General Commissioning Procedure and Report: Service Manual

ABB Power Converters Product Group, September 8, 2016
SERVICE MANUAL
General commissioning procedure and report
Valid for:
− Conceptpower DPA500
− Conceptpower DPA D1M / D2M / D3M
− DPA UPScale
− PowerWave 33 S1 / S2
− PowerWave 33 S3
− PowerScale
Contents Introduction
Introduction ........................................................................... 2 The aim of this document is to provide guidelines and
Safety .................................................................................... 2 procedures addressed to the elimination of all incidents and
accidents from commissioning operations.
Introduction ........................................................................ 2 The procedures and suggestion in this document are
Safety recommendation ..................................................... 2 described in a general manner to cover all the following UPS
models:
Project and site information .................................................... 3
− Conceptpower DPA500
A Commissioning info ....................................................... 3 − Conceptpower DPA D1M / D2M / D3M
B End customer info ......................................................... 3 − DPA UPScale
− PowerWave 33 S1 / S2
C Field Service Engineer info ............................................ 3 − PowerWave 33 S3
D Environment.................................................................. 3 − PowerScale
UPS system information ......................................................... 4 Therefore, where for the same function different devices are
used for the different UPS models, a general term instead of
A UPS system .................................................................. 4 the specific names is used (e.g.: isolator is used to indicate
B Electrical installation ...................................................... 4 fuses, switches and breakers).
C Load ............................................................................. 4
D Input ............................................................................. 4
E Output .......................................................................... 5
Safety
F Battery .......................................................................... 5 Introduction
Safety is central to the ABB way of doing things, both for its
General commissioning procedure ......................................... 6 own people and for everyone whose lives and businesses it
A UPS damage cheks ................................................. 6 touches.
Promoting safety must be at the heart of a company’s culture
B UPS positioning ....................................................... 6 and commitment. Therefore, ABB is working hard to achieve
C Electrical installation ................................................. 6 best practice and demonstrate its continuous drive for
improvement.
D UPS Electrical connections ...................................... 7
E UPS parallel installation ............................................ 9 Safety recommendation
F UPS Multidrop installation (optional) prerequisites for Commissioning and service have to be performed only by
all UPS models .......................................................10 qualified and certified Field Service Engineers.
G All models (except ConceptPower DPA & DPA  Please note: if a UPS has been commissioned or serviced
UPScale ST S2) Multidrop installation and by a technician without a valid certificate released by the
configuration ...........................................................10 supplier the warranty does not apply.
H ConceptPower DPA Multidrop installation and Before starting the UPS installation and commissioning:
configuration ...........................................................11 − read carefully both the UPS User Manual and Service
Manual, as well as the Safety documentation (“Safe
I DPA UPScale ST S2 Multidrop installation and working on Electrical Installation”).
configuration ...........................................................11 − read carefully this document to be aware of all the
L Customer interface options .....................................11 necessary steps.
M Modular UPS insertion into the cabinet ....................12

N UPS power-on and settings ....................................12
O UPS switches check ...............................................13
P UPS start-up sequence ...........................................14
Q UPS start-up - battery operation check (all models
except ConceptPower DPA500 & PW33 S3)...........16
R UPS start-up - battery operation check
(ConceptPower DPA500 & PW33 S3) .....................18
S UPS start-up – dummy load test .............................19
T UPS start-up – critical load transfer to the UPS parallel
system ....................................................................20
U End of commissioning tasks....................................20
V Additional commissioning remarks ..........................21
Note .....................................................................................23
2 SERVICE MANUAL | General commissioning procedure and report

Project and site information
A Commissioning info
 1 Name of the project / reference number Ampliación del Laboratorio de Cromatografía La Pampilla
 2 Date of commissioning 04-oct-2018
 3 UPS system location on site Refinería La Pampilla REPSOL, El Callao, Lima, Perú.
B End customer info

 4 End customer name Grupo Tamoin
 5 Contact person Diego Justiniano
 6 Street address Refinería La Pampilla, El Callao.
 7 City and postal code Lima
 8 Country Peru
 9 E-mail / fax 01 500 1583
 10 Telephone number 01 500 1580
C Field Service Engineer info

 11 Field Service Engineer name Carlos Alberto Bermúdez Vargas
 12 Company Pertel Peru
 13 Street address San Luis
 14 City and postal code Lima
 15 Country Peru
 16 E-mail / fax 01 326 7755
 17 Telephone number 01 326 7755
D Environment
 18 Risk level of corrosive gases No Aplica. Indoor
 19 Tidiness of environment No Aplica. Indoor
 20 Dustiness of environment No Aplica. Indoor
 21 How often is the place cleaned? Semanal
 22 Risk level of condensation Existe Aire Acondicionado de Confort .Ajuste 22 grados
 23 Humidity 80 % relative
 24 Temperature Max: 24 °C Min: 20 °C
 25 Air conditioning with cooling Si. En ambas salas. Both Rooms
 26 Raised floor (false floor) Solo sala de UPS.
SERVICE MANUAL | General commissioning procedure and report 3

