery Circuit Breaker (Optional)
Parallel mode digital interface cable
Parallel mode analog interface cable
5.3 Equipment Positioning
1. The equipment’s installation place must be an easy serving place.
2. Install the UPS in a protected area with adequate air flow and free of excessive dust.
3. You must therefore allow for a minimum gap of 250 mm behind the unit to allow adequate air flow (See
Figure 5.1)
4. Select a suitable place (temperature is between 0 C and 40 C) and the relative humidity (%90 max)
5. It is recommended to air-conditioned the room (24 C)
6. Temperature is a major factor in determining the battery life and capacity. Battery manufacturers quote
figures for an operating temperature of 20 C. On a normal installation the battery temperature
is maintained between 15 C and 25 C. Keep batteries away from main heat sources or main air inlets etc.
7. In case of an operating the UPS in a dusty place, clean the air with a suitable air filtration system.
8. Keep out of your equipment from the explosive and flammable items.
9. Avoid direct sunlight, rain, and high humidity.
WARNING!!!
Check the capacity of the forklift if it is available for lifting.
DO NOT MOVE THE BATTERY CABINET WHILE THE BATTERIES ARE INSTALLED.
28
5.4 Connecting The UPS Power Cables
CAUTION! Only qualified personnel should install or service UPS / batteries.
The ac input to the UPS should be supplied by a separate line from the ac distribution board.
The input/output cables can be sized to suit the modules rating according to the table below.
The connections of the electric panel should be supplied by grounded outlet. Cables enter the UPS modules via
entry panels in the base of cabinet. All control cables should be screened and run in a separate trunking to the
power cables.
The input/output cables can be sized to suit the modules’ rating according to the table below.
X
H
P
L
UPS
(KVA)
3 Phase Input/Output
40
50
60
80
100
120
150
160
L
550
720
1100
1195
P
855
800
800
870
H
1360
1450
1600
1730
X (min)
250
NOTE : All the dimensions are in mm .
Figure 5-1 Installation Diagram
29
200
NOMINAL CURRENT : Amps / Recommended Cable Size (mm2)
UPS
RATING
(kVA)
Input Mains
With full battery Recharge
380V
400V
Bypass / output
At full load
415V
380V
400V
415V
Battery
at min.
Battery
Voltage
BUS BAR CONNECTION
STUD SIZE
Input/Output
Battery
Cable
Terminations
Terminations
A / mm
A / mm
A / mm
A / mm
A / mm
A / mm2 A / mm2
U-V-W-N
+&-
85A / 25
78A / 25
73A / 25
61A / 16
58A / 16
56A / 16 110A / 35
M6
M8
128A / 35 117A / 35 109A / 35
91A / 25
87A / 25
84A / 25 163A / 50
M6
M8
168A / 50 160A / 50 154A / 50 121A / 35 115A / 35 111A / 35 220A / 70
M6
M8
100-120 256A / 70 234A / 70 218A / 70 182A / 70 174A / 70 168A / 70 326A/100
M8
M8
150-160 329A / 95 312A / 95 301A / 95 230A / 70 218A / 70 210A / 70 430A/120
M8
M8
M8
M10
2
40
50-60
80
200
NOTES:
5.4.5
2
2
2
2
357A /185 339A /185 327A /185 243A /150 230A /150 223A /150 560 /185
The neutral conductor should be sized for 1,5 times the output/bypass phase current. The Earth
conductor should be sized at 2 times the output/bypass conductor (this is dependent on the fault
rating, cable lengths, type of protection etc.) These recommendations are for guideline purposes only
and are superceded by local regulations and codes of practice.
Safety Earth
The safety earth cable must be connected to the earth BUS BAR and bonded to each cabinets in the system
and also the earthing and neutral bonding arrangements must be in accordance with the local laws.
ATTENTION!!!
Failure to follow adequate earthing procedures can result in electric shock hazard to
personnel, or the risk of fire.
5.4.6 Cable Connections
ATTENTION!!!
All the cable connections of the ups must be done by the authorized service personnel.
Once the equipment has been finally positioned and secured, connect the power cables as described in the
following procedure:
30
Normal Connections
AC
AC
A
B
Split By-Pass Connections
AC
AC
A
B
Figure 5-2-a
40-50-60 kVA UPS Power Connections
31
Normal Connections
AC
AC
A
B
Split By-Pass Connections
AC
AC
B
A
Figure 5-2-b
80 kVA UPS Power Connections
32
S4
A
These links
must be
removed for
split bypass
system
S3
Output
connections
(To load)
B
S2
Input
connections
U2
V2
W2
N2
Battery power
connections
U3
V3
W3
N3
C
S1
UPS rectifier and inverter input connections. Normally
these terminals are not used for the input connections.
