Sect-2

Section 2: Installation & Commissioning

Chapter 1 - Installation

1.1 Introduction ........................................ .............................................................. ............................................ ................................ .......... 2-1 1.1.1 Equipment Equipment positioning positioning and environmental considerations considerations .......... 2-2 1.1.2 Raised Floor Floor Installation ............................................. .............................................................. ................. 2-2 1.1.3 Battery Location ..................................................... ........................................................................... ...................... 2-2 1.2 Preliminary Preliminary Checks ........................................ ............................................................... .......................................... ................... 2-4 1.3 Connecting Connecting the UPS power cables ............................................. ........................................................... .............. 2-5 1.3.1 Cable entry ............................................................ .................................................................................. ........................ 2-5 1.3.2 Cable rating ....................................... .............................................................. ........................................... .................... 2-5 1.3.3 Cable connections .......................................... ................................................................ .............................. ........ 2-6 1.3.4 Safety earth ........................................ .............................................................. .......................................... .................... 2-6 1.3.5 Cabling procedure .................................................... ........................................................................ .................... 2-6 1.4 Battery Battery Installation ........................................ ............................................................... ......................................... .................. 2-10 1.4.1 Battery circuit breaker boxes boxes ........................................... ..................................................... .......... 2-11 Chapter 2 - Commissioning Procedure

2.1 Introduction ........................................ .............................................................. ............................................ .............................. ........ 2-13 2.2 Procedure overview ....................................... ............................................................ ......................................... .................... 2-14 2.3 Pre-commissioning Pre-commissioning Checks ......................................... ................................................................ ........................... .... 2-16 2.3.1 Power Power cable installation ............................................................. ............................................................. 2-16 2.3.2 Control Control cable installation ............................................ ........................................................... ............... 2-17 2.3.3 Battery Power Cable Installation ........................................... ............................................... .... 2-19 2.3.4 Printed circuit board board configuration jumper selection ................. ................. 2-20 2.3.5 Pre-power checks ....................................... ............................................................ ................................ ........... 2-26 2.3.6 Initial utility power power connection .................................................. .................................................. 2-28 2.4 Start-Up Start-Up and software commissioning ......................................... ................................................... .......... 2-29 2.4.1 Operator Control Panel display display screen ...................................... ...................................... 2-29 2.4.2 Applying power to the UPS ............................................ ....................................................... ........... 2-30 2.4.3 Password protection and operation operation .......................................... ............................................ .. 2-30 2.4.4 Language Selection Selection ......................................... ................................................................ ........................... .... 2-31 2.4.5 Selecting the UPS UPS SETUP parameters parameters ....................................... ....................................... 2-33 Setting the basic basic UPS configuration ................................ ................................ 2-34 Setting the UPS UPS working voltage parameters .................. 2-34 Setting the UPS frequency parameters ............................ ............................ 2-35 Setting the Battery parameters ......................................... ......................................... 2-36 2.4.6 Selecting the UPS UPS MAINTENANCE parameters ...................... 2-39 Accessing the maintenance menu .................................... .................................... 2-39 Entering the Serial Number Number .......................................... ............................................. ... 2-39 Entering the current Date and Time ................................. ................................. 2-40 Entering the Service details ............................................ .............................................. 2-40

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i

SECTION 2 - In s t al l at i o n & Co m m i s s i o n i n g

7200 Ser i es UPS Ser v i c e Man u al

2.4.7 Selecting the UPS UPS FUNCTION parameters parameters ............................... 2-40 Accessing the function menu ........................................... ........................................... 2-40 Setting the Battery Battery Test parameters ................................. ................................. 2-42 Setting the the Generator parameters ..................................... ..................................... 2-43 Setting the Panel Panel Setup selections .................................... .................................... 2-44 Setting the NEXT NEXT PAGE selections ................................ ................................ 2-46 2.5 Power checks ...................................... ........................................................... ........................................... ............................... ......... 2-47 2.5.1 Applying power to the UPS ............................................ ....................................................... ........... 2-47 2.5.2 Monitoring Monitoring & recording the UPS operating parameters ............ 2-47 2.5.3 Power module ON/OFF functional checks ................................ ................................ 2-49 Accessing the ON/OFF menu screen ............................... ............................... 2-49 Inverter test ......................................... ................................................................ ............................. ...... 2-50 Bypass test .......................................... ................................................................. ............................. ...... 2-50 Rectifier and battery autonomy test ................................. ................................. 2-50 2.5.4 Battery test .......................................... ................................................................. ....................................... ................ 2-51 2.5.5 Emergency Emergency remote power power off check ......................................... ........................................... 2-53 2.5.6 Battery boost boost test (if applicable) applicable) ........................................... ................................................ ..... 2-53 2.5.7 On-Generator test (if applicable) ...................................... ............................................... ......... 2-54 2.6 Commissioning conclusion (‘single module’) ....................................... ....................................... 2-55 2.7 Parallel System System Start Up (‘1+1’ System) ......................................... ............................................... ...... 2-55 2.7.1 Initialisation ........................................... ................................................................... .................................... ............ 2-55 2.7.2 Parallel logic PCB calibration .................................................... .................................................... 2-56 2.8 Testing the Complete Parallel System ................................... .................................................... ................. 2-57 2.8.1 Module Module starting ........................................ ............................................................... .................................. ........... 2-57 2.8.2 Inverter bypass bypass re-transfer checks ...................................... ............................................. ....... 2-57 Redundant configuration configuration system power checks ............... 2-58 Non-redundant configuration system power power checks ........ 2-59 2.9 Commissioning conclusion conclusion (‘1+1’ system) ............................................ ............................................ 2-60 2.10 Voltage and Frequency Conversion ............................................ ..................................................... ......... 2-61 2.10.1 Rating considerations and battery sizing ................................. ................................. 2-61 2.10.2 Hardware conversion ........................................ ............................................................ ....................... ... 2-61 2.10.3 Software conversion ..................................... ........................................................... ............................ ...... 2-62 Setting the UPS UPS working voltage parameters .................. 2-63 Setting the UPS frequency parameters ............................ ............................ 2-63 Setting the Battery parameters ......................................... ......................................... 2-64 2.10.4 Calibration conversions ........................................... ........................................................... ................ 2-67 Recalibrating the battery battery charging voltages ..................... 2-67 Completion of UPS SETUP configuration ...................... 2-68 Chapter 3 - Converting single (pre Jan 1997) units to 1+1 capability

3.1 Introduction ........................................ .............................................................. ............................................ .............................. ........ 2-69 3.2 Conversion Conversion Procedure ......................................... ............................................................... ................................... ............. 2-69

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S-2.FM5 - Issue 2 Dated 21/08/97

Section 2:

Chapter 1 - Installation

1.1

Introduction

WARNING

Do not apply electrical power to the UPS equipment before the arrival of the commissioning engineer.

WARNING

The UPS equipment should be installed by a qualified engineer in accordance with the information contained in this chapter and the drawing package shipped inside the UPS cabinet.

WARNING

Battery hazards: Special care should be taken when working with the batteries associated with this equipment. When connected together, the battery terminal voltage will exceed 400 Vdc and is potentially lethal. Eye protection should be worn to prevent injury from accidental electrical arcs. Remove rings, watches and all metal objects. Only use tools with insulated handles. Wear rubber gloves. If a battery leaks electrolyte, or is otherwise physically damaged, it should be placed in a container resistant to sulphuric acid and disposed of in accordance with local regulations. If electrolyte comes into contact with the skin the affected area should be washed immediately.

This chapter contains information regarding the positioning and cabling of the UPS equipment and batteries. Because every site has its peculiarities, it is not the aim of this chapter to provide step-by-step installation instructions, but to act as a guide as to the general procedures and practices that should be observed by the installing engineer. Important Note:

1+1

Options:

1+1

These instructions are written specifically for a ‘single-module’ installation. If you are installing a two-module ‘1+1’ system you should follow the instructions provided for the ‘single-module’ installation installation and then complete the inter-module control cabling to complete the installation. If you are converting an early (pre January 1997) module for ‘1+1’ operation then refer to Chapter 3 and 3 and carry out the necessary modifications prior to installing the module. There are several options available in conjunction with a ‘1+1’ configured system, such as common battery operation. Read the instructions that accompany any such option prior to commencing installation to understand their impact (if any) on the following procedure.