UPS system information
The UPS system information in this section should be collected before going on site. This enables the Field Service Engineer to have all
the necessary data to configure the UPS units and check the correctness of the complete system once on site.
A UPS system
✔
 1 UPS model Powerwave 33 S3 de 100 Kva
Serial Number of the frames in parallel in the system No Aplica

 2 (for modular systems)
Serial Number of the UPS (module or standalone) in parallel in PWA1756

the system
✔
 3
UPS system configuration ✔

 Single
✔
 4
 Parallel
 Capacity
 Redundancy  redundancy configuration: aN + b
B Electrical installation
✔
 5 External maintenance bypass type and size Manual Switch Breakers ABB XT1C 4X150 Amperios.
✔
 6 Electrical installation configuration (TN-C, TN-S, TT, IT) TN-S
✔
 7 Single pole neutral disconnector Breakers Tetrapolares ABB XT1C 4X150 Amperios
C Load
✔
 8 Load type Cromatógrafos y Compuradoras aún no operativas
Load values Active power: 0 kW Reactive power: 0 kVAr

✔
 9
Apparent power: 0 kVA Power Factor: 1
D Input

✔ 10 Input nominal voltage 380 Vac

✔ 11 Input nominal frequency 60 Hz
Mains rectifier input transformer configuration Primary configuration: 380 Voltios Delta
✔
 12
Secondary configuration: 380 Voltios Estrella
Mains bypass input transformer configuration (only for dual Primary configuration: No Aplica
 13
input feed) Secondary configuration: No Aplica
✔
 14 Input configuration (single or dual input feed) ✔
 Single input feed  Dual input feed
✔
 15 Mains rectifier cable section 120 mm2
✔
 16 Mains rectifier isolator type and size ITM ABB XT1C 4X150 Amp
✔
 17 Mains bypass cable section (only for dual input feed) 120 mm2
 18 Mains bypass isolator type and size (only for dual input feed) No Aplica

E Output
✔
 19 Output nominal voltage 380 Vac
✔
 20 Output frequency 60 Hz
Output transformer configuration Primary configuration: No Aplica

✔
 21
Secondary configuration: No Aplica
✔
 22 Output cable section 120 mm2
✔
 23 Output isolator type and size ABB 250 Amp
F Battery
✔
 24 Battery type ✔
 Lead Acid  Nickel Cadmium
✔
 25 Battery manufacturer and model Kaise KBL121500
Strings: 1 50 Ah: 150

✔
 26
Battery configuration Blocks:
Cells per block: 6
Battery autonomy time estimated at full load

 The battery autonomy (backup time) can be calculated using
✔
 27
the battery manufacturer calculator, or the Service Manual
battery calculator (manual colculation) together with the
30 minutes
battery datasheet. In both cases the maximum UPS power

value must be used for the calculation.
✔
 28 Battery configuration (common or separate) ✔
 Common  Separate
✔
 29 Battery nominal voltage 13.5 Vdc
✔
 30 Battery cable section 70 mm2
✔
 31 Battery isolator type and size ABB 250 Amp

General commissioning procedure
A UPS damage cheks
Check the status of the «TiltWatch» fixed on the UPS box.
− TiltWatch indicator is red: tilting has occurred, check carefully
the status of the complete UPS.
− TiltWatch indicator is green: no tilting occurred ✔
 Green  Red
✔
 1
Note: ok
✔
 2 Unpack the UPS and check for any possible damage. Note: ok
Check for any possible problem on the mechanical structure Note: ok

and components of the UPS.
− Check visually if the functionality of the system may be
compromised (broken cables, stripped screws, IGBT, THY,
Transformer etc. damaged)
− Take pictures where the damage/s is/are clearly evident
✔
 3 − Inform immediately your responsible and the shipping
insurance
− Wait confirmation from your insurance company before
proceeding with the UPS installation. Otherwise, the
insurance probably won’t cover any damage that could
appear during or after the installation
− Inform the ABB After Sales dept. raising a ticket
B UPS positioning
Make sure the UPS is placed in the correct position. Note: ok
 UPS positioning and space recommendation are described
in the User Manual under the “installation and wiring”
section.
PW33 example:
✔
 4
C Electrical installation
Disconnect completely your system from life parts. Refer Note: ok
always to the normative and law present in your country.

✔ 5
 In the Service Manual the document “Safe working on
Electrical Installation” must be used as guideline.
Check that UPS connections cables (Input, Output, Battery) and Note: ok
any fuses mounted on the customer distribution cabinet respect
the size and type recommendation.
✔
 6
 UPS electrical connection description and recommendation
can be found inside the User Manual and the Technical
Datasheet.