Split (External) By-pass Connection
a. Remove the shown links (in the figure)
b. Connect the R-S-T-N cables to the B terminals from
the external by-pass source.
c. Connect the mains input R-S-T-N cables to
the C terminals.
d. The external by-pass’s voltage and frequency
must be suitable With the UPS’s.
Figure 5-2-c 100-120-150-160-200 kVA UPS Power Connections
1) Verify that the UPS’s switches are totally at “0” position.
2) Connect the AC input supply cables coming from the input mains distribution panel to the B terminals as in
Fig. 5-2-a,b,c.
ATTENTION!!!
ENSURE CORRECT PHASE SEQUENCE
If there is a phase sequence fault, A21/A39 “ROTATE PHASE” message appears
on the front panel and the UPS can’t work.
THE CORRESPONDING AC INPUTS OF BOTH UPS’s (U3-V3-W3) MUST BE EXACTLY OF THE SAME PHASE.
3) Connect the UPS output cables from the output terminals to the load distribution panel.
ATTENTION !!!
For proper load sharing during parallel operation the cables between the AC
distribution panel and the AC output terminals of one UPS must be exactly the
same size and length as the cables between the distribution panel and the AC
output terminals of the second UPS.
4) Make the connection of the battery groups. Please look at the 5.4.3 Battery Installation item for it.
ATTENTION!!!
Remove the battery fuses before making the connection of the battery circuit
Breaker during the battery installation. (Turn off into “0” (OFF) position)
5) Connect the copper earth bus, which is under the safety earth and the cables power connection.
Note: The earth and the neutral connections must be in accordance to the local Rules.
6) If the REMOTE STOP option is going to be used, you should connect the remote stop button (normally
open), to the pins 4 and 5 of the remote stop connector (CN3) on the PCB ITF3.
33
34
BATTERY
GROUP
Neutral
Figure 5-3-a
(-)
(+)
AC INPUT
3 PHASE+Neutral
LOAD
U VWN
POWER CONNECTIONS OF TWO UPS’s FOR PARALLEL OPERATION (40-50-60-80 kVA)
(To be supplied by the customer)
(+) BATTERY
(-) GROUP
35
-
+
Neutral
Neutral
LOAD
U VWN
-
+
BATTERY
GROUP
(To be supplied by
the customer)
AC INPUT
3 PHASE + Neutral
Figure 5-3-b POWER CONNECTIONS OF TWO UPS’s FOR PARALLEL OPERATION (100-120-150-160-200 kVA)
BATTERY GROUP
DIGITAL
ANALOG
Figure 5-4-a Switch and Fuse Positions and Signal cable connections
for parallel operation (40-50-60 kVA)
DIGITAL
ANALOG
Figure 5-4-b Switch and Fuse Positions and Signal cable connections
for parallel operation (80 kVA)
36
37
Figure 5-4-c Switch and Fuse Positions and Signal cable connections for parallel operation (100-120-150-160-200 kVA)
ANALOG
DIGITAL
5.4.7
Battery Installation
ATTENTION!!!
Remove the battery fuse before making the connection of the battery circuit breaker box
during the battery installation.
The batteries associated with the UPS equipment are usually contained in a purpose-built battery cabinet, which
sits alongside the main UPS equipment. Sealed, maintenance-free batteries are normally used in this type of
installations.
Where battery racks are used, they should be sited and assembled in accordance with the battery
manufacturer’s recommendations. In general, batteries require a well-ventilated, clean and dry environment at
reasonable temperatures to obtain efficient battery operation.
In general a minimum space of 10 mm must be left on all vertical sides of the battery block. A minimum
clearance of 20 mm should be allowed between the cell surface and any walls. A clearance of minimum150 mm
should be allowed between the top of the cells and the underside of the shelf above (this is necessary for
monitoring and servicing the cells). All metal racks and cabinets must be earthed. All live cell connections must
be shrouded.
The batteries are connected to the UPS through a circuit breaker (optional), which is manually closed and
electronically tripped via the UPS control circuitry. If the batteries are cabinet-mounted this circuit breaker is
fitted within the cabinet; however, if the batteries are rack-mounted or otherwise located remote to the main
UPS cabinet then the battery circuit breaker must be mounted as near as possible to the batteries themselves,
and the power and control cables connected to the UPS using the most direct route possible.
1. Unpack each battery and check its terminal voltage. If any battery has terminal voltage less than 10,5 V it
must be charged before continuing.
