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PS-SP Series 3:3 Phase, 10 60 kVA, 3 X 208 Vac, 60 Hz, 192 Vdc

Gamatronic Electronic Industries Ltd.


Har Hotzvim Industrial Park 14 Hartom St. PO Box 45029 Jerusalem 91450 Israel Tel: +972-2-588-8222 Fax: +972-2-582-8875 Email: info@gamatronic.co.il Website: www.gamatronic.com
This UPS has been designed for commercial/industrial use only, and is not for use in any life support application. Copyright 2008 by Gamatronic Electronic Industries Ltd. All rights reserved worldwide. The information contained in this document is proprietary and is subject to all relevant copyright, patent and other laws protecting intellectual property, as well as any specific agreement protecting Gamatronic Electronic Industries Ltd. rights in the aforesaid information. Neither this document nor the information contained herein may be published, or reproduced, in whole or in part, without the express, prior, written permission of Gamatronic Electronic Industries Ltd. In addition, any use of this document or the information contained herein for any purposes other than those for which it was disclosed is strictly forbidden. Gamatronic Electronic Industries Ltd. reserves the right, without prior notice or liability, to make changes in equipment design or specifications. Information supplied by Gamatronic Electronic Industries Ltd. is believed to be accurate and reliable. However, no responsibility is assumed by Gamatronic Electronic Industries Ltd. for the use thereof nor for the rights of third parties which may be affected in any way by the use thereof. Any representation(s) in this document concerning performance of Gamatronic Electronic Industries Ltd. product(s) are for informational purposes only and are not warranties of future performance, either express or implied. Gamatronic Electronic Industries Ltd. standard limited warranty, available upon request, stated in its sales contract or order confirmation form, is the only warranty offered by Gamatronic Electronic Industries Ltd. in relation thereto. This document may contain flaws, omissions or typesetting errors; no warranty is granted nor liability assumed in relation thereto unless specifically undertaken in Gamatronic Electronic Industries Ltd. sales contract or order confirmation. Information contained herein is periodically updated and changes will be incorporated into subsequent editions. If you have encountered an error, please notify Gamatronic Electronic Industries Ltd. All specifications are subject to change without prior notice.

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PS-SP Series 3:3 Phase, 10 60 kVA, 3 X 208 Vac, 60 Hz, 192 Vdc

TABLE OF CONTENTS
1. SAFETY PRECAUTIONS ...................................................................................... 1 1.1 Dos .............................................................................................................. 1 1.2 Donts........................................................................................................... 1 2. GENERAL FEATURES ......................................................................................... 2 2.1 Parallel Operation ....................................................................................... 3 2.1.1 Advantages of Parallel Operation ..................................................... 3 2.2 Major Subsystems ...................................................................................... 3 2.2.1 Rectifier................................................................................................ 3 2.2.2 Batteries............................................................................................... 4 2.2.3 Inverter................................................................................................. 4 2.2.4 Static Switch........................................................................................ 4 2.2.5 Bypass Isolation Transformer (option)............................................. 4 2.2.6 Control System ................................................................................... 4 2.3 Control Panel .............................................................................................. 5 2.4 Power-on Self Tests ................................................................................... 6 2.5 Measurement............................................................................................... 6 2.6 Real Time..................................................................................................... 6 2.7 Communications......................................................................................... 6 2.8 Event Logs .................................................................................................. 6 2.9 Ease of Use ................................................................................................. 6 2.10 Battery Check.............................................................................................. 6 2.11 Service Mode............................................................................................... 7 2.12 Emergency Power-Off (EPO) ..................................................................... 7 2.13 Connections ................................................................................................ 7 3. PARALLEL OPERATION (OPTION)..................................................................... 8 3.1.1 Centralized vs. Decentralized Static Switch..................................... 8 3.1.2 Decentralized Parallel Mode of Operation ........................................ 8 4. CONTROL PANEL & INDICATORS ................................................................... 11 4.1 The Control Panel on the Standard Cabinet........................................... 11 4.1.1 Function Buttons on the Standard Cabinet.................................... 12 4.1.2 Information Buttons on the Standard Cabinet ............................... 12 4.2 The Control Panel on the Larger Cabinet ............................................... 16 4.2.1 Function Buttons on the Larger Cabinet ........................................ 17 4.2.2 Information Buttons on the Larger Cabinet ................................... 17 4.3 The LOG, SET, and HELP Buttons for All Models ................................. 21 4.4 System Fault Diagnostics ........................................................................ 25 4.5 LED Indicators .......................................................................................... 27 5. OPERATING THE PS SERIES UPS ................................................................ 29 5.1 Turning the UPS ON ................................................................................. 29 5.2 Turning the UPS OFF ............................................................................... 30 5.3 Activating Maintenance Bypass .............................................................. 31 5.4 Deactivating MAINTENANCE BYPASS ................................................... 32 5.5 After Use of the Emergency Power-Off Switch ...................................... 33 5.6 Setting the Real Time Clock .................................................................... 33

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PS-SP Series 3:3 Phase, 10 60 kVA, 3 X 208 Vac, 60 Hz, 192 Vdc

6. COMMUNICATIONS............................................................................................ 34 6.1 RS232 Interface......................................................................................... 34 6.2 The Alarm Interface .................................................................................. 35 6.3 Remote Monitor Box (Optional)............................................................... 36 6.3.1 Connecting the Monitor Box to the UPS......................................... 37 7. TROUBLESHOOTING......................................................................................... 38 8. SITE PREPARATION .......................................................................................... 41 8.1 Installation Considerations...................................................................... 41 8.2 Electrical Wiring........................................................................................ 42 8.3 Terminal Connections .............................................................................. 44 9. INSTALLATION ................................................................................................... 45 9.1 Accessibility.............................................................................................. 45 9.2 Circuit Breakers ........................................................................................ 45 9.3 Installation of Standalone UPS................................................................ 47 9.3.1 Wiring/Cabling Instructions ............................................................. 47 9.3.2 External Battery Cabinet .................................................................. 48 9.3.3 Turning On the UPS for the First Time ........................................... 49 9.4 Installation of Decentralized Parallel Systems....................................... 51 9.5 Parallel Start-Up........................................................................................ 52 9.5.1 Decentralized (2 UPSs only) ............................................................ 52 10. TECHNICAL SPECIFICATIONS ......................................................................... 54

LIST OF FIGURES
Figure 1: Schematic Diagram of the Operation of the UPS................................................. 2 Figure 2: Control Panel on the 10 kVA to 60 kVA models................................................... 5 Figure 3: Control Panel on the 40 60 kVA model with optional larger cabinet .............. 5 Figure 4: Decentralized Parallel PS - cable connections ................................................... 9 Figure 5: Centralized Parallel PS - cable connections ..................................................... 10 Figure 6: Control panel on the standard cabinet (10kVA to 60kVA models) .................. 11 Figure 7: Control panel on the larger cabinet (optional for 4060KVA models)............ 16 Figure 8: LOG Messages Structure ..................................................................................... 21 Figure 9: Accessing the Log on the standard cabinet ...................................................... 21 Figure 10: Accessing the Log on the large cabinet ........................................................... 22 Figure 11: Active Current Sharing ....................................................................................... 26 Figure 12: Voltage Correction .............................................................................................. 26 Figure 13: LED Indicators on the standard cabinet ........................................................... 27 Figure 14: LED Indicators on the optional larger cabinet ................................................. 27 Figure 15: Remote Monitor Box ........................................................................................... 36 Figure 16: External circuit breakers .................................................................................... 42 Figure 17: Terminal Connections ......................................................................................... 44 Figure 18: Circuit breakers on the 10-20KVA models ....................................................... 45 Figure 19: Circuit breakers on the 30-60 kVA models ....................................................... 46 Figure 20: Connecting the external battery cabinet ........................................................... 48

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PS-SP Series 3:3 Phase, 10 60 kVA, 3 X 208 Vac, 60 Hz, 192 Vdc

LIST OF TABLES
Table 1: Log Variables .......................................................................................................... 23 Table 2: LED Indicators......................................................................................................... 28 Table 3: RS232 Connector Pin Assignment ....................................................................... 34 Table 4: LED Indicators on Remote Monitor Panel............................................................ 36 Table 5: Control Buttons on Remote Monitor Panel.......................................................... 37 Table 6: Trouble Shooting and Problem Solving ............................................................... 38 Table 7: PC Board Check Points & Voltage Ranges.......................................................... 40 Table 8: External circuit breakers required minimum ratings ....................................... 43 Table 9: Wiring requirements ............................................................................................... 43 Table 10: Technical Specifications...................................................................................... 54

STANDARDS AND CONVENTIONS


This manual contains diagrams that include an image of the UPSs LCD display screen. Unless otherwise indicated, the readings on the display screen in the diagrams are representational only, and are not intended to match the readings on any specific system in a particular environment.