Check if the maintenance bypass IA1 is mounted (for PW33 Note: IA1
400/500 and DPA500 models it is optional). If not, be sure that
the customer provides an external maintenance bypass, better
if fitted with an auxiliary contact as feedback to be connected
on the UPS customer interface board.

✔ 7
 The customer interface input terminals for the auxiliary
contact of the external maintenance bypass is provided as
standard only for PW33 400/500 and DPA500 models, for all
the other models it is necessary the request of a special
project.
Check that the input and output cables/wires have the same Note: No Aplica
length on all UPS of the same parallel system. This allow a
correct load sharing both in Inverter and static bypass mode.

✔ 8
Input neutral connection is required to operate the rectifier Note: OK


✔ 9
(3ph + N + PE).
Check the battery polarity before connecting it to the battery Note: OK


✔ 10
isolator, which must be in OFF position.
In case of multiple battery strings always check the polarity of Note: No Aplica
each single string before connecting them together.
All other UPS DPA500 and PW33 S3
✔
 11
D UPS Electrical connections

Check that the UPS connection terminals are correctly Note: OK
configured
− single or dual input feed
− separate or common battery
 UPS connection terminals description can be found inside
the User Manual and in the Technical Datasheet.
PW33 P3W example:
✔
 12
UPScale ST200 example
Never remove the neutral link both in Note: OK

Single and Dual Input Feed.

✔ 13 UPScale ST60 example:
neutral link

Check carefully that all cables are correctly connected and all Note: OK
screws and nuts properly tightened.
✔
 14
 The recommended tightening torque value can be found
inside the User Manual.
Check with a ohm-meter that there are not short circuits Note: OK

✔ 15
between all the UPS power connections.
Re-energize your system following the safety rules. Refer Note: OK


✔ 16
Measure the mains rectifier voltage L1 voltage: 222 Vac
L2 voltage: 221 Vac


✔ 17
L3 voltage: 222 Vac
NPE voltage: 0 Vac
Measure the mains bypass voltage (only for dual input feed) L1 voltage: 222 Vac
L2 voltage: 222 Vac


✔ 18
L3 voltage: 222 Vac
NPE voltage: 0 Vac
Check the correctness of the phase rotation and phases Measures:

sequence, both on the mains rectifier and mains bypass mains bypass L1  L2  L3
connections.
222 Vac 221 Vac 222 Vac
 In case an external maintenace bypass switch is connected
to the UPS, check the phase rotation and sequence both in mains rectifier L1  L2  L3
the input and output of the switch leaving it in OFF position.
This can be done only afterwarts once on the external ext. maintenance L1  L2  L3
maintenance bypass output is present the voltage given by bypass input

✔ 19 222 Vac 221 Vac 222 Vac
the UPS output.
ext. maintenance L1  L2  L3
L1  L2  L3 Clockwise  bypass output
How to check the phase sequence: Note: OK
mains bypass L1  L2  L3
~0Vac ~0Vac ~0Vac
mains rectifier L1  L2  L3
Disconnect completely your system from life parts. Refer Note: OK

✔
 20

E UPS parallel installation
Insert the parallel adapter into the connector JD8 of the parallel Note: No Aplica
interface of each UPS in the parallel system, and fix it with the
two fixing screws
 UPS parallel installation and setting description can be found
inside the User Manual, or with more detail inside the “UPS
parallel configuration” document inside the Service Manual.
DPA500 example:
JD8
 21
Fixing screws
before after
Connect together all the UPS in the parallel system using the Note: No Aplica
proper parallel cables available in various lengths (5 to 25
meters).
Start from JD6 on the first frame (Master) and connect the
cable to JD5 of the second UPS in the series. Then continue on
the same way with the remaining UPS.
DPA500 example:
 22
Set correctly the dip switches and jumpers on the parallel Note: No Aplica
interface and on the NW4019 parallel adapter of all frames.
 The dip-switches and jumper configuration can be found on
the “UPS parallel configuration” document inside the Service
Manual. The configuration change according to the UPS
position and parallel interface layout revision.
 23
DPA500 example:
Dip-switches