2. Please check the battery connecting hardware.
3. Please locate 8 pieces of the batteries to each rack.
4. Start locating the batteries from top to the bottom on the racks.
5. Connect the cable between the battery circuit breaker’s positive port (BAT+) first then battery tray (+) at the
left topside as in the figure 5-5-a-b
6. Connect the cable between the battery circuit’s negative port (BAT-) first then battery tray (-) at the right
bottom side as in the figure 5-5-a-b
7. Please pay attention to the connections and the poles’s directions between the racks.
8. Connect the battery circuit breaker’s “UPS(+)
BATT(+)” and “UPS (-)
group connection terminals at the UPS cabinet.
BATT(-)” Ports to the battery
9. Connect the shielded control cable between the UPS and the battery circuit breaker as in the following.
Battery circuit
Breaker box
BAC60 Board
CN1
Inside of the UPS
1.....................1
2.....................2
3.....................3
ITF3 Board
BATT. CB
CN3
38
Battery
Fuse
To UPS Cabinet
Figure 5-5-a
39
UPS Battery Group Connection
(With Battery Fuse)
Electronically
Controlled
Battery Circuit
Breaker
Control
Cable
To UPS Cabinet
Figure 5-5-b
40
UPS Battery Group Connection
(With Battery Circuit Breaker)
5.4.8
The Communication (UPS-Server)
Dry relay alarm contacts or optional RS232 communication port can be used to inform the user about any
possible alarm like “Battery Low” “Line Failure” “Load On By-pass”. The relay interface AS400 and Windows NT
is an special edition for the systems.
You should use ITF3 and RS330 board for the communicate with the PC. For this connections there must be a
dedicated serial port.
ATTENTION!!!
The communication cables of this option must be shielded and must install away from the
voltage cables.
The RS232 port (at RS330 board and DB9 female) definition :
RS232 Signal Gnd (isolated)
RS232 Receive
RS232 Transmit
7
6
9
The settings for the Microsoft NT server
accordance to the each user’s needs.
Battery Circuit
Breaker Input
Emergency Stop
, IBM AS400
connections will be done by the system’s operator in
Line Failure
Relay
Battery Low Relay
CN4
CN3
Figure 5-6
ITF3 Board Connection Details
41
By-Pass
Relay
VI . CUSTOMER SERVICE
WARNING!
There are no customer serviceable components inside. DO NOT open the cover or attempt to service the unit.
High voltage may remain when the unit is shut down.
Unauthorized service will void the warranty and could cause serious injury.
6.1 Maintenance
The unit is designed for easy maintenance. Very little customer maintenance is required. The following will
help to ensure trouble -free operation for several years:
1. Vacuum the dust from the ventilation intake on the front panel.
2. Wipe the cover with a dump cloth.
3. Check the batteries charge with the manual battery test procedure. See Automatic And Manual Battery
Test.
CAUTION!
It is recommended to test the battery discharging capability only after the software in use has been saved
and all files have been closed.
6.2 Troubleshooting
Due to the unique design, the unit can be serviced only by authorized people. In case of a persistent failure
or problem properly turn off the unit first. Then review the following check list. Be prepared to answer the
questions before calling the service.
1. Did you follow the operation procedure? Did it happen on installation?
2. Did a power failure occur just after or before the malfunction noted on the UPS?
3. What is the indicators status? (see LCD alarms and FAULT codes)
4. Were any changes made recently to unit or the critical equipment connected to the unit?
5. Did an overload condition occur? Remove load from the unit and restart it.
6. Is the utility power phase sequence correct (were any changes phase sequence of the mains)?
6.3 Storage
1. Check the batteries charge with the manual battery test before storage.
2. Connection’s uninstall operation will be done by the authorized service.
3. During the storage period the batteries should be charged once, per six months.
4. Keep the equipment and the batteries in a dry, cool place.
Best storage temperature for the UPS
: Between 0 C and 40 C max.
Best storage temperature for the batteries : Between 10 C and 35 C max.
42
VII. REMOTE MONITORING AND CONTROL
Following external connections are available at HP-300 series
Communication By serial port connection
Dry contact (interface board) connection
Remote panel monitoring
7.1 Using Serial Port
A standart Serial communication port is installed to all HP-300 series UPS ,by using this port user can take all
information about UPS . All measured parameters ,alarms can monitor by this port. This port is interactive and
some commands for UPS is available these commands are listed below.
Switch to BYPASS
Switch to INVERTER
SOUND on/off
Adjust UPS time and date
Start SIMULATION mode
Short BATTERY TEST
BATTERY TEST until battery low alarm
CANCEL battery test
Turn off UPS output voltage immediately (SHUTDOWN)
Turn off UPS output voltage after delay (WAITING SHUTDOWN)
Turn off UPS output voltage (SHUTDOWN) and turn on UPS output voltage (WAITING RESTART)
CANCEL SHUTDOWN
RENAME UPS
UPS will give response to these commands if the REMOTE: ENABLE opsion is selected from SETTINGS
MENU .