Gamatronic Electronic Industries Ltd.

User Guide and Instruction Manual

PS-SP Series 3:3 Phase, 10 60 kVA, 3 X 208 Vac, 60 Hz, 192 Vdc

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Gamatronic Electronic Industries Ltd.

User Guide

1. SAFETY PRECAUTIONS
1.1

Dos
Read this manual carefully before operating the UPS. Review the safety precautions described below to avoid damaging users or equipment. Install the UPS in a clean and well-ventilated location. Leave at least 20 cm of clearance space between the ventilation holes of the UPS and other objects or walls. The UPS must be well grounded to the buildings grounding system with a conductor that has a current carrying capacity that matches the rating of the UPS. If the unit contains an external battery cabinet, periodically check the grounding connection between the external cabinet and the main UPS cabinet. (The batterys cabinet body must be connected with the grounding screw located on the electronic cabinet or directly to the grounding circuit.) Use the UPS only for its intended purpose. Allow only qualified technicians to service the UPS. There are no userserviceable components. Do not try to repair it yourself!

WARNING
Appropriate precautions should be taken during inspection and servicing; there is a risk of lethal electric shock. The battery cabinet contains 12-Volt batteries that provide high voltage even when the UPS is not connected to the mains.

1.2

Donts
Do not open the cover under any circumstances. Do not insert any objects through the ventilation holes. Do not put objects on the UPS. Do not move the UPS while it is operating. Do not turn the UPS upside down during transportation. Do not connect or disconnect the cable to the battery cabinet before the battery circuit breaker is turned off Do not turn on the battery circuit breaker when the battery cabinet is disconnected from the UPS.

WARNING
Do not touch the battery terminals of external batteries with bare hands.

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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2. GENERAL FEATURES
The PS Series 3/3 Phase Uninterruptible Power Supply (UPS) employs Pulse Width Modulation (PWM) and is controlled by a high performance RISC 1 micro-controller, to provide reliable, sophisticated protection for every type of line fluctuation, including interruption of the AC input .

Figure 1: Schematic Diagram of the Operation of the UPS

In the event of a power failure, the UPS provides backup power for a specific period of time. The system is user friendly. Its operation is simple and requires no previous technical knowledge. The UPS operates on-line and once activated, the unit provides a voltage of 3 208VAC at a stabilized 60 Hz frequency to any practical load. When backup service is provided (when there is a power breakdown in the mains), the UPS is powered by batteries and maintains a constant output voltage supply. The system informs the operator, by means of LED indicators and audible signals, when a power failure occurs. The UPS is equipped with a Static Switch that enables the load(s) device(s) to continue normal operation when the inverter is unable to supply exceptionally heavy loads, such as during power surges, or in case of inverter failure, for any reason. An LCD display on the UPS front panel provides real time, current operational status of the UPS, providing the user with complete up-to-date information. Similar status information may be viewed on a computer monitor via an RS232 communications port. The system can also be connected to the service center via a modem and a telephone line, or to a computer network via an SNMP/WEB agent. The unit consists of two major subsystems:
1

Reduced Instruction Set Computing

General Features

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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Electronic Cabinet that contains all electronic components: charger, inverter, static switch, microprocessor board, panel, etc.

Battery Cabinets that contain batteries and circuit breaker. The unit can operate in parallel with similar Gamatronic UPS units. In this case, the load is shared between the units. The parallel UPS system is the most reliable energy source for any critical load. If the system uses N+1 UPS units (the redundant parallel system), the output voltage is not interrupted even if one of units is faulty. If the parallel system is equipped with a Gamatronic Static Switch unit, the output voltage is not interrupted even if more than one UPS unit is faulty.

2.1

Parallel Operation

The PS-SP UPS can be operated in parallel with similar UPSs. Up to 10 units can be connected in parallel to feed and backup the same load. Two topologies are supported: centralized and decentralized. With a decentralized parallel system, each UPS has its own static switch in which case two systems can be connected in parallel, to provide full redundancy. With a centralized parallel system, the static switch is external instead of inside each UPS. In this configuration, two to ten UPS units may be connected in parallel. See Parallel Operation beginning on page 8.

2.1.1

Advantages of Parallel Operation

Redundancy Parallel operation of the UPS provides redundancy in the event of a UPS failure. Parallel operation is appropriate where the devices supported by the UPS are of critical importance and higher MTBF is required. Load Sharing The PS SP UPS includes a high-speed microcontroller to manage the process of load sharing between the units connected in parallel. The microcontroller also ensures synchronization of the phase and frequency of the output of all of the UPSs.

2.2

Major Subsystems

The PS SP UPS consists of the following modules:

2.2.1

Rectifier

The rectifier supplies a stabilized DC voltage to the device at 216V 2V.

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2.2.2

Batteries

The batteries are always connected to the rectifier output and they supply voltage to the inverter during power failures. During normal operation, the batteries are in standby mode. The batteries for all models are housed in separate battery cabinets.

2.2.3

Inverter

The inverter receives a DC voltage from the charger or batteries and supplies a regulated, frequency-stabilized, AC voltage (power). The inverter incorporates an IGBT transistorized bridge, driver, (PC968 board), an L-C filter circuit, isolated output transformer circuit, current transformer, PC906 board, and a PC801 control board.

2.2.4

Static Switch

In case the inverter cannot supply the load with the correct voltage (for example: because of overload, inrush current on connecting the load, inverter malfunction, etc.), the ST.SW/Bypass automatically transfers the load from the inverter to the mains without voltage interruption or disturbance. When the UPS is in BYPASS mode, the load draws power directly from the mains, bypassing the inverter. The ST.SW automatically switches the load back to the inverter when inverter's output voltage returns to normal. The inverter is synchronized with the mains in both frequency and phase to ensure correct operation of the static switch. The static switch includes the PC690 board and the RA101 - RA103 contactors.

2.2.5

Bypass Isolation Transformer (option)

For customers requesting this option, the UPS includes an isolation transformer connected to the Bypass AC input. The function of this transformer, together with the Inverter isolation transformer, is to create a condition of complete galvanic isolation between the input and output of the UPS.

2.2.6

Control System
Tests input, bypass, inverter, battery voltage, output current, input/output signal frequency, and temperature. Controls the inverter and the bypass changeover contactorRA101 and manages the static switch and charger voltage during battery tests. Controls the Alarm interface. Reads the panel keyboard and sends messages to the front panel LCD display.

The control system performs the following functions:

General Features

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Communicates with devices via the RS232 interface. The control system includes the PC801 control board, PC075/PC085 panel board, PC873 power supply, current, and temperature sensors. Measured voltages and currents are connected to the control board via the PC800 interface board.

2.3

Control Panel

The UPS is equipped with an LCD display and touch pad control panel that enables the user to effectively manage the UPS. Once the UPS is installed, the control panel serves as the users primary interface with the system. Messages, warnings and error conditions are relayed to the user through the control panels LCD display and through audible alarms.

Figure 2: Control Panel on the 10 kVA to 60 kVA models

Figure 3: Control Panel on the 40 60 kVA model with optional larger cabinet

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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2.4

Power-on Self Tests

The UPS automatically performs the following series of diagnostic tests when initially powered on: LED test. All LEDs are lit individually for the operator to monitor. Real-time clock EEPROM. Memory (setup, calibration and events log) is tested.

2.5

Measurement

The user can receive real time information regarding the units operation and condition simply by pressing the appropriate status button. The real time results are displayed on the front panel.

2.6

Real Time

The system includes a real time clock and calendar that sequentially manage the log file and provide historical data to the user. This information is accessible via the LCD display or, optionally, through the RS232 communications port.