F UPS Multidrop installation (optional) prerequisites for all UPS models
 The Multidrop installation is required only if the customer Note: No Aplica
needs to collect from a single point the information coming
from all UPS working in parallel (via SNMP, USHA etc.).
− It is not necessary for the normal parallel operation.
− If required, a Mulitdrop cable must be connected between all
UPSs working in parallel.
− On the Master frame insert the SNMP or USHA adapter
− Connect the SNMP/USHA to the network with an Ethernet
cable.
 24
 UPScale S2 models don’t use the Multidrop cable. The
Multidrop signals are transferred in the parallel system
through the parallel cable.
 ConceptPower DPA models use a serial communication
cable, whereas the other models use a special networking
cable for the Multidrop communication.
 UPS Multidrop installation and setting description can be
found inside the User Manual, or with more detail inside the
“UPS Interface board Setting & Multidrop Configuration”
document inside the Service Manual.
G All models (except ConceptPower DPA & DPA UPScale ST S2) Multidrop installation and configuration
Connect the Multidrop networking cable (available in different Note: No Aplica
lengths) to each customer interface in the parallel system.
− Connect the end of the Multidrop cable labelled «Previous»
on JR1 of the customer interface board (NW22080/85,
NW24083) inside the first frame. The second cable end
labelled «Next» must be connected to JR1 of the next frame.
− In case of more than two frames present in the Multidrop
configuration, insert a «splitter» into the interface boards
mounted on the intermediate frames.
 25
Set the customer interface of the first frame as master and the Note: No Aplica
others as slave.
 26
 The configuration change according to the UPS model and
the customer interface layout revision.
Set the customer interfaces dip-switches and jumpers. Note: OK


✔ 27  The configuration change according to the UPS model and

H ConceptPower DPA Multidrop installation and configuration
In the ConceptPower DPA models connect the Multidrop serial Note: No Aplica
cable (available in different lengths) to each customer interface
in the parallel system.
− Connect the cables between JD11 (female) on the customer
interface board NW8142 inside the first frame and JD12 of
the customer interface board inside the following frame.
Continue on the same way with all frames connected in
parallel.
 UPS Multidrop installation and setting description can be
found inside the User Manual.
 In this case there is no need to configure the customer
 28 interface as master or slave, as it is made automatically.
Example:
I DPA UPScale ST S2 Multidrop installation and configuration

Set the customer interface of the first frame as master and the Note: No Aplica
others as slave.
 29
 The configuration change according to the UPS model and
Set the customer interfaces dip-switches and jumpers. Note: No Aplica

 30  The configuration change according to the UPS model and
L Customer interface options

If required install the battery temperature probe inside the Note: No Aplica
battery frame in the top section (or on the top of the battery
rack as close as possible to the battery), and connect it to the
customer interface.
 31
If required insert and connect to the network the SNMP or Note: OK

USHA adapter card.

✔ 32
 If the Multidrop is not used you need to install this device in
each UPS of the parallel system.

If required connect the necessary signaling cables to the UPS Note: OK
dry contacts (for alarm, battery low, mains status, and other
signals).
 The dry contacts are enabled only if the customer interface
board is «Master». In case it is set as «Slave» (Multidrop
configuration) this contacts are disabled.
For the exceptions and for details read the “UPS Interface
board Setting & Multidrop Configuration” document inside
the Service Manual.
DPA500 example:

✔ 33
M Modular UPS insertion into the cabinet

Slide in carefully the modules until ca. 2.5/3cm to the end of the Note: No Aplica
cabinet slot in order to center them. Then one by one firmly
 34
push the modules completely inside the slot.
 For UPScale modules a minimal force is required.
 35 After the insertion tighten all the module fixing screws Note: No Aplica
For ConceptPower DPA, connect the control panel to the Note: No Aplica
 36
module.
N UPS power-on and settings

Make sure the internal maintenance bypass IA1 and the Note: OK
✔
 37
external maintenance bypass are in OFF position.
Make sure the parallel isolators (output switches) IA2 are in OFF Note: OK

✔ 38
position.
Make sure the battery isolators (fuses, breakers, switches) are in Note: OK
✔
 39
OFF position.
Make sure the bypass isolator is in OFF position. Note: OK

 This action is only possible if the UPS is provided of
✔
 40 accessible bypass fuses or switch. Alternatively it is possible
to de-energize the bypass input line by turning in OFF
position the external isolator (if available).
Re-energize your system following the safety rules. Refer Note: OK

✔
 41
Turn in ON position the UPS mains rectifier isolator in order to Note: OK

✔
 42
supply the UPS logic.
Check on the control panel if the mains rectifier indicator L1 Note: OK

 43
lights in gree color.

Using the control panel set correctly all the UPS parameters Note: OK
according to the installation configuration and the customer
needs.
 UPS parameters setting and description can be found inside
the User Manual, or with more detail inside the “Module
Command Panel” document inside the Service Manual.
The most important parameters to be verified are:
− battery type, number of blocks/cells, and autonomy time
− common or separate battery
− inverter output voltage1 and frequency
− identification number (see below example, set a unique id.
✔
 44 number for each UPS in the same parallel system)
 1If the UPS output voltage value need to be changed, it must

be set during P UPS start-up sequence following the
procedure “Set output voltage” inside the Service Manual.
Note: OK
✔
 45
Make sure that the parameter SERVICE MODE is set to NO
in all the UPS.
O UPS switches check

Check if the status of the maintenance bypass IA1 auxiliary Note: OK
contact is correctly detected in all the UPS of the parallel
system.
✔
 46
− Turn IA1 to ON position, and check that its status is correctly

detected. The UPS display shows the message MANUAL
BYP IS CLOSED.
− Turn IA1 to OFF position, and check that its status is
correctly detected. The UPS display shows the message
MANUAL BYP IS OPEN.
− Repeat the same operations with all the external
maintenance bypass switches IA1 present in the UPS
electrical installation which fit an aux. contact connected to
the UPS customer interfaces.