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SECTION 2 - In s t al l at i o n & Co m m i s s i o n i n g CHAPTER 1 - Installation Procedure

1.1. 1.1.1 1


Equipment positio ning and environmental considerations The UPS cabinets are fitted with castors to facilitate ease of movement and positioning. When the equipment has been finally positioned ensure the adjustable jacking feet are set so that the UPS will remain stationary and stable. The UPS can be lifted using either a fork lift or a cradle. When lifting, take care not to damage the castors or jacking feet located on the bottom of the unit.

WARNING

Ensure the UPS weight is within the designated S.W.L. of any handling equipment. See the UPS specification for weight details. Do not move battery cabinets with the batteries fitted.

The UPS module should be located in a cool, dry, clean-air environment with adequate ventilation to keep the ambient temperature within t he specified operating range. Where ventilation is poor and the ambient temperature high, a system of extractor fans should be installed to aid cooling-air flow; and a suitable air filtration system used where the UPS is to operate in a dirty environment.

Cables: All control cables should be screened and run in metal conduits (or ducts) separate from the power cables; all conduits and ducts should be electrically bonded to the metalwork of the cabinets to which they are connected.

Cooling air flow: All the models in the 7200 range are force-cooled by internal fans. Cooling air enters the cabinet through ventilation grills located at the bottom of the front doors and is exhausted e xhausted through the fan grills located on the rear panel; you must therefore allow for a minimum gap of 250mm behind the unit to allow adequate air flow (See Figure 2-1) .

Clearances: Clearance around the front of the equipment should be s ufficient to enable free passage of personnel with the doors fully opened.

1.1.2 1.1.2

Raised Floor Installatio n If the equipment is to be located on a raised floor it should be mounted on a pedestal suitably designed to accept the equipment point loading. The installati on diagrams accompanying the system identify the location through which the cabinet can be secured to the floor.

1.1.3 1.1.3

Battery Locati on Temperature is a major factor in determining the battery life a nd capacity. Battery manufacturers quote figures for an operating temperature of 20ºC. Operating above this temperature will reduce the battery life, yet operating below will reduce the battery capacity. In a normal installation the battery temperature should be maintained between 15ºC and 25ºC. Batteries should be mounted in an environment where the temperature is consistent and even over the whole battery. Ke ep batteries away from main heat sources or draughty air flows etc. Pedestals are required for the battery cabinets if they are to be installed on raised floors, in the same way as for the UPS cabinets.

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7200 Series UPS Service Manual

SECTION 2 - Installation & Commissioning CHAPTER 1 - Installation Procedure

Figure 2-1: Installation Diagram FRONT VIEW 250

SIDE VIEW 800

4

0 0 4 1

FRONT

3

5 5

710 Adjustable fixing feet

Castors for ease of movement

REAR VIEW

BASE 5 5 0 6

5 2 1

0 0 8

0 4

200 85 10 200 125 710

5 . 2 9

REAR VIEW

3

1

Entry panel for all power cables

2

Entry panel for all control cables

3

Air inlet ventilation grills

4

Minimum clearance from wall 250mm

5

Cabinet extractor fans - additional fans are fitted when the input harmonic filter is included Weights 30kVA = 480kg.

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40kVA = 540kg.

60kVA = 620kg.

2-3


1.2


Prelimin ary Checks Before you install the UPS hardware you should carry out the following preliminary checks: 1. Verify that the UPS room satisfies the environmental conditions stipulated in the equipment specification, paying particular attention to the ambient tem perature and air exchange system. 2. After removing any packaging debris, visually examine the UPS and battery equipment for transit damage, both internally and externally. Report any such damage to the shipper immediately. 3. Verify that the shipment is complete - e.g. that the battery contains the correct number of cells etc. Report any discrepancy immediately. 4. When you are satisfied that the equipment is complete and in good condition move it to its proposed final position. Figure 2-2: Cable Entry Locations

Auxiliary terminal block (X3) Main chassis earth busbar

Power cable entry panel

Adjustable fixing feet

2-4

Castors

Control cables entry position

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1.3


Connectin g the UPS pow er cables Before cabling-up the UPS, ensure that you are aware of the location and operation of the external isolators that connect the UPS input/bypass supply at the mains distribution panel. Check that these supplies are electrically isolated, and post any necessary warning signs to prevent their inadvertent operation.

WARNING

1.3.1

Cable entry Cables enter the UPS modules via entry panels in the base of the cabinet. As shown in Figure 2-2, separate entry points are provided for the power cables (which include the input, output and battery cables) and control cables (which includes battery control, remote stop and remote communication wiring).

1.3.2

Cable ratin g The input/output cables can be sized to suit the modules' rating according to Table 2-1 below. Table 2-1: BUSBAR CONNECTION STUD SIZE

NOMINAL CURRENT: A mps Recommended Cable Size (mm2) UPS RATING (kVA)

30

40

60

Input Mains with full battery recharge

Bypass/Output at full load

Battery at min. battery voltage

380V

400V

415V

380V

400V

415V

64

59

56

46

44

42

82

(16)

(16)

(16)

(10)

(10)

(10)

(25)

85

78

73

61

58

56

110

(25)

(25)

(25)

(16)

(16)

(16)

(35)

128

117

109

91

87

84

163

(35)

(35)

(35)

(25)

(25)

(25)

(50)

Input/ Output Cable Terminat ions U-V-W-N

Battery Terminat ions +ve & -ve

M6 Bolt

M8 Bolt

M6 Bolt

M8 Bolt

M6 Bolt

M8 Bolt

(nn) mm2 is the recommended minimum size according to BS7671 Table 4D1A (IEE regs. 16th Edition). The following recommendations are guidelines only and superseded b y local regulations and codes of practice where applicable:

1. The neutral conductor should be sized for 1.5 times the output/bypass phase current. 2. The earth conductor should be sized at 2 times the output/bypass conductor (this is dependent on the fault rating, cable lengths, type of protection etc.). 3. BS7671 Table 4D1A applies to single core PVC-insulated, non armoured cable in an ambient temperature of 30ºC, according to fixing method 1 – sam ples shown in Figure 2-3.

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Figure 2-3: Cable fixing samples from method 1

Sheathed cables clipped direct to or lying on a non-metallic surface

1.3.3

Cable conn ection s The input (bypass) mains cables, UPS output cables and main battery cables are connected to busbars fitted to the power isolator switches (lug terminations required). The battery circuit breaker control cables and the external emergency stop cables (optional) are connected using female spade connectors to an auxiliary terminal block identified as “X3” - (See Figure 2-5).

1.3.4

Safety earth The safety earth busbar is located near the input and output power supply connections as shown in Figure 2-5. The site safety earth cable must be connected to the earth busbar and bonded to each cabinet in the system and all cabinets and cable trunking should be earthed in accordance wit h local regulations.

WARNING

1.3.5

Failure to follow adequate earthing procedures can result in electric shock hazard to personnel, or the risk of fire, should an earth fault occur.

Cabling proc edure Once the equipment has been finally positioned and secured, connect the power cables as described in the following procedure. Study the connection diagram in Figure 2-5. Input mains supply cables

1. Verify that the UPS equipment is totally isolated from its external power source and all the UPS power isolators are open. 2. Connect the a.c. input supply cables between the mains distribution panel and the UPS rectifier input supply busbars (top of Q1) and tighten the connections to 5,4 Nm – ensure correct phase rotation. Bypass mains supply cables

3. If the installation does not include the provision of a separate bypass supply then: a) Ensure that the ‘split bypass’ links are fitted between the input mains bus bars (top of Q1) and the bypass supply busbars (junction of Q2/Q3) – see Figure 2-5. b) Ensure that the input supply neutral is connected to N3. c) Jump to step 5. 4. If the installation does include the provision of a separate bypass supply then: a) Connect the bypass supply cables between the bypass mains distribution

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panel and the bypass supply busbars (junction of Q2/Q3) – see Figure 2-5. – ensure correct phase rotation. b) Ensure that the bypass supply neutral is connected to N3 c) Tighten the connections to 5,4 Nm. d) Remove the ‘split bypass’ links are (if fitted) between the input mains bus bars (top of Q1) and the bypass supply busbars (junction of Q2/Q3) – see Figure 2-5. Figure 2-4: UPS External Cables

A B C

D E F G H

A

Rectifier a.c. input supply

E

Battery control/temp. compensation

B

Bypass a.c. input supply

F

Communications to PC or modem

C

UPS a.c. output

G

Communications to AS400/external alarms

D

Battery power

H

Remote emergency power off (EPO)

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2-7



Figure 2-5: Power and control cable connections

K1

3 1 F

Reset button Auxiliary terminal block (X3) Terminals are male type spade connectors

Safety Earth

These links must be removed for split bypass systems

1

R S T N Output Connections (to Load)

2

3

. t t p a m B e T

R S T N Input connections for split bypass system (from mains a.c. supply) R S T N

4

5

6

7

8

9 10 11 12

n t p i r o c a t m t n B m o C o c t . t C x a u B a B C t t a B

E.P.O.