2.7

Communications

The UPS relays all the measured data and events of the log file through an RS232 communications port to a host computer or, using a modem connected to a telephone line, to a remote location, or via GMAC or GMACi, proprietary SNMP agents, for network access.

2.8

Event Logs

The system compiles a listing of up to 256 extraordinary events of the mains, unit and load during operation. This data is written to the log file and can be accessed easily at any time through the display panel or computer (optional). This information is very useful for maintenance and analyzing performance statistics.

2.9

Ease of Use

The UPS includes an on-line help feature that explains the systems features and describes each of the LCD control buttons.

2.10

Battery Check

The unit automatically and continuously checks the battery status and the battery cabinet connection with the UPS.

General Features

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2.11

Service Mode

The UPS has a technicians SERVICE MODE that is password protected. Access to the service mode is only permitted after the technician successfully enters an assigned password.

2.12

Emergency Power-Off (EPO)

The system includes a pair of wires linking two Emergency Power-Off terminals, located together with the other terminals. These terminals are labeled EMERG. OFF or EPO (N.C.) The Emergency Power-Off terminals should be connected by a normally closed, 48V 0.1A mushroom-type pushbutton. Pressing the pushbutton opens the contact and shuts down the unit. Power to the load is cut. See also section 5.5, After Use of the Emergency Power-Off Switch on page 33.

2.13

Connections

For the 30-60 kVA models: All connectionsconnection panel, input, output, and batteriesare accessed via the lower portion of the front of the UPS. The user must unlock the door with a flathead screwdriver to access these areas. For the 10-20 kVA models: All connections are made on the rear panel of the UPS.

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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3. PARALLEL OPERATION (OPTION)


Each UPS can optionally operate in parallel with similar units as part of a modular UPS system. Up to ten units can be connected in parallel. Special technical solutions are used to synchronize all the units of the system, to prevent circulation of energy between the UPS units and to isolate the faulty unit from the common power bus. In addition, an active current sharing circuit changes the output voltage of each UPS to provide proportional load sharing between the units. One of the system's units takes on the function of Master. This unit is synchronized to the mains power. The other units are Slaves and follow the Master. The function of Master is not dedicated to one of the units. Any normally functioning UPS can be the Master.

3.1.1

Centralized vs. Decentralized Static Switch

The UPS employs a Static Switch for functional override. In parallel mode there are two possible options of Static Switch operation, centralized and decentralized. In decentralized mode each UPS includes its own Static Switch which works independently. However, if one UPS were to fail, the Static Switch would instantly be triggered and supply the load directly from the mains. Two or more units would then be connected in parallel. This would connect the inverter of the other UPS directly to the mains which could potentially damage the other UPS. Therefore, to avoid such a hazard in decentralized mode, the Static Switches are synchronized using a 3-wire cable. Figure 4 on page 9 shows a cabling diagram for parallel decentralized operation of multiple UPSs. For additional security, a second option is available as a centralized Static Switch. As illustrated in Figure 5 on page 10, in centralized parallel operatoin there is only one Static Switch (in a separate housing) for the entire system. Local static switches are inhibited.This method significanly increases system reliability, because the output voltage is constant even if both UPSs are disconnected. Up to ten units can be connected in parallel.

3.1.2

Decentralized Parallel Mode of Operation

The PS SP UPS uses a simple master/slave hierarchy, where one unit at any given time is designated as the Master UPS and the remaining parallel units are considered Slave UPSs. The Master unit synchronizes its output voltage with the bypass phase and frequency, and transmits the phase and frequency information to the Slave UPSs, which synchronize themselves accordingly. When the Master UPS fails, the next UPS in line becomes the Master, and is now responsible for transmitting phase and frequency information to the Slave UPSs.

Parallel Operation (option)

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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Special Cable for Parallel Operation Gamatronic provides a special cable for connecting the PS SP units in parallel. It is a 15-pin cable that includes Master/Slave logic path A path for the phase and frequency syncronization pulses Buses for active current sharing
UPS 1 Bypass AC Input Static Switch Output

DC link AC Input

Battery Control

AC Output Power Bus

Parallel ST.SW. Bus

Parallel Comm. Bus

AC Output To Load

UPS 2 Static Switch Output

AC Input

DC link

Battery Control

Figure 4: Decentralized Parallel PS - cable connections

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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Bypass AC Input

UPS 1 DC link AC Input


Output Contactor

Static Switch AC Output To Load

Output

Battery
Bypass Reference
- - -

Control

AC Output Power Bus Parallel Comm. Bus

UPS 2 DC link AC Input


Output Contactor

Output

Battery
Bypass Reference

Control

UPS N+1 DC link AC Input


Output Contactor

Output

Battery
Bypass Reference

Control

Figure 5: Centralized Parallel PS - cable connections

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Parallel Operation (option)

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4. CONTROL PANEL & INDICATORS


The control panel serves as an interface between the UPS and the user. Real time information is displayed visually and audibly. Textual information is presented on the LCD display. These messages are often reinforced with audible alerts to alert the user of extraordinary circumstances. Because the control panel of the standard cabinet (used for the 10-60KVA models) differs in appearance from the console of the larger cabinet (an option for the 40-60 kVA models), we discuss two control panels separately, according to cabinet type. The description of the standard 10-60 kVA control panel begins in section 4.1 on this page; the control panel on the larger cabinet (option for 40-60 kVA models) is described beginning in section 4.2 on page 16.

4.1

The Control Panel on the Standard Cabinet

The control panel has 6 round function buttons for controlling the unit and 12 square information buttons for reporting the status of the UPS.

Figure 6: Control panel on the standard cabinet (10kVA to 60kVA models)

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

Control Panel & Indicators

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4.1.1
BUTTON

Function Buttons on the Standard Cabinet


DESCRIPTION

UPS OFF
UPS OFF Pressing the UPS OFF button turns off the UPS. Confirmation of this action is required. Wait 2 seconds, and confirm it by pressing UPS OFF again.

UPS ON
UPS ON Pressing the UPS ON button turns on the UPS and sequentially displays the results of the start-up diagnostic tests

ALARM OFF
ALARM OFF

Pressing the ALARM OFF button silences the alarm that sounds when there is a system fault. If another fault occurs, the alarm returns to active mode. Note: The ALARM LED remains lit until the problem is resolved to notify users about the continued existence of a system fault.

BATTERY TEST
BATTERY TEST

Pressing the BATTERY TEST button manually initiates a battery test. The unit also continuously checks the battery cabinet connection with the UPS. Battery checks are automatically performed at the following times: Upon start-up Every 200 hours of accumulated operating time After battery cabinet reconnection (following a disconnection)

INV
INV Pressing the INV button connects the inverter to the output, manually taking the UPS out of BYPASS mode. Note: There is no display associated with this action.

B/P
B/P

Pressing the B/P button connects the mains to the output, putting the unit into BYPASS mode. The unit requires confirmation of this action. Wait approximately 2 seconds, and confirm the selection by pressing the B/P button a second time.

4.1.2

Information Buttons on the Standard Cabinet

The UPS continually monitors its operational status. The user can display real-time information about this status by pressing the appropriate information button. If an alarm is triggered, the information buttons (except for LOG and ?) display information for approximately 10 seconds, after which the LCD display reverts to the default STATUS display. The UPS maintains an event history in its log. The log can be accessed by pressing the LOG button or, alternatively, by a computer using the optional RS232 connection, or from a remote location via a modem.

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Control Panel & Indicators

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Where appropriate, the LCD display provides information for the R, S, and T phases and for voltage and current. Sample LCD displays are presented below. IN (Input) Press the IN button to display the units Input Voltage. NOTE: Input current current display is available as an option.

IN.

230

230

231

B/P (Bypass) Press the B/P button to display the units Bypass Voltage and Current.

BYP. 232 230 231 45 45 45

INV (Inverter) Press the INV button to display the unit's Inverter Voltage and Current.

INV 230 231 230 45 46 45

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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OUT (Output) Press the OUT button to display the units Output Voltage and Current.

OUT. 230 230 230 45 45 45

FREQ (Frequency) Press the FREQ button to display the units Bypass and Inverter Frequency.

BYP.FREQ. INV.FREQ.