Check if the status of the parallel isolator (output switch) IA2 Note: OK
auxiliary contact is correctly detected in all the UPS of the
parallel system.
− Turn the parallel isolator IA2 to ON position, and check that

its status is correctly detected. The UPS display of the
respective UPS shows the message PARALLEL SW CLOSE.
− Turn the parallel isolator IA2 to OFF position, and check that
✔
 47 its status is correctly detected. The UPS display of the
respective UPS shows the message PARALLEL SW OPEN.
 For ConceptPower DPA D1M/D2M and D3M the messages
PARALLEL SW CLOSE and PARALLEL SW OPEN are
displayed only when the UPS has been in load-on condition
at least once after being energized. Therefore, leaving IA2 in
OFF position load-on and then load-off the modules. Now
the IA2 check can be done as per above.
 The parallel isolator IA2 is not mounted on all the UPScale
model.
 If the UPS is set as single “S” the parallel isolator IA2 status
is not monitored.
 On stand-alone UPS without parallel option installed (parallel
interface board not mounted) the aux. contact of the parallel
isolator IA2 is not mounted. Therefore its status is not
monitored.
P UPS start-up sequence

After the steps of procedure O UPS switches check, make Note: OK
sure the internal maintenance bypass IA1 and the external
✔
 48
maintenance bypass as well as the parallel isolators IA2 (output
switches) are still in OFF position.
Start the following steps from the last UPS in the parallel Note: OK
system.
ConceptPower DPA example:
last UPS module
✔
 49
Check if the mains rectifier L1 (Line 1) indication in control panel Note: OK

✔
 50
is green.
Give the command to load-on the last UPS. Note: OK

✔
 51
The output of this UPS will be now supplied.
Check if the starting sequence is correctly executed and the Note: OK

✔
 52
UPS switches to Inverter mode (Inverter indication is green).
Close the relative bypass isolator, and check that the L2 (Line 2) Note: OK

✔ 53
indication in the control panel becomes green.
Give the command to transfer the UPS from Inverter mode to Note: OK
✔
 54 Static Bypass mode and back again to inverter mode. Check if
the UPS behavior is correct.
If necessary, set the UPS output voltage to the desired value Note: OK
✔
 55 following the procedure “Set output voltage” inside the Service
Manual.

✔
 56 If all is ok give the command to load-off the UPS. Note: OK
Turn now the parallel isolator IA2 (and then the UPS external Note: OK
✔
 57
output isolator if present) of the UPS under test to ON position.
✔
 58 Give the command to load-on the UPS. Note: OK
Check if the starting sequence is correctly executed and the Note: OK

✔
 59
Check that the message UPS NOW IS MASTER is present in Note: OK

the event log.
✔
 60  This means that the last UPS is able to operate as “Master”
and can pilot the “Slave” UPS (if present) inside the parallel
installation.
✔
 61 Let this last UPS running in Inverter mode. Note: OK
Proceed with the following steps from the previous UPS which Note: No Aplica
is second last the parallel system.
 In case of a modular system proceed with the modules on
the slot below the last module, or in the previous frame with
the module in the uppermost slot.
 62 last UPS module
second last UPS
module
 63 Give the command to load-on the second last UPS. Note: No Aplica
Check if the starting sequence is correctly executed and the Note: No Aplica
 64
Close the relative bypass isolator, and check that the L2 (Line 2) Note: No Aplica
 65
indication in the control panel becomes green.
Give the command to transfer the UPS from Inverter mode to Note: No Aplica
 66 Static Bypass mode and back again to inverter mode. Check if
the UPS behavior is correct.
If necessary, set the UPS output voltage to the desired value Note: No Aplica
 67 following the procedure “Set output voltage” inside the Service
Manual.
 68 If all is ok give the command to load-off the UPS. Note: No Aplica
Turn now the parallel isolator IA2 (and then the UPS external Note: No Aplica
 69
output isolator if present) of the UPS under test to ON position.
 70 Give the command to load-on the UPS. Note: No Aplica
Check if the starting sequence is correctly executed and the Note: No Aplica
 71  In this case the UPS will synchronize its output with the last
UPS already running before transferring to Inverter mode
(this operation is done automatically).
Check that the message UPS NOW IS MASTER is present in Note: No Aplica
the event log.
 72  This means that also the second last UPS is able to operate
as “Master” and can pilot the “Slave” UPS inside the parallel
installation.
Check that on the next UPS (last UPS) the message UPS NOW Note: No Aplica
 73
IS SLAVE is present in the event log.