Bypass input supply neutral (split bypass system) OR Input supply neutral (non-split bypass) UPS Rectifier (input mains) connections (from mains a.c. supply)

R S S T 3 1 2 1 1 1 F F F

2-8

All power connections require lug type terminations. Connections torque loading is 5,4Nm

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5. Connect the UPS output cables between the output busbars (junction Q3 &Q4) and the load distribution panel, and tighten the connections to 5,4 Nm. 6. Connect the battery power cables between the UPS battery terminals and the associated battery circuit breaker - see Figure 2-5 and Figure 2-7 - observe the correct battery cable polarity. As a safety precaution remove the battery fuse in the module until the arrival of the commissioning engineer.

WARNING

Do not close the battery circuit breaker before the equipment is commissioned.

7. Connect the safety earth and any necessary bonding earth cables to the copper earth busbar located below the battery power connections. Note: The earthing and neutral bonding arrangement must be in accordance with local and national codes of practice. 8. Connect the battery circuit breaker control and temperature compensation cables between the UPS auxiliary terminal block ‘X3’ and battery circuit breaker controller board as shown in Figure 2-5 and Figure 2-7. These cable must be shielded. Caution

If battery temperature compensation is not to be used, it must be de-activated by the commissioning engineer.

9. If the remote emergency power off (EPO) facility is to be used then remove the link between terminals 10 and 11 of the auxiliary terminal block ‘X3’ and connect the ‘normally closed’ remote stop switch between these two terminals using shielded cable.

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1.4


Battery Installatio n

SAFETY WARNINGS

Only qualified personnel should install or service batteries. Batteries present a risk of electric shock or burn from high short circuit currents. Eye protection should be worn to prevent injury from accidental electrical arcs. Remove rings, watches and all metal objects. Only use tools with insulated handles. Wear rubber gloves.If a battery leaks electrolyte, or is otherwise physically damaged, it should be placed in a container resistant to sulphuric acid and disposed of in accordance with local regulations. If electrolyte comes into contact with the skin the affected area should be washed immediately. Batteries must be disposed of according to local environmental laws.

Due to the IGBT inverter design, the required DC busbar voltage level is dependent on the system output a.c. voltage; the required number of battery blocks therefore differ according to the system voltage, as shown below:380V a.c. system requires a 432V DC busbar = 192 battery cells. 400V a.c. system requires a 446V DC busbar = 198 battery cells. 415V a.c. system requires a 459V DC busbar = 204 battery cells. The batteries associated with the UPS equipment are usually contained in a pur pose-built battery cabinet which sits alongside the main UPS equipment. Sealed, maintenance-free batteries are normally used in this type of installation. There are three types of battery cabinet offered with the Series 7200 UPS which are graded according to their recommended ampere hour capacity. Type B is rated at 38 Ah; Type C is rated at 50 Ah and Type D is rated at 85 Ah. The cabinets are of the same height as the UPS and can be sited on either side of the UPS cabinet. A full description of these cabinets is given in the Options Section of this manual. Where battery racks are used, they should be sited and assembled in accordance with the battery manufacturer's recommendations. In general, batteries require a well ventilated, clean and dry environment at reasonable temperatures to obtain efficient battery operation. Battery manufacturers’ literature provides detailed safety measures to be observed when employing large battery banks: these should be studied, and the pro posed battery installation checked, to verify compliance with the appropriate recommendations. In general a minimum space of 10 mm must be left on all vertical sides of the battery block. A minimum clearance of 20 mm should be allowed between the cell surface and any walls. A clearance of 150 mm should be allowed between the top of the cells and the underside of the shelf above (this is necessary to for monitoring and servicing the cells). All metal ra cks and cabinets must be earthed. All live cell connections must be shrouded. The batteries are connected to the UPS through a circuit breaker which is manually closed and electronically tripped via the UPS control circuitry. If the batteries are cabinet-mounted this circuit breaker is fitted within the cabinet; however, if the batteries are rack-mounted or otherwise located remote from the main UPS cabinet then the battery circuit breaker must be mounted as near as possible to the batteries themselves, and the power and control cables connected to the UPS using the most direct route possible. Liebert offer a purpose-designed remote bat-

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tery circuit breaker box, containing the circuit breaker and its necessary control board, as a standard option kit. The battery cabinet or circuit breaker box should be bonded to the UPS cabinet to maintain EMC compliance.

1.4.1

Battery circ uit breaker boxes A battery circuit breaker box houses the battery circuit breaker and its controller board and is used to connect the battery to the UPS in installations where the batteries are not contained in the standard battery cabinet. Two boxes are available which are similar in design and content, and described below: • •

100 Amp C/B Part No. 4641027 B for use with 30 - 40 kVA models. 160 Amp C/B Part No. 4641028 C for use with 60kVA model.

Usually the ‘box' is fitted as close as possible to the batteries. Battery circuit breaker boxes must be earthed. The connections are similar to the connections made to the battery cabinet. Figure 2-6 shows details of the power and control cable connections between the circuit breaker box or battery cabinet and the UPS itself. Two methods of connecting the three pole battery circuit breaker are illustrated. Method A shows the spare pole being used to divide the battery bank in half, thereby reducing the battery total voltage to half when the circuit breaker is open during servicing etc. Method B connects the spare pole in series with the posit ive connection, thereby providing two sets of contacts in the positive line as an added safety precaution. When installing the battery cabinet remove the battery fuse in the UPS before making the battery circuit breaker power connections. Figure 2-6: Battery CB layout of switching poles

UPS

Half Potential Switching Method

UPS

Double Positive Pole Method

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Figure 2-7: Battery Control and Power connections LM355A Sensor 0835047F

TO BATTERIES

UPS CABINET 123456

12

D2 V< 11

X3

14

D1

X3 X4 X5 X2 X6 X10 X8 X9 Battery CB Controller

BATTERY CIRCUIT BREAKER

12 3 4 5

HALF POTENTIAL SWITCHING METHOD

TO BATTERIES LM355A Sensor 0835047F

UPS CABINET 123456

12

D2 V<

X3 11

14

BATTERY CIRCUIT BREAKER

D1

X3 X4 X5 X2 X6 X10 X8 X9 Battery CB Controller 12 3 45

DOUBLE POSITIVE POLE METHOD

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Section 2:

Chapter 2 - Commissioning Procedure

2.1

Introduction The information contained in this calibration procedure is intended for use only by engineers employed by the Liebert service organisation or who have attended a training course concerning the Series 7200 equipment. While every precaution has been taken to ensure the accuracy of this information, Liebert assume no responsibility and disclaim all liability for damages resulting from the use of this information or any errors or omissions contained within. This procedure aims at satisfying two functions: first it should enable a producttrained engineer to commission the equipment safely and correctly; second, it should provide a recovery procedure to supplement the procedures contained in the troubleshooting section of this manual – i.e. if the troubleshooting procedures fail to identify/rectify a problem then this procedure provides the means of com pletely recalibrating the UPS equipment.

WARNING NOTICES Please read.