49.9Hz 49.9Hz

The operating inverter frequency is determined by the bypass frequency when operating normally. Otherwise, the inverter frequency is determined by the quartz oscillator and should be set at 50/60 Hz. BATT (Battery) Press the BATT button to display the battery voltage. Note: Battery current display is also available as an option

BATTERY

230V

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Control Panel & Indicators

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TIME Press the TIME button to display the units current day/month (DD/MM), and current time (HH:MM:SS). To set the proper time or date use the SET button, described on page 23.

UPS OK 18/12 12:35:40

STAT (Status) Press the STAT button to display the units status and accumulated working time (HHHHH:MM:SS). For status and fault analysis, see System Fault Diagnostics on page 25.

UPS OK TIME 00548:05:40

Note: This is the default display. TEMP (Temperature) Press the TEMP button to display the status of the unit's thermosensors.

TEMPERATURE NORMAL

LOG The LOG, SET, and HELP buttons are described in section 4.3, which begins on page 21.

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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4.2

The Control Panel on the Larger Cabinet

The control panel has 6 function buttons for controlling the unit and 12 information buttons for reporting the status of the UPS.

Figure 7: Control panel on the larger cabinet (optional for 4060KVA models)

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Control Panel & Indicators

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

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4.2.1
BUTTON

Function Buttons on the Larger Cabinet


DESCRIPTION

UPS ON/OFF
When the UPS is OFF, pressing the UPS ON/OFF button turns on the UPS and sequentially displays the results of the start-up diagnostic tests When the UPS is ON, pressing the UPS ON/OFF button turns off the UPS. Confirmation of this action is required. Wait 2 seconds, and confirm it by pressing UPS OFF again.

BATTERY TEST
BATT TEST
Pressing the BATTERY TEST button manually initiates a battery test. The unit also continuously checks the battery cabinet connection with the UPS. Battery checks are automatically performed at the following times: Upon start-up Every 200 hours of accumulated operating time After battery cabinet reconnection (following a disconnection)

B/P INV
B/P INV
When the UPS is in Inverter mode, pressing the B/P INV button connects the mains to the output, putting the unit into Bypass mode. The unit requires confirmation of this action. Wait approximately 2 seconds, and confirm the selection by pressing the B/P INVbutton a second time. When the UPS is in Bypass mode, pressing the B/P INV button connects the inverter to the output, manually taking the UPS out of Bypass mode. Note: There is no display associated with this action.

ALARM OFF
Pressing the ALARM OFF button silences the alarm that sounds when there is a system fault. If another fault occurs, the alarm returns to active mode. Note: The ALARM LED remains lit until the problem is resolved to notify users about the continued existence of a system fault.

4.2.2

Information Buttons on the Larger Cabinet

The UPS continually monitors its operational status. The user can display real-time information about this status by pressing the appropriate information button. If an alarm is triggered, the information buttons (except for LOG and ?) display information for approximately 10 seconds, after which the LCD display reverts to the default STATUS display. The UPS maintains an event history in its log. The log can be accessed by pressing the LOG button or, alternatively, by a computer using the optional RS232 connection, or from a remote location via a modem. Where appropriate, the LCD display provides information for the R, S, and T phases and for voltage and current.

PS-SP 3:3, 3x220 in, 3x208 60 Hz out

Control Panel & Indicators

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Sample LCD displays are presented below. IN (Input) Press the IN button to display the units Input Voltage.
IN. 230 230 231

NOTE: Input current current display is available as an option.

B/P (Bypass) Press the B/P button to display the units Bypass Voltage and Current.

BYP. 230 230 231 45 45 45

INV (Inverter) Press the INV button to display the unit's Inverter Voltage and Current.

INV. 230 230 231 45 45 45

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Control Panel & Indicators

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OUT (Output) Press the OUT button to display the units Output Voltage and Current.

OUT. 230 230 231 45 45 45

FREQ (Frequency) Press the FREQ button to display the units Bypass and Inverter Frequency.

BYP.FREQ. 49.9Hz INV. FREQ. 49.9Hz

The operating inverter frequency is determined by the bypass frequency when operating normally. Otherwise, the inverter frequency is determined by the quartz oscillator and should be set at 50/60 Hz. BATT (Battery) Press the BATT button to display the battery voltage.
BATTERY 192V

Note: Battery current display is also available as an option

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TIME Press the TIME button to display the units current day/month (DD/MM), and current time (HH:MM:SS). To set the proper time or date use the SET button, described on page 23.

UPS OK 0 01/11 14:23:01

STAT (Status) Press the STAT button to display the units status and accumulated working time (HHHHH:MM:SS). For status and fault analysis, see System Fault Diagnostics on page 25.

UPS OK TIME 00611:01:59

Note: This is the default display. TEMP (Temperature) Press the TEMP button to display the status of the unit's thermosensors.

TEMPERATURE NORMAL

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4.3

The LOG, SET, and HELP Buttons for All Models

This section describes use of the LOG, SET TIME, and HELP information buttons, which operate identically on all models of the UPS, from 10KVA to 60KVA.
Figure 8: LOG Messages Structure LOG Pressing the LOG button displays the units event log, which contains a history of the last 256 important events to occur to the UPS, or to the input AC power or the load, while the UPS was operating.. Examples of logged events include machine startup and shutdown, AC input failure, AC input restore, a swich to Bypass or Battery mode, or a return to Normal mode.

Each log entry is two screens long. The first window to appear is the first part of the most recent fault. Press the down arrow to view the second window of the event. To view the 1st window of a previous event, press the up arrow ; pressing the up arrow once again will show the 1st window of the event previous to that. The down arrow will show the second window. The display cycle is illustrated in Figure 8.

1. 2. 3.

To view the contents of the log: Press the LOG button to enter LOG mode. Press the arrow buttons to scroll through the information recorded in the log.

Figure 9: Accessing the Log on the standard cabinet

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BATTERY LOW 0 01/11 14:23:01

Figure 10: Accessing the Log on the large cabinet

Each log entry requires 2 screens that can be navigated using the up and down arrows. The first screen provides a description of the event with date and time. The second screen shows the log number, variable values and fault results. The log variables include typical UPS parameters for the event, listed in Table 1.

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Table 1: Log Variables

Event Overload Inverter fault Bypass fault

LOG Variable Sum of currents in all phases Vinv (average inverter voltage) in all phases Vbyp (average bypass voltage) in all phases where there is a bypass voltage fault or Hz (Frequency) where there is a bypass frequency fault Average Vin on all phases Temperature C DC voltage Average Vout for all phases

Input fault High temperature Rectifier fault, battery low Other fault

Faults are represented as a hexadecimal word comprising 16 bits: Bit 0: 1 = Overload Bit 1: Inverter Bit 2: Bypass Bit 3: Rectifier Bit 4: Input Bit 5: Phase sequence Bit 6: Temperature Bit 7: Battery test failure Bit 8: Output Bit 9: Load on bypass Bit 10: Circulation (for parallel) Bit 11: Slave receive failure (parallel only) For example, fault 0009H = 0000000000001001 binary which translates as overload and battery test failure. SET (Time) Pressing this button sets the units real-time clock (see Setting the Real Time Clock on page 33.

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"?" (Help Button) Pressing this button provides on-line configuration data for display purposes. Note: Configuration can be modified in service mode only 1. Use the UP and DOWN arrows to scroll through the information. The following messages are presented: Model type: True on-line UPS, model name etc.) Serial number Nominal power Number of phases in and out Nominal input and output voltage between phase and neutral Voltage range of input and bypass Nominal output current per phase Nominal output frequency Frequency tracking range when the inverter is synchronized to the bypass Number of batteries connected in series Nominal capacity of each battery (for use in calculating backup duration where the battery current meter option is installed) DC shutdown voltage in battery discharge mode Bypass: YES for option with bypass, NO for option without bypass Rectifier: YES for UPS, NO for DC/AC inverter Distance shutdown: YES if EPO and shutdown via interface alarm and RS232 are supported, NO if shutdown is inhibited Par. Operation: YES for parallel UPS, NO for stand-alone UPS Load LED bar: Triple for panel with 3 LED bars, Single for one integral bar Input current meter: YES for specified option, NO as standard Battery current meter: YES for specified option, NO as standard Date of manufacture: Format DD/MM/YY Date of last battery installation: Format DD/MM/YY Software version number