 It is now tested that the first started UPS (the last one on the No Aplica
series) can operate either as “Master” or as “Slave”.
 This ability cannot be verified if the start-up sequence is
started from the first UPS in the parallel system (the first one
becomes Master and all next UPS will just start as a Slave).
On the second last UPS give the command to transfer the load Note: No Aplica
from Inverter mode to Static Bypass mode.
 74
Check that both UPS switch together from Inverter to Static
Bypass mode.
Give the command to transfer the load from Static Bypass Note: No Aplica
mode to Inverter mode.
 75
Check that both UPS switch together from Static Bypass to
Inverter mode.
 76 Let this two UPS running in Inverter mode. Note: No Aplica
Proceed with the same series of operation with all the UPS Note: No Aplica
present in the parallel system.
 In case of a modular system proceed with the modules on
the slot below, or in the previous frame with the module in
the uppermost slot.
 77
last UPS module
second last UPS
module
Check always that the messages UPS NOW IS MASTER and Note: No Aplica
 78 UPS NOW IS SLAVE are present with the correct sequence on
all the UPS.
After every UPS is tested check always if all of the tested UPS Note: No Aplica
 79 transfer from Inverter to Static Bypass mode and vice-versa at
the same time.
 80 Let the complete UPS parallel system running in Inverter mode. Note: No Aplica
Q UPS start-up - battery operation check (all models except ConceptPower DPA500 & PW33 S3)
 81 Give the commands to load-off the UPS parallel system. Note: No Aplica
Disconnect completely your system from life parts. Refer Note: No Aplica
 82
 83 Check that there is no voltage on the battery charger outputs Note: No Aplica
Connect the battery stabilizer to the battery isolator on the UPS Note: No Aplica
 84
side (it is not used for DPA500 and PW33 S3).
Re-energize your system following the safety rules. Refer Note: No Aplica
 85
 86 Give the commands to load-on the UPS parallel system. Note: No Aplica
In case it is not automatically done, give the command to Note: No Aplica

 87
transfer the UPS parallel system to Inverter mode.

Set SERVICE MODE = YES on all the UPS in the parallel Note: No Aplica
system.
 88
The battery charger will now start and its output voltage will rise
up.
Measure that both the voltage values and the polarity on the Measures:
two sides (UPS side and battery side) of the battery isolator Vdc Vdc
match.
All other UPS battery isolator outputs + N -
 89
battery isolator inputs + N -
Vdc Vdc
 90 Set the parameter SERVICE MODE back to NO. Note: No Aplica
 91 Give the commands to load-off the UPS parallel system. Note: No Aplica
Disconnect completely your system from life parts. Refer Note: No Aplica
always to the normative and low present in your country.
 92
In the Service Manual the document “Safe working on
 93  Disconnect the battery stabilizer from the battery isolator. Note: No Aplica
 94
In the Service Manual the document “Safe working on Electrical
Installation” must be used as guideline.
 Turn the battery isolator to ON position and check that the Note: No Aplica
 96
battery indicator on the control panels becomes green.
In case of separate battery installation repeat the same series of Note: No Aplica
 97
operation (above steps for) for each separate battery.

 98
If possible turn to OFF position the external general mains Note: additional details and example at step 107
rectifier isolator (mains failure simulation) of the UPS parallel No Aplica
system, and check that the complete system start working in
Battery mode for some minutes (depending on the battery
autonomy).
 If general mains rectifier isolator is not available, this test can
be carried out opening one by one the external isolator
connected to the input of each UPS frame of the parallel
 99
system.
In the design phase it must be considered that the UPS is a
power source, which requires the Neutral bonding to be
uninterrupted in all operating modes to maintain the ground
reference of the UPS downstream TN-S distribution system.
A three pole switching device should therefore be used in
the UPS upstream circuit, together with a separated single
pole neutral disconnector used only during maintenance.
Turn back to ON position each mains rectifier isolator, and Note: No Aplica
check both that the complete UPS parallel system switch
 100
back to normal operation and that the battery string are
charging.

R UPS start-up - battery operation check (ConceptPower DPA500 & PW33 S3)
✔
 101 Make sure the UPS parallel system is in load-on condition Note: OK
In case it is not automatically done, give the command to Note: OK

✔
 102 transfer the UPS parallel system to Inverter mode.
Measure the polarity on the two sides (UPS side and battery Measures for DPA500 and PW33 S3:
side) of the battery isolator match.
On the UPS side the DC link voltage is supplied (it will be 641 Vdc
regulated to the floating voltage once the battery are battery isolator outputs + N-
connected). battery isolator inputs + -
 DPA500 and PW33 S3 don’t have the battery string neutral Vdc
central point, the negative side of the battery string is
✔
 103 connected to the neutral of the UPS.
DPA500 and PW33 S3
 Turn the battery isolator to ON position and check that the Note: OK
✔
 104 battery indicator on the control panels becomes green.
In case of separate battery installation repeat the same series of Note: No Aplica
operation (above steps for R UPS start-up - battery operation
 105
check (ConceptPower DPA500 & PW33 S3)) for each separate
battery.