The UPS equipment contains POTENTIALLY LETHAL VOLTAGES at all times once power has been applied from the MAINS DISTRIBUTION PANEL. Therefore, before applying mains power to the UPS ensure that the UPS output cables are safely isolated or, If they have already been connected to the load equipment, ensure the load equipment is ready to receive power. DO NOT close the battery circuit breaker before instructed to do so. Closing the battery circuit breaker before the DC busbar is live could damage the UPS. DO NOT apply BOOST CHARGE to sealed batteries. Before commencing this procedure confirm the location and operation of the external power isolators used to switch the UPS input mains supply. If these isolators cannot be LOCKED OUT, then post notices warning against their closure. These precautions should be taken as ne cessary at any time during the commissioning procedure.

The 7200 Series UPS leaves the manufacturer fully tested and adjusted t o operate at 400Vac, 50Hz, but it can be converted to operate at 380V or 415V, at either 50 or 60Hz. Such a conversion is effected by selecting the appropriate tap voltages on the control power supply transformers and operating parameters via the Operator Control Panel menuing system – details are provided at the appropriate stages of this procedure. An additional procedure is included at the end of the chapter (See paragraph 2.10) which provides instructions for changing the working voltage/frequency parameters on an already-commissioned module. In both cases, where reference is made to the ‘nominal’ voltage, this should be taken as the required equipment working voltage – e.g. 380/400/415 volts. A set of Commissioning Records are included at the end of this section which can be used to record the parameters set during commissioning and handed to the customer if required. The pages are published in a single-sided format to facilitate photocopying for in-field use.

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SECTION 2 - Installation and Commissioning CHAPTER 2 - Commis sioni ng Proc edure

Important Note:

1+1

2.2


When commissioning a ‘1+1’ system we recommend that the system is split into two single modules; and each module then commissioned independent of the other. Once both modules are fully working as ‘single modules’ they can be reconfigured for ‘1+1’ operation and the remaining ‘parallel control’ functions checked and calibrated as instructed. This commissioning procedure is therefore based on a ‘single-module’ installation, and any actions which specifically apply to ‘1+1’ systems are identified by a “1+1” graphic in the margin – as shown here. Note: if you are converting an early (pre Jan ‘97) single module to operate in a ‘1+1’ system then ensure the appropriate control boards are fitted prior to commencing the commissioning (See Chapter 3). (Later models are shipped with the appropriate boards already fitted).

Procedure overview This procedure has several defineable stages: 1. Pre-commissioning checks verify that: – the main equipment has been correctly installed – the circuit board configuration links have been selected correctly – the battery installation is satisfactory – the control power transformers are wired for the required working voltage 2. Start-up and software commissioning: – low voltage supply checks – Operator Control Panel language selection – UPS Setup parameters selection (from Operator Control Panel) – UPS Maintenance parameters selection (from Operator Control Panel) – UPS Function parameters selection (from Operator Control Panel) 3. UPS Power checks: – UPS Power measurements – inverter checks – bypass checks – rectifier and battery autonomy checks – programming automatic battery check parameters – emergency power off (emergency stop) checks – battery boost set-up (if applicable) – on generator checks (if applicable)

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SECTION 2 - Installation and Commissioning CHAPTER 2 - Commi ssioni ng Proc edure

Figure 2-8: Major component location

14

7

8 1 9 2 10 T 5 2 0 0 3 5 4

3

11

12

4 4550007H

13 X1

4520075B X2 X3

5 15 6

Table 2-2: 1. Battery Cable Connections

9. AC - AC Power Supply PCB 4503030M

2. UPS Output Cable Connections

10. Rectifier Logic PCB 4520074A

3. Static Bypass Input Cable Connections

11. Inverter Logic PCB 4530025T

4. Rectifier Input Cable Connections

12. UPS Logic PCB 4550007H

5. Main Chassis Safety Earth Connection

13. Remote Alarm Interface 4590056Q

6. Auxiliary Terminal Block X3

14. UPS Serial Number Tag

7. Control Power Transformers T2 & T3

15. 1+1 Parallel Option 4645004A (consisting of Parallel Logic Board 4520075B & ribbon cables)

8. DC - DC Power Supply 4503028K


2-15


2.3


Pre-comm issi oni ng Checks

WARNING 2.3.1

Ensure these checks are carried out before applying power to the unit.

Power cable inst allation 1. Verify that the input, output and battery cables are suitably rated, in accordance with local regulations – see notes on cable rating in paragraph 1.3.2. 2. Check that the power cables entering the UPS have been correctly routed and the appropriate gland has been fitted to the power cable entry panel. 3. Check that the power cables are correctly terminated and securely fitted to the stepped input and output busbar studs as shown in Figure 2-9. 4. Check that the bypass links have been removed if the unit is to be operated in the ‘Split Bypass’ configuration. If a separate supply is connected to the bypass terminals without the “split bypass” links removed it could cause damage to the supply distribution system.

Important Note:

1+1

5. In a ‘1+1’ system ensure that the paralleled module output cables are connected with the correct phasing (i.e. U2-U2; V2-V2; W2-W2; N2-N2). Figure 2-9: Power cable connections

Bypass Links These links must be removed for split-bypass operation

Output Cables connected to load

Input cables for split-bypass system Connected to Q2/Q3 busbar connection U3, V3, W3 & N3 From Bypass Supply distribution panel

Battery Cables

Bypass Supply Neutral connection (split-bypass system) OR Input Supply Neutral connection (non-split-bypass system) UPS rectifier input connection from input mains s upply: For non-split-bypass system: a) Connect to Q1 busbar connections U1,V1,W1. b) Connect input neutral to Q2/Q3 busbar connection N3. Note: an input neutral connection to N3 is not required in a split-bypass system as the bypass neutral will be used to reference the inverter output.

2-16



2.3.2


Contro l cable ins tallatio n 1. Verify that the battery control cables are correctly terminated and connected to the auxiliary terminal block (X3) shown in Figure 2-10 in accordance with Table 2-3. Note: terminal block X3 requires 4mm (yellow) female spade terminations. Figure 2-10: Auxiliary terminal block X3

Battery Temperature

Batt CB trip Batt CB Aux contact

E.P.O.

Common

Table 2-3: Auxiliary terminal block connections UPS Auxili ary Terminal blo ck X3 Termination X3 - 2

Function

Battery Control Board (4520067T) termin ation

Battery temperature sense signal

X1 - 5

X3 - 4

Battery circuit breaker control common

X1 - 3

X3 - 5

Battery circuit breaker status signal

X1 - 2

X3 - 6

Battery circuit breaker trip signal

X1 - 1

X3 - 10

Remote Emergency Stop normally closed

Terminals normally linked if not used

X3 - 3

X3 - 11


X1 - 4

2-17


Important Note:

1+1


2. In a ‘1+1’ system: a) Ensure that the Parallel Logic Board Part Nº 4520075B is firmly fitted in the correct location as shown in Figure 2-8. b) Ensure that the 60 way ribbon cable is connected from X1 on the Parallel Logic Board, to X7 on the UPS Logic Board. c) Ensure that the two 34-way ribbon cables providing inter module control are fitted between the Parallel Logic Board connector X2 of one module and X3 in the second module (See Figure 2-11). Note that it is crucial that these cables are cross-coupled between X2/X3 as shown. Failure to observe this rule will result in the modules being permanently shut down. Figure 2-11: Module parallel logic PCB interconnection Module 1 4520075B

2-18

Module 2 4520075B

X2

X2

X3

X3



2.3.3


Battery Power Cable Installatio n 1. Verify that the battery has been correctly installed and all cables are connected to the batteries and battery circuit breaker as shown in the installation instructions (see paragraph 1.4 on page 2-10) . Typical connection configurations are shown in Figure 2-12. 2. Verify that the battery power cables are correctly terminated and securely fitted to the DC busbar studs as shown in Figure 2-9. Figure 2-12: Battery control and power connections Temperature Sensor

To Batteries

X3

Battery Circuit Breaker

Half Potential Switching Method of Connection Battery C.B. Controller PCB Part Nº 4520067T To Batteri es

Double Positive Pole Method of Connection

Temperature Sensor

X3

Battery Circuit Breaker


2-19


2.3.4


Printed circuit board configur ation jumper selection Ensure that the printed circuit board jumpers are selected appropriately according to the following tables: Table 2-4: Rectifier Logic Board – 4520074A. 30 to 60kVA JUMPER