2. To quit the help, press the ? button once again.

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4.4

System Fault Diagnostics

Select the STAT button and press the down arrow . The display will show 2 bytes representing the FAULT (see LOG on page 21) followed by two bytes (each of 8 bits) are now on display, each representing the STATE and the INSTRUCTION. To use the hexadecimal indicators, make a note of the bit representations. The STATE byte indications are as follows: Bit 0: Bit 1: Bit 3: Bit 4: Bit 5: UPS power 1 = ON, 0 = OFF Load supply 1 = On bypass, 0 = On inverter Audible alarm 1 = Disabled, 0 = Enabled Load transfer 1 = In progress, 0 = Pending Battery check 1 = In progress, 0 = Pending

The INSTRUCTION byte indications are as follows: Bit 0: UPS power 1 = ON, 0 = OFF Bit 1: Load supply 1 = On bypass, 0 = On inverter Bit 5: Battery check 1 = In progress, 0 = Pending To view fault condition details, press the down arrow , and 9 bytes are displayed on the panel: Byte 1 shows input diagnostics. Indications are as follows: Bit 0: Bit 1: Bit 3: Bit 7: 1 = Fault is in phase R 1 = Fault is in phase S 1 = Fault is in phase T 1 = Fault exists

Byte 2 shows the result of bypass symptoms analysis. Byte 3 shows result of inverter symptoms analysis. Byte 4 shows output voltage diagnostics. Indications are as per byte 1. Byte 5 shows DC voltage diagnostics. Indications are as follows: Bit 0: Bit 1: Bit 2: Bit 3: Bit 4: Bit 6: Bit 7: 1 = Battery is currently discharging 1 = Battery is discharged 1 = Battery is disconnected 1 = Battery check failed 1 = Excessive current difference in battery sets. (Option) 1 = Rectifier failure 1 = Fault exists

Byte 6 shows measured temperature diagnostics. Indications are as follows: Bit 0: 1 = Shutdown limit exceeded Bit 1: 1 = Alarm limit exceeded

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Bit 2: 1 = Fault detected by bi-metal temperature sensor Bit 7: 1 = Fault exists Byte 7 shows bypass frequency diagnostics: Bit 0: 1 = Bypass frequency incorrect Byte 8 shows over-current diagnostics. Indications are as follows: Bit 0: Bit 1: Bit 2: Bit 7: 1 = Over-current detected in phase R 1 = Over-current detected in phase S 1 = Over-current detected in phase T 1 = Fault exists

Byte 9 shows load transferring diagnostics. Indications are as follows: Bit 0: Bit 1: Bit 2: Bit 3: Bit 4: Bit 5: Bit 6: 1 = Transferring started 1 = Inverter is OFF 1 = Inverter restarting 1 = Inverter under diagnosis 1 = Switching to inverter SRSW SCR is ON 1 = Switching to inverter SRSW SCR is OFF 1 = System in wait state .

To view the active current sharing status, press the down arrow

Iact Iavr

IaR IavR

IaS IavS

IaT IavT

Figure 11: Active Current Sharing

I and Ia in Figure 14 show the results of active average current measurements on phases R, S and T using a half-scale offset. Zero current is presented as 128. With positive current this value increases, with negative current, this value decreases. To view the register used for inverter voltage correction, press the down arrow .

CORR RR

RS

RT

Figure 12: Voltage Correction R in Figure 12 shows the contents of the correction register, depending on the load, DC votage abd active current sharing conditions. Initial value of the correction registers is zero.

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4.5

LED Indicators

LED indicators provide at-a-glance information regarding the status or operation of the UPS. They are color coded so that the user can easily and quickly identify areas for concern. Red indicates a fault or abnormal status (usually associated with an audible alarm), and green indicates normal status and operation.

Figure 13: LED Indicators on the standard cabinet

Figure 14: LED Indicators on the optional larger cabinet

The meaning of each of the LEDs is explained in Table 2.

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Table 2: LED Indicators LED BYPASS B/P OVERLOAD BATTERY SYNC CHARGER INVERTER INV LOAD LEVEL LOAD LEVEL MEANING Bypass Normal Output Connected to the Bypass Overload Battery Not Normal Synchronized Inverter Charger Operating Inverter Normal Output Connected to the Inverter Load Level Load Greater Than 100% COLOR Green Red Red Red Green Green Green Green Green Red

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5. OPERATING THE PS SERIES UPS


5.1 Turning the UPS ON

To turn the UPS ON: 1. Turn on the Static Switch Bypass circuit breaker.

2. Wait 20 seconds, then turn on the Rectifier CB. 3. Wait 1 minute and then turn on the BATTERY circuit breaker. On the 10, 15, and 20KVA models the Battery circuit breaker is located on the UPS. On the 30 60 kVA models, the Battery circuit breaker is found on the battery cabinet. 4. The UPS performs a self-test that takes approximately one minute. Verify that the UPS OFF message is displayed on the LCD display after the test is completed. 5. Verify that both the Output circuit breaker and the Maintenance Bypass circuit breaker are turned off 6. Press the UPS ON button on the front panel and wait approximately 40 seconds. The message UPS ON PLEASE WAIT appears as the unit turns on. While you are waiting, the UPS turns on the Inverter, then checks the Bypass voltage. If the Bypass voltage is acceptable the UPS connects the Bypass voltage to the output terminal. The unit then begins to construct the Inverter voltage, after which time it transfers to Inverter mode.

''UPS OFF''

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7. Check the LED indicators to verify that the UPS is now in Inverter mode.

B/P LED INV LED

is is

OFF GREEN

8. The UPS executes an automatic "TIME XXXXXXXX" battery test for 1 minute. 9. Verify that the message UPS OK appears on the LCD display, and that "UPS OK" NO RED LED is lit. 10. Turn ON the UPS Output circuit breaker. 11. The UPS is ready for use and begins charging the batteries. Connect the equipment to be protected by the UPS and verify that it is functioning correctly.

5.2

Turning the UPS OFF

To turn the UPS OFF: 1. Turn off all the loads connected to the UPS. 2. Press twice on the UPS OFF button on the display panel. (On the large-cabinet model, press twice on the UPS ON/OFF button) 3. Turn OFF all the circuit breakers.

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5.3

Activating Maintenance Bypass

The UPS includes a Maintenance Bypass switch which allows the UPS to be shut down for servicing without interrupting the loads. The Maintenance Bypass switch is locked in the OFF position with a small padlock or a protective cover.

WARNINGS !! !!
The Maintenance Bypass switch should be operated by authorized personnel only. To avoid accidental short-circuiting of the UPS output to the mains when entering or leaving Maintenance Bypass mode, be sure to follow these instructions in the order given! To avoid accidental disconnection of the load devices from AC power, be sure to follow these instructions in the order given! NEVER lift the MAINTENANCE BYPASS circuit breaker without first putting the UPS in BYPASS mode (the red B/P light must be lit). For UPSs with the optional Bypass Isolation Transformer, DO NOT turn off the Static Switch Bypass circuit breaker when using the Maintenance Bypass switch.

!! !! !!

To activate the MAINTENANCE BYPASS mode: 1. The UPS must first be transferred to regular Bypass mode. Verify that the SYNC and BYPASS LEDs are lit. If they are not lit, the UPS cannot go into Bypass mode. 2. To put the UPS into regular Bypass mode: 3. 4. 5. 6. 7. 8. On the standard cabinet: press the B/P function button twice (see section 4.1.1 on page12.) On the large cabinet (option for the 40 60 kVA models): press the B/P INV function button twice (see section 4.2.1 on page 17).

Verify that the B/P LED is lit. Turn on the MAINTENANCE BYPASS circuit breaker. Turn off the OUTPUT circuit breaker. Press twice on the UPS OFF button on the display panel. Turn off the RECTIFIER and BATTERY circuit breakers. For units WITHOUT the optional Bypass Isolation Transformer: turn off the Static Switch Bypass circuit breaker.

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Verify that there are no LEDs lit on the display panel. The UPS can now be serviced.

5.4
!! !!