Apply Your local distrubitor, for supply available programs to monitor and control the UPS.
7.2 Serial Communication Cable
The maximum length for RS232 communication cable is 25 meters, cable connector pins are as fallowed :
UPS side
9 Tx
7 Gnd
6 Rx
PC side
2 Rx
5 Gnd
3 Tx
For remote panel – UPS connection this cable is okay.
SERIAL PORT SETUP
BAUD RATE
STOP BIT
DATABITS
PARITY
2400 baud
1
8 BIT
None
43
7.3 Modem Connection
A HP-300 UPS can be controlled through a normal telephone line by means of a remote operator connected
through a PC with modem device, who performs a phone call to the UPS connected number. So the operator
can see all parameters and control the UPS (if permitted from SETTINGS MENU).
7.3.1 Hardware Configuration
All needs for modem connection is as follows :
PC with modem
WINDOWS 98
Available UPS control software
DUMP modem which is connected to UPS
In order to perform this function a PC with UPS control software and an external or internal modem device
connected to telephone line are needed.
A standart modem device, configured according to DUMP and auto answer modes, will be installed on the UPS
and, once programmed, will following a telephone call of the PC-embedded modem ,connect the UPS to the
telephone line.
7.3.2 Functioning Principle
The remote operator, by means of a PC and a modem device and using the remote connection function of the
control software, calls the UPS through the number to which this is connected.
The dumb modem device, connected to the UPS, will answer the call and convert the data coming from UPS
serial on the telephone line. This way all measures and controls allowed by the RS232 serial port can be carried
out.
7.3.3 SMART Modem Programming (PC modem)
The connected modem to PC (smart modem) will be programmed from UPS control software automaticly.
B0 E1 F1 M1 Q0 V1 X3
BAUD = 2400
PARITY = N
WORDLEN = 8
DIAL = TONE
&A3 &B1 &C1 &D0 &H1 &I0 &K1 &M4
&N0 &R2
&S0 &T5 &Y1
7.3.4 DUMB Modem Programming
The connected modem to UPS can be program from COMMAND MENU ,ENTER :MODEM INIT automaticly.
But the user can program this modem from a PC by following options.
B0 E1 F1 M1 Q0 V1 X3
BAUD = 2400
PARITY = N
WORDLEN = 8
DIAL = TONE
&A3 &B1 &C1 &D0 &H1 &I0 &K1 &M4
&N0 &R2
&S0 &T5 &Y1
44
7.3.5 DUMB Modem –UPS Connection Cable
The connection cable between dumb modem and UPS is as followed:
UPS
DB9 female
6
7
9
MODEM
DB25 male
3
7
2
7.4 Dry Contact (Interface) Connection
Some important events can be monitored by this connection for each event a relay is located on interface board
and NC-C-NO contacts are connected terminals .
these events are:
LINE FAILURE
BATTERY LOW
LOAD ON BYPASS
BATTERY CB input
BATTERY CB output
EMERGENCY STOP input
Battery Circuit
Breaker Input
Emergency Stop
Line Failure
Relay
Battery Low Relay
CN3
By-Pass
Relay
CN4
7.7 Remote Monitoring Panel
Remote monitoring panel can be used from 400 meters away from UPS. Up to 25 meters there is no need extra
hardware RS232 communication is okay. But if distance is longer than 25 meters extra RS485 hardware is
needed.
Up to 5 remote monitoring panel can be used in system.
45
VIII. LIMITED WARRANTY
The UPS is warranted against all defects in workmanship and materials under normal use for a period of one ( )
year from the date of shipment to the original user. The conditions of this warranty and the extent of
responsibility of
……………………………………………………………………………………………………………………
corporation under this warranty are as follows.
1. The warranty does not apply if the product has been subjected to physical abuse, improper installation,
unauthorized service or modification.
2. The sole responsibility of
………………………………………………………………………………………………………………
corporation under this warranty shall be limited to the repair or replacement of the product, at the sole
discretion of
………………………………………………………………………………………………………………
corporation.
3. If it becomes necessary to send a defecting unit to
………………………………………………………………………………………………………………
corporation, the product should be shipped in its original carton or in suitable equivalent, and with shipping
charges prepaid.
………………………………………………………………………………………………………………
corporation will not assume any responsibility for any loss damage incurred in shipping.
46
AGKK3255 02/2008
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