POSITION

FUNCTION

1 - 2

Disable battery temperature/voltage compensation (Standard)

2 - 3

Enable battery temperature/voltage compensation

1 - 2

Increased DC regulation speed for units below 60kVA

2 - 3

Decreased DC regulation speed for units above 80kVA

1 - 2

Fast walk-in : 1 Second

2-3

Slow walk-in : 5 Seconds

0 - 1

open

0-2

open

0 - 1

closed

0-2

open

0 - 1

open

0-2

closed

0 - 1

closed

0-2

closed

X5

X6

X7

Rectifier in Auto mode (Standard)

Rectifier in Float mode

Rectifier in Boost mode

X9

Set Rectifier to Manual Mode from the Dis play Panel

Rectifier in ‘Test’ mode closed

Reduced input current limit forced on

open

(Standard)

closed

Rectifier forced on - Ignore UPS Logic

open

UPS Logic control enabled (Standard)

open

Disable driver IC - D6

closed

Enable driver IC - D6 (Standard)

0-3

0-4

0-5 1-2

Enable rectifier temperature monitor

2-3

Disable rectifier temperature monitor (Standard)

X10

2-20




Table 2-5: Inverter Logic Board 4530025T. 30 - 60kVA JUMPER

X12

POSITION open

0-1

closed

0-2

open

0-2

closed

Disable ribbon cable detector

closed

Voltage select override

0-4

X16

Test Inverter over-temperature sensors (Enables open cct. sensors)

0-1

0 - 3

X15

FUNCTION

Disable Inverter over-temperature sensors (Standard) Enable ribbon cable detector (Standard)

Manual inverter volts Adj R243

0-5

Frequency select override

0-6

Force the Inverter ON => ignore all blocks

0-7

Ignore Inverter ‘On Load’ signal

0-1

2400 Hz switching frequency (Standard)

0-2

4800 Hz switching frequency

0-1 0-2


0-5


0-1 0-2

6 pulse Inverter current feedback (Standard)

0-3

12 pulse Inverter current feedback

Testing only Open = standard

Table 2-6: UPS Logic Board 4550007H. 30 - 60kVA Note: when commissioning a ‘1+1’ system these jumpers will required temporary reconfiguration (See paragraph 2.3.5.1) JUMPER

X12

POSITION

FUNCTION

open

Pre- Release Rev.:5.0G Software

1 - 2

Link if Rev.:5.0G or later and HVI PCB Part Nº 5490054O is fitted.

3 - 4

Link if Rev.:5.0G 0r later and HVI PCB Part Nº 5490058S is fitted.

1 - 2

EPROM Enable

2-3

RAM Enable (Standard)

1 - 2

Not Required

3 - 4

Not Required

5-6

Not Required

7-8

Not Required

X13

X14


Testing only normally open

2-21


JUMPER


POSITION

FUNCTION

1-2

PLL option with

CAP IN

2-3

PLL option with

FIN AUX

open

CAN Bus to display disabled

1-2

CAN Bus to display enabled (Standard)

1-2

ALE enable data save

2-3

Power supply fail enable data save (Standard)

1-2

EPROM II enable (not required)

2-3

RAM II enable (not required)

1-2

+5V PCB enables microprocessor ref. For VA calculations (Standard)

2-3

V ref. enables microprocessor ref. For VA calculations

1-2

Not Required

2-3

RAM enable (Standard)

1-2

EPROM enable (Standard)

2-3

Not Required

1-2

Not Required

2-3

EPROM enable (Standard)

3-4

Not Required

4-5

Not Required

1-2


2-3

EPROM enable (not required)

3-4


4-5

EPROM enable (not required)

1-2

Manual reset of output buffers

2-3

Microprocessor reset of output buffers (Standard)

1-2

Inverter operation in ‘Manual’ mode (Bypass preferred) = Closed Inverter operation in ‘Auto’ mode (Inverter Preferred) = Open (Standard)

3-4

Inverter Bad voltage for 10 seconds Off latch enabled = Closed (Standard) Off latch disabled = Open

5-6

Not Required

7-8

Security Password Over-ride. Closed = Over-ride security Password Open = Enable security Password (standard)

X15 (Standard)

X16

X17

X19

X20

X21

X22

X23

X24

X25

X26

2-22



JUMPER


POSITION open

FUNCTION Power up reset enabled (Standard)

X28 closed

Power up reset disabled

open

2.5V power supply monitor enabled (Standard)

1-2

2.5V power supply monitor disabled

open

Internal battery disabled

1-2

Internal battery installed and charger enabled (Standard)

open

RS485 port disabled

1-2

RS485 port enabled (Standard)

1-2

Calendar IC supply from VRAM (Standard)

2 -3

Calendar IC supply from internal battery

1 -2

G.V.C.O. to inverter logic (parallel module operation)

2-3

Micro V.C.O. to inverter logic (single module operation)

1-2

Separate battery per module (1 for each rectifier)

2-3

Common battery (parallel rectifiers)

1-2


2-3


X29

X31

X32

X33

X34

X35

X36

Table 2-7: Operator Control Board 4550005F 30-60 kVA JUMPER

POSITION open

FUNCTION +5v enable main CPU (Standard)

X11 closed

ALE enable main CPU

1 - 2

Main CPU enable EPROM

2-3

+5v enable EPROM (Standard)

1 - 2

Main CPU enable RAM

2-3

+5v enable RAM (Standard)

1 - 2

Not Required

2-3

Not Required

1-2

Main CPU enable EPROM (Standard)

2-3

Not Required

X12

X13

X14

Testing Only Open = Standard

X15


2-23


JUMPER


POSITION

FUNCTION

1-2

Not Required

2-3

Main CPU enable EPROM (Standard)

3-4

Not Required

4-5

Not Required

1-2

Write to RAM enable (Standard)

2-3

Not Required

3-4

Main CPU enable RAM (Standard)

4-5

Not Required

1-2

Not Required

2-3

Main CPU enable RAM (Standard)

1-2

Not Required

2-3

Not Required

1-2

Read/Write RS232 enable (Standard)

2-3

Read/Write RS485enable

1-2

Enable port x4 for RS485

2-3

Enable port x4 for RS232 (Standard)

1-2

Enable port x4 for RS485

2-3

Enable port x4 for RS232 (Standard)

1-2

Inhibit buzzer

2-3

Enable buzzer (Standard)

1-2

Enable CAN bus to UPS logic (Standard)

2-3

Disable CAN bus to UPS logic

1-2

Enable RS485 bus to port x4 (Standard)

2-3

Disable RS485 bus to port x4

open

+5v power supply reset enabled (Standard)

x16

x17

X18

x19

RAM extension Normally open

x20

x21

x22

x23

x24

x25

x26 closed

2-24

+5v power supply reset disabled




Table 2-8: Static Switch Driver Board 4542043Z 30-60 kVA JUMPER

POSITION

X11

FUNCTION Enable load on inverter command (Standard)

0-1

open

0-1

closed

0-2

open

0-2

closed

0-3

open

0- 3

closed

0-4

N/A

Not used

0-5

open

Test static switch temperature monitor

0-5

closed

Disable load on inverter command Enable load on bypass command (Standard) Disable load on bypass command Disables bypass fire command Enable bypass fire command (Standard)

Inhibit static switch temperature monitor (Standard)

Table 2-9: High Voltage Interface Board 4590058S & (old 4590054O) 3060kVA JUMPER

POSITION

—

0-1

X31

0-2

X31 : X32 : X33 : X34 : X35 : X37 : X38 : X39 : X40

0-3

—

0-1

X31 : X32 : X33 : X34

0-2

X35 : X36 : X37 : X38 : X39 : X40

0-3

—

0-1

—

0-2

X31: X32 : X33 : X34 : X35 : X36 : X37 : X38 : X39 : X40


FUNCTION

30 kVA CT burden selection



0-3

2-25


Applicable only to:


Table 2-10: Parallel Logic Board 4520075B

1+1 JUMPER

POSITION

FUNCTION open

Priority selector disabled

closed

Priority selector enabled (standard 1+1)

open

Priority selector for ≥ 2 modules (multi module use only) open = standard for 1+1

open closed

Link combination sets logic for number of units operating For 1+1 operation links 0 - 1, 0 - 2, 0 - 3 are closed.