 106
If possible turn to OFF position the external general mains Note: OK

rectifier isolator (mains failure simulation) of the UPS parallel
system, and check that the complete system start working in
Battery mode for some minutes (depending on the battery
autonomy).
 If general mains rectifier isolator is not available, this test can
be carried out opening one by one the external isolator
connected to the input of each UPS frame of the parallel
system.
In a five wire TN-S distribution system, the neutral reference Example of TN-S system
depends on the bonding of the Neutral to the Protective
Earth in the upstream of the UPS near the power source. UPS
In the design phase it must be considered that the UPS is a
✔
 107 power source, which requires the Neutral bonding to be
uninterrupted in all operating modes to maintain the ground
reference of the UPS downstream TN-S distribution system.
A three pole switching device should therefore be used in the
UPS upstream circuit, together with a separated single pole
neutral disconnector used only during maintenance.
When a four pole isolator (switch, breaker,…) is used to
interrupt the mains during UPS operation with load supplied
undesired situations will occur, such as:
 uncontrolled transients, Load
 incorrect operation of the protection against earth faults,
 disturbed operation of downstream equipment connected
to the TN-S system based on the assumption that in this
case the normal potential of the neutral is near ground.
Turn back to ON position each mains rectifier isolator, and Note:

check both that the complete UPS parallel system switch
✔
 108
back to normal operation and that the battery string are
charging.

S UPS start-up – dummy load test
✔
 109 Give the commands to load-off the UPS parallel system. Note: OK

always to the normative and low present in your country.
✔
 110
Connect a dummy load to the output of the UPS parallel Note: No Aplica
✔
 111 system.
 112

 114
Turn on the dummy load and increase gradually up to as close Note: No Aplica
as possible 100% of the UPS parallel system power.
 115
Disconnect the load should any problem be faced during this
procedure.
Check that the load is shared equally between all the UPS of Load %: No Aplica
the parallel system.
 116
 MEASUREMENTS  OUTPUT POWER % Note: No Aplica
Measure the output voltage and current L1 voltage: 220 Vac L1 current: 0A
L2 voltage: 220 Vac L2 current: 0A

✔
 117
NPE voltage: 2.0 Vac N current: 0A
Measure the mains rectifier voltage and current L1 voltage: 229 Vac L1 current: 0A

✔
 118
0A
L3 voltage: 228 Vac L3 current:
NPE voltage: 2.0 Vac N current: 0A
Give the command to start a deep battery test. Estimated autonomy full load: No Aplica min
 The actual battery autonomy can now be measured.
 119 Measured autonomy actual load: No Aplica min
Note: No Aplica
Check on all the UPS of the parallel system that there are not Note: OK
✔
 120 active alarms.
✔
 121 Give the commands to load-off the UPS parallel system. Note: OK

✔
 122
 123 Disconnect the dummy load Note: No Aplica

T UPS start-up – critical load transfer to the UPS parallel system
 Ideal UPS parallel system represented in a state of complete Note: OK
isolation, with the load supplied through the External
Maintenance Bypass.
External Maintenance Bypass
Bypass Input
Manual BYP
IA2
UPS 1
Rectifier Input
✔
 124
Manual BYP
IA2
UPS 2
Critical Load
Main External
Output Isolator
Manual BYP
IA2
UPS n
External Output Isolators
External Input Isolators
Make sure the UPS parallel system is running in Inverter Mode Note: OK
✔
 125 with external output isolators in ON position.
Give the command to transfer the UPS parallel system from Note: OK
✔
 126 Inverter mode to Static Bypass mode.
Turn to ON position the UPS maintenance bypass switch (called Note: OK

✔
 127 also manual bypass) IA1 (if they are present)
Turn to ON position the Main External Output isolator. Note: OK
✔
 128  The critical load is now supplied in parallel through the
External Maintenance Bypass, the UPS maintenance bypass
IA1 and the UPS static bypass line.
Turn to OFF position the External Maintenance Bypass and lock Note: OK
✔
 129 it.
✔
 130 Turn to OFF position all the UPS maintenance bypass IA1. Note: OK
Give the command to transfer the UPS parallel system from Note: OK
✔
 131 Static Bypass mode to Inverter mode.
 The critical load is now protected.
U End of commissioning tasks

The following 3 files must be downloaded with NewSET service Note: No Aplica
 132 tool from all the UPS in the system at the end of the
commissioning, or in case of problems.
 133 Download the event log, and only after that clear the alarm list! Note: No Aplica
 134 Download the main control board parameters. Note: No Aplica
 135 Download the customer interface parameters. Note: No Aplica

V Additional commissioning remarks
Remarks:
 136

Note
Should technical support be needed during the commissioning
of an ABB UPS please open a ticket and through it send us the
followings:
− this report filled in with all the information up to the step
were you are facing problems;
− the complete event log file downloaded from all the UPS in
the same system;
− the main control board parameters downloaded from all the
UPS in the same system;
− the customer interface parameters downloaded from all the
frames in the same system.
Having all this information already from the beginning of the
troubleshooting enables a faster resolution of the issue.