Deactivating MAINTENANCE BYPASS


WARNINGS

The Maintenance Bypass switch should be operated by authorized personnel only. To avoid accidental short-circuiting of the UPS output to the mains when entering or leaving Maintenance Bypass mode, be sure to follow these instructions in the order given! To avoid accidental disconnection of the load devices from AC power, be sure to follow these instructions in the order given! NEVER lift the MAINTENANCE BYPASS circuit breaker without first putting the UPS in BYPASS mode (the red BYPASS light must be lit). For UPSs with the optional Bypass Isolation Transformer, DO NOT turn off the Static Switch Bypass circuit breaker when using the Maintenance Bypass switch.

!! !! !!

To deactivate MAINTENANCE BYPASS and restart the UPS: 1. Verify that the OUTPUT circuit breaker is turned off. 2. Turn on the RECTIFIER , STATIC SWITCH BYPASS, and BATTERY circuit breakers. 3. Verify that the message SELF-CHECK OK appears on the LCD. It is automatically followed by the message UPS OFF. 4. Press the UPS ON button (on the large-cabinet models, the UPS ON/OFF button) and wait 40 seconds (approximately) until the UPS OK message appears on the LCD. 5. Press twice on the B/P button to put the UPS into BYPASS mode. 6. Verify that the B/P LED is lit. 7. Turn on the OUTPUT circuit breaker. 8. Turn off the MAINTENANCE BYPASS circuit breaker. 9. Press on the INV button on the display panel to put the UPS in INVERTER mode. 10. Verify that the green INV light is lit on the display panel. The loads are now supplied by the UPS.

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5.5

After Use of the Emergency Power-Off Switch

After use of the optional Emergency Power-Off switch, the UPS must be restarted as follows: 1. Return the Emergency Power-Off switch to its normal position (N.C.). 2. Turn off all of the ciruit breakers: Output CB Static Switch CB Battery CB Charger CB.

3. After turning off the circuit breakers, wait for 30 to 60 seconds. The UPS can now be turned on as described in Section 5.1, Turning the UPS ON, on page 29.

5.6

Setting the Real Time Clock

The real time clock is composed of the date and time fields and may be set by the user. The date field contains three subfields (DD/MM/YY) and the time field contains two subfields (HH:MM). To set the real time clock: 1. Press the TIME button to enter the time mode. The normal TIME display is shown on the LCD panel. 2. Press the SET button to initiate setting mode. The year is presented as 2 digits. 3. Press the SET button to increase the value. 4. Press the up arrow to continue with the settings, setting month [1-12], day [1-31], hour [0-23] and minutes [0-59].

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6. COMMUNICATIONS
The UPS is connected to a computer or a modem using a shielded cable, with an RS232-type 9-pin female connector. Maximum allowed cable length is 15 meters. There are two types of UPS connections: Directly to a host computer with dedicated software. Remote monitor through a SNMP/WEB management programs for communication with a computer network (optional).
LOCAL DIRECT CONNECTION

6.1

RS232 Interface

The UPS supports standard UPS protocol. Full information about the status of the UPS, the value of its parameters, and the memory events log is displayed on a userfriendly graphic interface. The graphic interface also allows you to use the host computer to execute a set of instructions for the UPS that includes shutdown, restart, battery check, etc. Communication parameters:
COM

RS232
Tx Rx

2400 Baud rate No parity 1 stop bit No flow control


9 6 5 1

SIGNAL RD TD GND

UPS 2 3 5

Table 3: RS232 Connector Pin Assignment

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6.2

The Alarm Interface

The following diagram describes the Alarm Interface

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6.3

Remote Monitor Box (Optional)

The remote monitor box can be located a maximum distance of 50m from the UPS. It is directly connected to the UPS with a 4-wire cable connected to the REMOTE MONITOR interface of the UPS.

Figure 15: Remote Monitor Box

The monitor panel on the front of the monitor box displays audio and visual information about the condition of the UPS, the mains, and the load. Its LEDs are color coded. The meaning of each of the LEDs is explained in the following table:
LED BYPASS BYPASS B/P OVERLOAD BATTERY BATTERY CHARGER CHARGER INVERTER INVERTER INV LOAD LEVEL LOAD LEVEL UPS ON ALARM OFF SYNC MEANING Bypass Normal Fault in Bypass Output Connected to the Bypass Overload (Load more than 100%) Battery Faulty Battery Normal Input voltage is OK Input voltage is not OK Inverter is OK Inverter is faulty Output Connected to the Inverter Load Level Load Greater Than 100% UPS is activated Fault in the system Bypass voltage is synchronized with Table 4: LED Indicators on Remote Monitor Panel COLOR Green Red Red Red Red Green Green Red Green Red Green Green Red Green Red

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The monitor panel also contains buttons for controlling the UPS which are described in the following table:
BUTTON UPS ON UPS OFF INV B/P BATTERY TEST ALARM OFF PURPOSE Not in use Not in Use Manually switches the load from the bypass to the inverter Manually switches the load from the inverter to the bypass Manually starts a battery test Silences the audible alarm Table 5: Control Buttons on Remote Monitor Panel

6.3.1

Connecting the Monitor Box to the UPS


1. Attach the back of the monitor box to the wall. 2. The UPS PC908 board in the monitor box is connected to the PC021 board on the rear panel of the UPS with a 4-wire cable connected to the appropriate 1-4 Pin male or female DB9 connector terminal in the UPS row of terminals. 3. The cable is attached to the side of the monitor box with two screws.

DB9 Row of Terminals

The measurements of the Monitor box are: Length - 265mm, height -135 mm, and distance between the screws on the back of the box - 200mm.

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7. TROUBLESHOOTING
If unit stops operating normally, a red alarm light (ALARM) flashes, a warning beep sounds, and one of the following emergency messages appears on the LCD:
MESSAGE BATTERY LOW INPUT FAULT STATE Battery is low Input voltage is too low. Input voltage is too high. No input voltage Bypass voltage is too low. B/P FAULT Bypass voltage is too high. No bypass voltage OVERLOAD Overload The unit goes to bypass and stays that way as long as there is an overload. The load transfers from bypass to inverter when the load is corrected. Make up to 7 attempts to reconnect to the inverter. Over 90 paralyzes the inverters action and transfers the load to bypass. It returns automatically to normal operation only after the temperature goes below 55. Check the status of the battery switch and the connections to the batteries. A slow beep indicates that the battery is starting to discharge. A fast beep and a TEST BATT light indicates that the battery has almost finished discharging. Works on an independent frequency of the inverter and will synchronize back when the frequency will return to normal. Call service technician Call service technician Corrects itself automatically when the bypass voltage stabilizes or returns. Corrects itself automatically when the input voltage stabilizes or returns. COMMENTS

INVERTER FAULT OVER TEMPERATURE BATT. NOT CONNECT

Malfunctioning inverter

Over temperature

Battery is not connected

BATTERY UNDER LOAD

Power failure. Inverter operating on batteries.

BYPASS FREQ. FAULT FAULT CONDITION SERVICE REQUIRED RECTIFIER FAULT

The frequency bypass exceeds the allowable limits. Self-test has a negative result DC voltage is faulty

Table 6: Trouble Shooting and Problem Solving

Note: The following procedures are relevant in cases where the unit is not operating normally and there are no LCD display panel messages. These procedures are to be performed ONLY BY A TRAINED TECHNICIAN. In the event that the unit has stopped operating in a normal manner, and the display panel is not functioning, the technician should perform the following:

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START

Turn ALL UPS switches OFF

10

Check all board connectors are secure

Wait 5 minutes and restart the UPS

11

Check IC2 on PC901 is securely seated in socket

UPS operating properly?

12
YES
Correct the problem

Problems?

NO

4
YES END

Turn all UPS and battery cabinet switches OFF NO Disconnect UPS from the AC input (mains)

13

Connect UPS to AC input and turn charger switch ON

14

Check voltages between UPS chassis and points on voltage chart

Wait 5 minutes and make sure no control panel indicators are lit

15

YES
Replace PC901

Voltages within specifications?

NO
Replace PC921 or PC971

Remove UPS cabinet right and left panels

Connnect DC voltmeter across C101 and wait for discharge to 5V

16
YES

Is there a display on the LCD? NO


Replace PC950 LCD

Check for burned or damaged components

END A

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Table 7: PC Board Check Points & Voltage Ranges BOARD PC 801 PC 800 PC 800 CHASSIS CHECK POINT TP10 P13/1 P13/2 VOLTAGE 5V 5% 12V 5% 12V 20%

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8. SITE PREPARATION
Electrical codes may vary according to location. Observe all local, state, and Federal electrical codes for acceptable external wiring practices.