open

1 + 1 redundant module (standard)

closed

1 + 1 non-redundant module

open

Common battery for all UPS modules

closed

Separate battery for each module (std)

open

Priority selector enabled (std)

closed

Priority selector disabled

open

No MSSC installed (1 + 1) (std)

closed

MSSC installed

0 - 1 X4

X5

0 - 2 to 0-8 0 - 1 to 0-5

0-1

0-2

0-3

X6

0-4 0-5

N/A

0-6

N/A open

No contactor in MSSC (std)

closed

Contactor in MSSC

open

Normal operation

closed

Test mode active

0-7

0-8 1-2

60 Hz operation

2-3

50 Hz operation (std)

X7 open

G.V.C.O. slew rate = 0.1 Hz/Sec (std)

closed

G.V.C.O. slew rate = 0.2 Hz/Sec

X11 1-2

Parallel cable screen earthed

2-3

Parallel cable screen not earthed (std)

X13

2.3.5

Pre-power ch ecks 1. Ensure that all the UPS isolators, including the battery circuit breaker, are open – i.e. OFF or in position ‘0’. 2. Carry out a thorough visual examination of the equipment. Check the security of all cable terminations and ensure that all electrical connectors, plugs and sockets are correctly located and firmly fitted. 3. Ensure that the correct primary voltage tap selections are made on the Power Supply transformers T2 and T3, as shown below.

2-26




Table 2-11: Power supply transformers T2 and T3 voltage selection. 380V Operation

400V Operation

415V Operation

A3 - B

A2 - B

A1 - B

4. Ensure that on the UPS Logic Board (4550007H): a) S1 is selected OFF (Static Bypass disabled). b) S2 is selected OFF (Inverter disabled). c) S3 is selected OFF (Rectifier disabled). 2.3.5.1

‘1+1’ sys tem mod ule spl it

Only applicable to:

1+1

As mentioned at the beginning of this chapter, it is r ecommended that when dealing with a ‘1+1’ parallel-operating system each module is checked individually for correct single module function before any attempt is made at parallel operation. To satisfy this requirement the system must therefore be temporarily re-configured to allow single-module operation by completing the following steps: 1. Override the parallel control functions by disconnecting the ribbon cable between the Parallel Logic Board (4520075B) connector X7 and connector X1 of the UPS Logic Board (4550007H). 2. Reconfigure the UPS Logic Board (4550007H) jumpers for single module operation as shown in the table below – note that a complete link table for this board is shown in Table 2-6. Table 2-12: Temporary UPS Logic Board configuration changes.

X26

X34 X35 X36

1-2

*Inverter operation in ‘Auto’ mode (Open = Standard)

3-4

Inverter Bad voltage for 10 seconds *Off latch enabled = Closed (Standard) Off latch disabled = Open

5-6

Not Required

7-8

Security Password Override. *Closed = Override security Password Open = Enable security Password (standard)

1-2

G.V.C.O. to inverter logic (parallel module operation)

2 -3

*Micro V.C.O. to inverter logic (single module operation)

1-2

*Separate battery per module (1 for each rectifier)

2 -3


1-2

*Separate battery per module (1 for each rectifier)

2 -3


X34 must be in position 2-3 for single module operation. X26 must be in position 7-8 to override the password security control.

WARNING

These jumpers must be returned to the ‘1+1’ configuration before the system is operated in parallel (as instructed later in the commissioning procedure).


2-27


2.3.6


Initial utilit y power connection

WARNINGS

Check that the Maintenance Bypass isolator Q3 is open before applying external power. If Q3 is to be closed, inform the user that power will be connected to the load when the input utility isolator is made. When commissioning a ‘1+1’ system module do not close any power isolators in the second module while the module being commissioned is turned on.

1. Apply mains voltage to the input terminals – U1, V1and W1. a) Measure the line-to-line voltage of all three phases and ensure that the values are within ±10% of nominal rating. b) Ensure correct clockwise phase rotation U, V, W using an oscilloscope or rotation meter.

WARNING

If a separate supply is connected to the bypass terminals without the “split bypass” links removed it could cause damage to the supply distribution system.

2. If a split bypass is fitted, first ensure that the Split Bypass links have been removed (See Figure 2-9) then energise the (bypass) mains voltage to the bypass terminals – U3, V3, W3 and N. a) Measure the line-to-line and line-to-neutral voltages of all three phases and ensure that values are within ±10% of nominal rating. b) Ensure correct clockwise phase rotation U, V, W using an oscilloscope or phase rotation meter.

2-28



SECTION 2 - Installation & Commissioning CHAPTER 2 - Commi ssioni ng Proc edure

Section 2:

2.4

Start-Up and soft ware comm iss ioni ng During this part of the commissioning procedure, the bypass s upply is connected to the unit in order to power-up the control power supplies. With control power available, the control circuit boards are live a nd the programmable UPS operating parameters can be entered into control system’s non-volatile RAM (NVRAM) via the Operator Control Panel, before energising the UPS power sections.

2.4.1

Operator Contro l Panel disp lay screen The LCD screen can display four rows of up to twenty characters, and normally indicates the UPS operating status, warnings a nd alarms. However, it can also be selected to show messages associated with the UPS configuration setup menuing system which allows operational data to be entered, or control parameters to be set – these menus are shown in Figure 2-14 to Figure 2-27. Figure 2-13: LCD con trol scree n & sele ction b uttons

ENTER

ESCAPE

When selecting an option, pressing the ENTER button steps forward to the next LCD Display screen in the menu map. When entering data or selecting a parameter, pressing the ENTER button saves the chosen parameter i n non-volatile memory.

Pressing ESCAPE will cancel the most recent action – i.e. when entering data or selecting parameters, pressing ESC steps back the LCD display to the previous screen and exits the current screen without saving the new settings. To return to the default screen ESC must be pressed repeatedly.

The MENU buttons allow the window cursor to be moved up and down to select a desired menu option. UP The UP button moves the cursor up through the options displayed in the window; the highlighted option can then be selected by pressing ENTER. When selecting a parameter value it also moves a rectangular “entry” cursor horizontally to the next digit on the right. DOWN The DOWN button moves the cursor down through the options displayed in the window, the highlighted option can then be selected by pressing ENTER. When changing a parameter value the DOWN button will rotate through an available value table for the specific parameter digit.

s2-c2b.f m5 - Issue 3 Dated 09/11/98

2-29

SECTION 2 - Installation & Commissioning CHAPTER 2 - Commis sioni ng Proc edure

Important Note:

2.4.2


This procedure refers to Version 4.0 software installed in all units manufactured after 2nd May 1997. Units manufactured before this date may have Version 2.0, or earlier, software installed and will exhibit slightly different menu screens and parameter locations.

App lyi ng pow er to the UPS

WARNING

Do not close the Output Isolator Q4 during the setting-up procedure as this will connect power to the load.

1. Close the Bypass Isolator Q2. a) The power supply and electronics will energise. b) The Operator Control Panel display will power up. c) The rectifier and inverter power sections will remain off. 2. On the Operator Control Panel, verify that the bypass LED and amber battery isolator LED are illuminated. 3. Verify that the LCD control screen initialising window activates and then changes to the ‘Default’ screen. Note: the screen shown below is referred to as the default screen in the remainder of this procedure. INT USCITA APPERTO

OUTPUT BREAKER OPEN RECTIFIER BREAKER OPEN BYPASS INHIBIT 24-09-95

14:33:00

DEFAULT SCREEN

INT RADDRIZZ APERTO BATTERIA PINE SCAR 24-09-95

14:33:00

The module status alarms are initially displayed on the default screen in the default language, e.g. Italian. Note: The first three lines of the default screen will indicate any current UPS alarm conditions, but these can be ignored at this stage.