Contact us
Our support team can be reached in Your after sales team: ABB Power Protection SA
the following ways: Via Luserte Sud 9
Manager: CH-6572 Quartino
For support requests please use your Zoltan Gal Switzerland
credentials to log into the UPS Support
Ticketing Portal Service support
https://www226.abb.com David Muntwyler
Emanuele Ravano
The portal is handled by all our Service Marcello Soldini
Support Engineers, and the access is Giuseppe Landolfi
provided to trained and certified Field Miodrag Miladinovic
Service Engineers.
How to get the credentials to access Training
to the UPS Support Ticketing Portal: Giuseppe Landolfi
dm.nwp.tkt.access.request@ch.abb.com
Documentation
Hotline number: Alessandro Piccardi
Tel: +41 91 850 21 62
Administration and academy
Administration support: Ivo Quaresma
CH-ups-orders@abb.com
Service product management
CH-warranty-express@abb.com Marco Albasser
Note
We reserve the right to make technical changes or
modify the contents of this document without
prior notice. ABB does not accept any
responsibility whatsoever for potential errors or
possible lack of information in this document.
We reserve all rights in this document and in the

subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
utilization of its contents in whole or in parts is
forbidden without prior written consent of ABB.

General Commissioning Procedure and Report: Service Manual

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ABB Power Converters Product Group, September 8, 2016

M Modular UPS insertion into the cabinet ....................12

2 SERVICE MANUAL | General commissioning procedure and report

 2 Date of commissioning 04-oct-2018

B End customer info

 5 Contact person Diego Justiniano

 6 Street address Refinería La Pampilla, El Callao.

 7 City and postal code Lima

 9 E-mail / fax 01 500 1583

 10 Telephone number 01 500 1580

C Field Service Engineer info

 12 Company Pertel Peru

 13 Street address San Luis

 14 City and postal code Lima

 16 E-mail / fax 01 326 7755

 17 Telephone number 01 326 7755

 19 Tidiness of environment No Aplica. Indoor

 20 Dustiness of environment No Aplica. Indoor

 21 How often is the place cleaned? Semanal

 22 Risk level of condensation Existe Aire Acondicionado de Confort .Ajuste 22 grados

 24 Temperature Max: 24 °C Min: 20 °C

 25 Air conditioning with cooling Si. En ambas salas. Both Rooms

 26 Raised floor (false floor) Solo sala de UPS.

SERVICE MANUAL | General commissioning procedure and report 3

Serial Number of the frames in parallel in the system No Aplica

Serial Number of the UPS (module or standalone) in parallel in PWA1756

UPS system configuration ✔

Load values Active power: 0 kW Reactive power: 0 kVAr

4 SERVICE MANUAL | General commissioning procedure and report

Output transformer configuration Primary configuration: No Aplica

Strings: 1 50 Ah: 150

Battery autonomy time estimated at full load

battery datasheet. In both cases the maximum UPS power

SERVICE MANUAL | General commissioning procedure and report 5

Check for any possible problem on the mechanical structure Note: ok

6 SERVICE MANUAL | General commissioning procedure and report

Input neutral connection is required to operate the rectifier Note: OK

Check the battery polarity before connecting it to the battery Note: OK

D UPS Electrical connections

UPScale ST200 example

Never remove the neutral link both in Note: OK

SERVICE MANUAL | General commissioning procedure and report 7

Re-energize your system following the safety rules. Refer Note: OK

Measure the mains rectifier voltage L1 voltage: 222 Vac

L2 voltage: 221 Vac

NPE voltage: 0 Vac

L2 voltage: 222 Vac

NPE voltage: 0 Vac

Check the correctness of the phase rotation and phases Measures:

Disconnect completely your system from life parts. Refer Note: OK

8 SERVICE MANUAL | General commissioning procedure and report

SERVICE MANUAL | General commissioning procedure and report 9

Set the customer interfaces dip-switches and jumpers. Note: OK

10 SERVICE MANUAL | General commissioning procedure and report

I DPA UPScale ST S2 Multidrop installation and configuration

Set the customer interfaces dip-switches and jumpers. Note: No Aplica

L Customer interface options

If required insert and connect to the network the SNMP or Note: OK

SERVICE MANUAL | General commissioning procedure and report 11

M Modular UPS insertion into the cabinet

N UPS power-on and settings

Make sure the bypass isolator is in OFF position. Note: OK

Re-energize your system following the safety rules. Refer Note: OK