Note: These instructions make reference to two types of UPS cabinets. The 80K cabinet (this is just the cabinet name; it bears no relationship to UPS capacity) is shown on the right side of the cover illustration of this book; the 20B cabinet is shown on the left side of the cover.

8.1

Installation Considerations

The UPS is designed to operate under varied environmental conditions. To ensure long-term trouble-free operation, note of the following:
1) 2) 3) 4) Select a well ventilated and dust-free site that is conveniently located to both the electrical closet and the desired load. There must be a minimum of 1 meter of free space in front of the UPS for service accessibility. You must maintain at least 40 cm of free space at the rear of the UPS, for ventilation and to allow connection of required cables. There must be sufficient free space at the sides of the UPS, for service accessibility. For the 80K cabinet, 20cm of free space is required at the sides of the UPS. For the 20B cabinet, 60 to 70 cm of free space is required unless the cabinet is equipped with wheels, in which case 20 cm of free space at the sides of the unit is adequate. 5) 6) Make sure that the air vents are not obstructed. Make sure that the room temperature does not exceed 40C. Both UPS operation and battery charging generate heat. Battery life can be extended by ensuring a cool operating site. Place electrical equipment (load, computer monitor, etc.) at least 1 meter from the UPS. Use the shortest possible output distribution cable runs at the installation site, consistent with logical equipment arrangements and in compliance with NEC and local electrical codes. Allow space for future equipment additions. The permitted ambient temperature range for operating the UPS is 040C (32104F). The recommended ambient temperature for operation is 15-25C (5977F). Humidity must be less than 95% non-condensing. In altitudes above 2000 m. (6560 ft), the UPS rating is reduced.

7) 8)

9)

10) The route and foundation to the installation site must be capable of supporting the weight of cabinets and moving equipment. Plan the route to ensure that the

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unit will pass through all elevators, corners, and doorways without damage. Refer to Table 10 on page 54 for specific information about cabinet size and weight. 11) Heat output of UPS equipment is significant. Make sure that environmental conditioning systems can accommodate this heat load, even during utility outages.

8.2
1) 2)

Electrical Wiring
Verify that power wiring is run in an individual, separate conduit or cable tray. Verify that control wiring is run in an individual, separate conduit. Use of appropriately rated external circuit breakers on the lines from the electrical supply board to the UPS and from the UPS to the distribution board is critically important. See Figure 16 on page 42 and Table 8 on page 43 for the proper circuit breaker ratings. Use of appropriately rated cables between the electrical supply board and the UPS and between the UPS and the distribution board is critically important. For minimum conductor size, refer to Table 9 on page 43, which has been prepared in accordance with NEC requirements. (Please check your local electrical codes to verify compliance with the given grades.) Be sure to observe proper phase sequence when connecting the electrical supply board to the UPS.

3)

4)

Figure 16: External circuit breakers

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Table 8: External circuit breakers required minimum ratings UPS Model 10 kVA 15 kVA 20 kVA 30 kVA 40 kVA 50 kVA 60 kVA Notes: CB S1: Input to Rectifier 3 x 50 A 3 x 80 A 3 x 100 A 3 x 160 A 3 x 200 A 3 x 250 A 3 x 250 A CB S2: Bypass Input 3 x 40 A 3 x 63 A 3 x 80 A 3 x 120 A 3 x 160 A 3 x 200 A 3 x 250 A CB S2: Output from UPS 3 x 32 A 3 x 50 A 3 x 63 A 3 x 100 A 3 x 120 A 3 x 160 A 3 x 200 A CB S4: Battery Cabinet 63 A 80 A 120 A 160 A 250 A 300 A 300 A

1. S1, S2, S3 are 3-phase ac circuit breakers. 2. S4 is a dc circuit breaker rated at 250 Vdc
Table 9: Wiring requirements UPS Model 10 kVA 15 kVA 20 kVA 30 kVA 40 kVA 50 kVA 60 kVA Rectifier Input 3 x 10 mm2 3 x 16 mm2 3 x 25 mm2 3 x 50 mm2 3 x 70 mm2 3 x 70 mm2 3 x 70 mm2 Bypass Input 3 x 6 mm2 3 x 10 mm2 3 x 16 mm2 3 x 25 mm2 3 x 30 mm2 3 x 50 mm2 3 x 50 mm2 UPS Output 3 x 6 mm2 3 x 10 mm2 3 x 16 mm2 3 x 25 mm2 3 x 30 mm2 3 x 50 mm2 3 x 50 mm2 Battery 16 mm2 16 mm2 35 mm2 50 mm2 70 mm2 70 mm2 70 mm2

For the Emergency Power-Off switch (see section 2.12 on page 7), use 2 wires of 1 mm2 cross-section each. This applies for all UPS models described in this book.

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8.3

Terminal Connections

TERMINALS FOR 10-20KVA MODELS (WITH INTERNAL BATTERIES)

TERMINAL FOR 30-60KVA MODELS Figure 17: Terminal Connections

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9. INSTALLATION
9.1 Accessibility
All access to the UPS is through the front of the unit. All connectionsconnection panel, input, output, and static switchesare accessed by opening the front door of the UPS and removing the lower protective panel to reveal the terminal block. Cables should be introduced from the bottom of the UPS.

9.2

Circuit Breakers

The UPS has three automatic circuit breakers that are accessible via the front of the unit. Rectifier CB Static Switch Bypass CB Output CB

The UPS also has a Maintenance Bypass switch. This switch must only be operated by qualified technical personnel and according to the special procedures described in 5.3 and 5.4. Installation of a parallel UPS system is done by qualified technical personal authorized by Gamatronic. A signal cable and software EPROM chip are required for this installation (Contact Gamatronic for details).

Figure 18: Circuit breakers on the 10-20KVA models

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Figure 19: Circuit breakers on the 30-60 kVA models

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9.3
9.3.1

Installation of Standalone UPS


Wiring/Cabling Instructions
1. Open the front access door using a flathead screwdriver to turn the lock. 2. Remove the lower access panel or protection cover. 3. Turn off ALL the circuit breaker switches: Rectifier CB Static Switch Bypass CB Output CB Battery CB Maintenance Bypass CB (should already be off) 4. Ensure that the circuit breakers for all lines from the electrical supply board are OFF. Check for zero voltage on all lines before continuing. 5. Connect one electrical supply cables to the Rectifier AC Input. Connect a separate electrical supply cable and Bypass AC Input terminals of the UPS. Be sure correct phase sequence is followed. Use the proper wire grades, as listed in Table 9 on page 43.

Note: It is critically important that the Rectifier AC Input and Bypass AC Input are fed from different points of the electrical supply board, each with its own separate circuit breaker. For required circuit breaker capacities, see Table 8 on page 43. 6. Connect a cable to the UPSs AC Output terminal. Connect the other end of the cable to the distribution board or to a load device or a dummy load, according to your locations requirements. 7. Connect a ground cable to the UPS ground terminal or ground bus 8. An Emergency Power-Off switch can be installed to enable immediate shutdown of the UPS. Use of a large, external, mushroom-type NC (normally closed) pushbutton rated at 25VCD, 0.1A minimum, is recommended. Connect the Emergency Power-Off switch to the Emergency Power-Off terminals using a 2-wire cable with each wire having a cross-section of 1 mm2.