2.4.3

Password prot ection and operatio n A password is required to change parameters other than those listed below: • • • •

Time and Calendar ON/OFF UPS CONTROL (rectifier, inverter and bypass)

Battery test (star, time/date stamp, repetition rate) Modem configuration and operation

You can completely override the password system during initial start-up and commissioning by connecting a link to jumper X26 pins 7-8 on the UPS Logic Board. This link, which must be removed when commissioning is completed, can be fitted while the UPS is in its Normal Operation mode without affecting the system integrity. Note: any parameter not re-programmed during the commissioning procedure will maintain its factory default setting.

2-30

s2-c2b.f m5 - Issu e 3 Dated 09/11/98


2.4.4


Lang uage Selecti on If required, select the appropriate language us ing the following procedure: Figure 2-14: Languag e selec tion m enu m ap MAIN MENU SCREEN

FUNCTION MENU SCREEN

PANEL SETUP MENU SCREEN

1. Ensure a jumper link is fitted to X26 pins 7-8 on the UPS Logic Board (overrides the password protection facility as described previously). 2. Press the ‘ENTER ’ button to access the main menu screen. 3. Press the ‘DOWN’ menu button to scroll the cursor to ‘ FUNCTION ’. → MISURE

MEASUREMENT

→ FUNCTION

←

MAINTENANCE

MAIN MENU SCREEN

SETUP

←

FUNZIONI MANUTENZIONE IMPOSTAZIONE

4. Press the ‘ENTER ’ button to access the password entry screen. ↑ WRITE ↓ MOVE

SAVE ↵ EXIT

ESC

INPUT PASSWORD

PASSWORD SCREEN

↑ IMPOSTA ↓ SPOSTA

MEMOR. ↵ USCITA

ESC

DIGITARE PASSWORD

0000000 0

00000000

5. A password must be entered to gain further access to the function menu. The initial default password of ‘ 00000000’ need not be changed at this point in time – instructions for changing the password are given later. (See paragraph 2.4.7.4) . 6. Press the ‘ENTER ’ button to move from the password entry screen to the function menu screen. → TEST BATTERIA

BATTERY TEST GENERATOR

→ PANEL SETUP NEXT PAGE

←


←

GRUPPO ELETTR. DATI PANNELIO PAGINE SUCCESSIVE

7. Press the ‘DOWN’ menu button to select ‘ PANEL SETUP’. 8. Press ‘ENTER ’ to display the panel setup menu screen.


2-31



9. On the panel setup menu move the cursor to select ‘ LANGUAGE ’. → LANGUAGE TYPE 0000 GROUP 1 PASSWORD

ENG ← MASTER

→ LINGUA TIPO 0001


UPS 1

GROPPO 1

00000000

PASSWORD

ITA ← MASTER UPS 1 00000000

10.Press ‘ENTER ’ to display the language selection screen. ↑ ROTATE

SAVE ↵ EXIT

LANGUAGE

ENG

ESC

↑ LANGUAGE SELECTION SCREEN

MEMOR. ↵ USCITA LINGUA

ESC

ITA

11.Use the ‘UP’ menu button to rotate through the available options and select the required default language – e.g. ‘ ITA, ENG, FRA, DEU, SPA’ 12.Press ‘ENTER ’ to accept and store the language selection, then step back to the default screen by repeatedly pressing ‘ ESC ’, as required; the current alarms should now be displayed in the selected language. IMPORTANT

2-32

Ensure the data entered during the following procedures are recorded in the appropriate commissioning documentation.



2.4.5


Selecti ng th e UPS SETUP param eters The following procedure set-up the basic UPS operating parameters – e.g. kVA, working voltage/frequency and battery parameters. Menu selection is carried out in the same manner as previously described in the ‘language selection’ procedure – i.e. by first selecting a menu option using the ‘UP’ and ‘DOWN’ menu buttons and then accepting the selection by pressing the ‘ENTER’ button. In the remaining procedures these t wo actions are jointly summarized as ‘select and enter’. Figure 2-15: UPS system ‘SETUP’ menu map (Issue 5.0 software) MAIN MENU SCREEN

UPS MENU SCREEN

SETUP MENU SCREEN

VOLTAGE MENU SCREEN

FREQUENCY MENU SCREEN BATTERY MENU SCREEN

Continued in Figure 2-16


2-33



1. From the default screen press ‘ENTER ’ to access the main menu screen. 2. Select and enter ‘SETUP’ – the password screen will now be shown. 3. If the password has been left at the initial default setting, pressing ‘ENTER ’ will now step forward to the setup menu screen, as shown in Figure 2-15. If the password has been “set”, then enter the correct password to continue. 2.4.5.1

Setting the basic UPS conf iguration

1. Select and enter ‘UPS ’ – this will access the UPS menu screen. 2. Select and enter ‘POWER ’. 3. Enter the UPS module’s kVA rating using the data entry screen shown below. ↑ WRITE ↓ MOVE POWER

SAVE ↵ EXIT

ESC

0060 kVA

a) Pressing the ‘DOWN’ menu button will move the cursor to select each digit in turn: the value of the selected digit can then be incremented by pressing the ‘UP’ menu button. b) When the indicated kVA rating is correct, press ‘ ENTER ’ to save the selection, then press ‘ ESC ’ once to move back to the UPS menu screen. 4. Select and enter ‘TYPE’. a) Press the ‘UP’ menu button repeatedly until the ‘ TYPE ’ is shown as ‘ 3PH ’. b) Press ‘ENTER’ to save the selection, then press the UPS menu screen.

‘ESC’ once

to move back to

5. Select and enter ‘CONFIG’.

1+1

a) Using the data entry method described above enter the word ‘SINGLE’. ( Note: in a ‘1+1’ installation this will be changed to ‘ PAR 1+1’ later). b) Press ‘ENTER ’ to save the selection, then press UPS menu screen.

‘ESC’ to

move back to the

6. Verify that the UPS menu screen data shows the correct: – UPS kVA rating (shown as 60kVA in the example screen in Figure 2-15) – UPS type (3 phase) – UPS configuration (single) Repeat this procedure if any data is incorrect. 7. Press ‘ESC’ again to move back to the setup menu screen. 2.4.5.2

Setting the UPS wor kin g vol tage parameters

1. Select and enter ‘VOLTAGE’ – this will access the voltage menu screen. 2. Select and enter ‘RATED VOLTS. ’. a) Press the ‘UP’ menu button repeatedly until the appropriate input/output working voltage is indicated. b) Press ‘ENTER’ to save the selection and then press to the voltage menu screen.

2-34

‘ESC’ once

to move back




3. Select and enter ‘LOWER ’. a) Using the data entry method described above, enter the required input and output voltage undervoltage thresholds. Note: Standard settings are for -10% (input) and -10% (output). b) Press ‘ENTER’ to save the selection, then press the voltage menu screen.

‘ESC’ once

to move back to

4. Select and enter ‘UPPER ’. a) Using the data entry method described above, enter the required input and output overvoltage thresholds. Note: Standard settings are for +10% (input) and +10% (output). b) Press ‘ENTER’ to save the selection, then press the voltage menu screen.

‘ESC’ once

to move back to

5. Verify that the data shown on the voltage menu screen is correct and repeat this procedure if necessary. 6. Press ‘ESC’ again to move back to the setup menu screen. 2.4.5.3

Settin g the UPS frequ ency parameters

1. Select and enter ‘FREQUENCY’ – this will access the frequency menu screen. 2. Select and enter ‘ NOMINAL’. a) Press the ‘UP’ menu button repeatedly until the desired nominal frequency is indicated. b) Press ‘ENTER’ to save the selection, then press ‘ ESC ’ once to move back to the frequency menu screen. 3. Select and enter ‘SYNC WINDOW ’. a) Enter the required sync window limit. Note: Standard setting is ‘2.0%’. b) Press ‘ENTER’ to save the selection, then press ‘ ESC ’ once to move back to the frequency menu screen. 4. Select and enter ‘SLEWRATE’. a) Enter the required slew rate from the following selections. 0.1 Hz/sec 0.5 Hz/sec 1.0 Hz/sec Note: Standard setting is ‘0.10 Hz/s’. b) Press ‘ENTER’ to save the selection, then press the frequency menu screen.

‘ESC’ once

to move back to

5. Verify that the data shown on the frequency menu screen is correct and repeat this procedure if necessary. 6. Press ‘ESC’ again to move back to the setup menu screen.