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9.3.2

External Battery Cabinet

This section is relevant for all models of the UPS. The UPS batteries supply a nominal voltage of 192VDC. The battery cabinet houses 16 batteries of 12V each. 1. Connect the battery cabinet to the UPS with a 3-wire cable (plus, minus, ground). Be sure to use the proper grade of wire as listed in Table 8 on page 43. 2. An external circuit breaker should be installed between the battery cabinet and the UPS. The circuit breaker should be a 2-pole type, rated at 250VDC or better. The battery circuit breaker should be connected between the Auxiliary terminal of the battery cabinet and the Battery Test terminal of the UPS, using a 2-wire cable with each wire having a cross-section of 1 mm2. See Figure xx. 3. The Battery Test function can be used to monitor the status of the battery circuit breaker. When the circuit breaker is open, a Battery Test results in a Battery Low alarm. 4. Connect the battery cabinet to the appropriate terminals of the UPS as shown in Figure 17, on page 44, and according to the schematic in Figure 20.
EXTERNAL BATTERY CABINET

UPS

+
192VDC Battery Terminals

UPS GROUND BUS

Battery Test Terminals

Battery Test Terminals

Figure 20: Connecting the external battery cabinet

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9.3.3

Turning On the UPS for the First Time

1. Verify that all the circuit breakers on the UPS are turned OFF

2. Turn ON the circuit breakers on the electrical supply board. 3. Measure to insure that you have the indicated voltage at the UPSs Rectifier and AC Input terminals:
Between R and S Between S and T Between T and R

220V 10%, 60Hz

4. Measure to insure that you have the indicated voltage at the UPSs Bypass Input terminals:
Between R and N Between S and N Between T and N Between N and Gnd Between R and S Between S and T Between T and R Between N and Gnd 208V 10%, 60Hz 1V maximum! 208V 10%, 160Hz 1V maximum!

5. Turn ON the UPSs STATIC SWITCH BYPASS circuit breaker.

6. Wait twenty seconds, then turn on the UPSs RECTIFIER circuit breaker.

WAIT one minute, then turn on the UPSs BATTERY circuit breaker. 7. The UPS performs a self-test (that takes approximately one minute). Verify that the self-test takes place and that the UPS OFF ''UPS OFF'' message is displayed on the LCD screen when the self-test is completed. 8. Verify that both the Output CB and the Maintenance Bypass CB are turned off.

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9. Press UPS ON, and wait 60 seconds before proceeding to the next step. While you are waiting, the UPS turns on the Inverter, then checks the Bypass voltage. If the Bypass voltage is acceptable the UPS connects the Bypass voltage to the output terminal. The unit then begins to construct the Inverter voltage, after which time it transfers to Inverter mode. 10. Check the LED indicators to verify that the B/P LED is OFF INV LED is GREEN UPS is now in Inverter mode. 11. The UPS executes an automatic battery test for 1 minute. 12. Verify that the message UPS OK appears on the LCD display, and that NO RED LED is lit 13. Turn ON the UPS Output circuit breaker. 14. Measure to insure that the following voltages are present at the UPS output terminal:
BETWEEN R and S S and T T and R
208V 2%

VOLTAGE

15. The UPS is ready for use and begins charging the batteries. Connect the equipment to be protected by the UPS and verify that it is functioning correctly.

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9.4

Installation of Decentralized Parallel Systems

The installation of two or more PS-SP UPSs in Decentralized Parallel mode starts with the individual installation of each of the UPSs. The UPSs are installed as for Standalone mode (see section 9.3 beginning on page 47) with the following differences. The same bypass source is used for each unit, with the same phase order. The rectifier source can be different for each unit, if desired. The units are connected with the Gamatronic-supplied parallel communication cable. When in operation, if any of the UPSs decides to transfer to bypass mode, the other UPSs do the same. The output cables are connected to a common bus with the identical phase order.

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9.5

Parallel Start-Up

This section describes the start-up procedure for parallel UPSs. For a technical description of the parallel scenario, please refer to section 3.1.1 on page 8.

9.5.1

Decentralized (2 UPSs only)

To start-up both UPSs, after successfully completing the installation procedure, and connecting the cables to the rectifier input, ST.SW input, maintenance bypass output and batteries, perform the following steps: 1. Verify that all circuit breakers are turned off in both UPSs. 2. Verify that both UPSs are connected to the same bypass source and with the same phase sequence. 3. Verify that the parallel communication cable is securely connected to the D15 female connector labeled as PAR.COM. on both UPSs. 4. Make sure that the three PAR ST.SW bus terminals in both UPSs are connected to each other in the correct order (1 to 1, 2 to 2 and 3 to 3). The PAR. ST.SW terminals are located on the bottom of the UPS adjacent to the other terminals. 5. Start up one of the UPSs using the procedure described in Turning On the UPS for the First Time on page 49. 6. Start up the second UPS using the procedure described in Turning On the UPS for the First Time on page 49. 7. Leave the output circuit breakers of each UPS OFF. 8. Verify that the following voltage differences exist between the Bypass AC Input terminals of the two units:
V(R-R) V(S-S) V(T-T) V(N-N) 500 mvAC 500 mvAC 500 mvAC 500 mvAC

9. Verify that the MASTER MODE message appears on the LCD screen of the Master UPS when you press the STAT button. 10. Verify that the SLAVE MODE message appears on the LCD screen of the Slave UPS when you press the STAT button. 11. On the Master UPS, transfer the load to BYPASS by pressing the B/P button twice. 12. Check the status LEDs to verify that both UPSs have transferred to bypass mode. The B/P LED should be red, the INV LED should be off. 13. Transfer the Master UPS back to INVERTER mode by pressing the INV button once. 14. Turn ON the Output circuit breaker of the Master UPS.

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15. Turn ON the Output circuit breaker of the Slave UPS. 16. Measure the output current of the Master UPS. The current for each phase (R,S,T) should be less than 10% Inom, as shown in the table.
UPS Model Inom 10 kVA 3A 15 kVA 4A 20 kVA 5A 30 kVA 8A 40 kVA 10 A 50 kVA 12 A 60 kVA 16 A

17. Measure to insure that the following voltages are present at the UPS output terminal:
BETWEEN R and S S and T T and R
208V 2%

VOLTAGE

18. Start to connect loads and verify that both UPSs are automatically sharing the load equally.

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10. TECHNICAL SPECIFICATIONS


Table 10: Technical Specifications
MODEL INPUT 3 Phase X Voltage range Frequency Power walk-in Power factor (PF) OUTPUT Voltage (V) Free-running freq. (Hz) Power (kVA) (KW) Efficiency ac-ac (%) Dissipation (W) at full load (1W = 3.4 BTU) Inverter efficiency at 100% load (%) Regulation Freq. tracking range Slew rate Overload Load P.F. Waveform Crest factor Total harmonic distortion Protection Dynamic response to 100% load change Transition time: to and from line 10 8 90 888 92.5 15 12 90 1333 92.5 20 16 90 1580 93 3 X 208 Vac 60 0.1 % 30 24 90.5 2520 94 1% 0.5, 1, 2, 3, 4 Hz (selectable) 1 Hz/sec. 125 % 10 min.; 150 % 30 sec.; 1000 % 1 cycle 0.8 sinusoidal 3:1 Less than 2 % (at linear load) Overload and short circuit 2% Less than 0.5 msec. Balanced load 1
o

10 K

15 K

20 K

30 K 3 x 220 Vac 20 % 57-63 Hz 12 sec.

40 K

50 K

60 K

0.8 standard; 0.9 with optional filter

40 32 90.5 3360 94

50 40 91 3956 94

60 48 91 4750 94

Phase deviation
Rejection ratio BACKUP OPERATION Backup time Floating dc voltage Nominal dc voltage Batteries (12 Vdc each) Battery recharge time

More than 100 dB As per customer specifications 216 Vdc 192 Vdc External, sealed lead-acid, maintenance-free Approximately 6-8 hours

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MODEL COMMUNICATION OPTIONS RS232 Alarm Remote indication panel SNMP LCD DATA Input Output & Inverter Bypass Batteries Temperature Log (events memory) ENVIRONMENT & OTHER Ambient temperature: Operating permitted optimum Storage Relative humidity Altitude UPS Standard General & Safety EMC Design MTBF Audible noise (dB) at 1.5 m DIMENSIONS * Height (cm) Width (cm) Depth (cm) Weight (kg) w/o batteries

10 K

15 K

20 K

30 K

40 K

50 K

60 K

Shutdown, monitor Shutdown software Optional Optional Voltage Voltage, current, frequency Voltage & frequency Voltage Heatsink Last 256 events

0 to 40 C (32 to 104 F) o o 15 to 25 C (59 to 77 F) o o -20 to 60 C (-4 to 140 F) 95 % max., non-condensing 1500 m w/o derating EN50091-1 EN50091-2 ENV50091-3 100,000 hours, 250,000 hours with static switch 60 62 65 67

95 45 85 250 300 350 450 500

130* 55.5* 111* 650 750

* The 40, 50, and 60 kVA models have an optional, larger cabinet available, measuring 190 cm (h) x 70 cm (w) x 80 cm (d).

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