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2.4.5.4


Settin g the Batter y parameters

Continued from Figure 2-15

Figure 2-16: ‘SETUP’ menu map continued for battery parameter (Issue 5 software) UPS 0060 kVA VOLT AGE 400 V FREQUENCY 50 Hz BATT. CELLS 198

SETUP MENU SCREEN BATTERY MENU SCREEN

BATT. CELLS 198 CAPACI TY 052 Ah VOLTAGE/ CELL

WRI TE MOVE BATT. CELL S

BATT. CELL S 198 CAPACI TY 052 Ah VOLT AGE/ CELL

WRI TE MOVE CAPACI TY

BATT. CELL S 198 CAPACI TY 052 Ah VOLTAGE/ CELL

END DI S. 1. 67 v/ e BAT. LOW 1. 82 v/ e MAX. 2. 45 v/ e BOOST CHARGE

WRI TE MOVE END DI S.


WRI TE SAVE MOVE EXI T BAT. LOW 1. 82 v/ e


WRI TE MOVE MAX.

BATTERY VOLTAGE MENU SCREEN

SAVE EXI T 198

SAVE EXI T 052 Ah


SAVE EXI T 1. 67 v/ e



1. From the setup menu select and enter ‘BATT.CELLS ’ – this will access the battery menu screen (illustrated in Figure 2-16).

Setting the number of cells: 2. From the battery menu screen, select and enter ‘ BATT.CELLS ’. 3. Following the data entry method described earlier, using the ‘UP’, ‘DOWN ’ menu buttons, enter the number of cells contained in the battery string. 4. Press ‘ENTER ’ to save the data to memory, then press ‘ ESC’ once to return to the battery menu screen.

Setting the Battery Capacity: 5. From the battery menu screen, select and enter ‘ CAPACITY’. 6. Using the ‘UP ’, ‘DOWN ’ menu buttons, enter the total battery A/H r capacity (at the 10Hr rate C 10).

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7. Press ‘ENTER ’ to save the data to memory, then press ‘ ESC’ once to return to the battery menu screen.

Setting the battery voltage characteristics: 8. From the battery menu screen, select and enter ‘ VOLTAGE’ – this will take you to the battery voltage menu, which is concerned with selecting the battery charging characteristics. Battery undervoltage trip setting

9. From the battery voltage menu, select and enter ‘ END DIS.’. a) Using the ‘UP’, ‘DOWN ’ menu buttons, enter the specified ‘end-of-discharge’ voltage – standard setting is 1.67V/cell. Note: this is the ‘end-of-discharge’ voltage and is the voltage at which the battery breaker is tripped. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery voltage menu screen. Battery low voltage warning setting

10.From the battery voltage menu, select and enter ‘ BAT LOW’. a) Using the ‘UP’, ‘DOWN ’ menu buttons, enter the specified ‘low battery voltage’ – standard setting is 1.82V/cell. Note: this is the voltage at which ‘low-battery warning’ annunciates. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery voltage menu screen. Battery overvoltage trip setting

11.From the battery voltage menu, select and enter ‘ MAX’. a) Using the ‘UP’, ‘DOWN ’ menu buttons, enter the specified ‘max battery voltage’ – standard setting is 2.45V/cell. This sets the ‘slow’ overvoltage level which is effective only when the batteries are in the float charge mode, and is the voltage at which, after 3 minutes, the battery breaker is tripped, and the rectifier and inverter turned OFF. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery voltage menu screen. Battery boost charge values

WARNING

DO NOT apply BOOST CHARGE to sealed batteries


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Figure 2-17: Battery boost charge parameters Continued from Figure 2-16

BATTERY VOLTAGE MENU SCREEN BATTERY BOOST MENU SCREEN

BATTERY BOOST SETUP MENU SCREEN

12.From the battery voltage menu, select and enter ‘ BOOST CHARGE ’ – this will take you to the boost charge menu screen. 13.From the boost charge menu, select and enter ‘ SETUP ’ – this will take you to the battery boost setup menu screen. 14.From the battery boost setup menu, select and enter ‘ DURATION’. a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required boost operation time (in minutes) – factory setting is 600 mins. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery boost setup menu screen. 15.From the battery boost setup menu, select and enter ‘ THRESHOLD’. a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required current changeover threshold – factory setting is 20% of the battery current limit. Note: this is the level that the battery current must reach before boost charge is enabled upon mains return. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery boost setup menu screen. 16.It is advisable to set the ‘ NOW ’ and ‘AUTOMATIC’ parameters to ‘ NO ’ at this stage in the commissioning, and reset to ‘YES’ (if required) once the rectifier has been fully commissioned.

Verification: 17.Press ‘ENTER ’ to save the data to memory, then press ‘ ESC’ once to return to the battery voltage menu screen. 18.Verify that the data shown on the battery voltage menu screen is correct and repeat this procedure if necessary. 19.The setup menu parameters have now all been entered and stored in the control system’s non-volatile memory. Press ‘ ENTER ’ repeatedly to return to the default menu

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2.4.6


Selecti ng th e UPS MAINTENANCE paramet ers Figure 2-18: ‘MAINTENANCE’ me nu map

MA IN MENU SCREEN

DEFAULT SCREEN

MAINTENANCE MENU SCREEN

The UPS serial number, service information, and current time and date are all entered via the maintenance menu map shown in Figure 2-18. 2.4.6.1

Acc essin g the maintenance menu

1. From the default screen press ‘ENTER ’ to access the main menu screen. 2. Select and enter ‘MAINTENANCE’ – the password screen will now be shown. 3. If the password has been left at the initial default setting, pressing ‘ENTER ’ will now step forward to the maintenance menu screen, shown in Figure 2-18. If the password has been “set”, then enter the correct password to continue. 2.4.6.2

Enteri ng the Serial Number

1. From the maintenance menu screen, select and enter ‘ S.N. ’ Note: The UPS serial number can be found stamped on a circular metal plate attached to the top of the unit, behind the left hand door. 2. Using the ‘UP’ and ‘DOWN ’ menu buttons, enter the UPS serial number. 3. Press ‘ENTER ’ to save the settings, then press ‘ESC ’ once to return to the maintenance menu screen.


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2.4.6.3


Enteri ng the cur rent Date and Time

1. From the maintenance menu screen, select and enter the line showing the time and date. (This may initially indicate all zeroes). 2. Using the ‘UP’ and ‘DOWN’ menu buttons, enter the current time and date information. 3. Press ‘ENTER ’ to save the settings, then press ‘ESC ’ once to return to the maintenance menu screen. 2.4.6.4

Enteri ng the Servic e details

1. From the maintenance menu screen, select and enter ‘LAST SER. ’ to register the date of the current service or commissioning. 2. Using the ‘UP’ and ‘DOWN’ menu buttons, enter the current time and date information. 3. Press ‘ENTER ’ to save the settings, then press ‘ESC ’ once to return to the maintenance menu screen. 4. Select and enter ‘ NEXT SER. ’ to record the date of the anticipated next service. 5. Using the ‘UP’ and ‘DOWN’ menu buttons, enter the current time and date information. 6. Press ‘ENTER ’ to save the settings, then press ‘ESC ’ once to return to the maintenance menu screen. 7. Verify that the data shown on the maintenance menu screen is correct and repeat this procedure if necessary. Then press ‘ ESC’ repeatedly to step back to the default menu screen. 8. The maintenance menu parameters have now all been entered and stored in the control system’s non-volatile memory.

2.4.7

Selecti ng th e UPS FUNCTION paramet ers The function menu screens, shown in Figure 2-19 and Figure 2-20, enable certain parameters to be set and also gives access to various software-initiated functional checks. The procedures contained in this section are concerned with parameter setting; the ‘functional checks’ facilities are used later in the commissioning procedure, during the power checks.

2.4.7.1

Acc essin g the function menu

1. From the default screen press ‘ENTER ’ to access the main menu screen. 2. Select and enter ‘FUNCTION ’ – the password screen will now be shown – if the password has been left at the initial default setting, pressing ‘ENTER ’ will now step forward to the main menu screen. If the password has been “set”, then enter the correct password to continue. 3. From the main menu, select and enter ‘FUNCTION’ to access the function menu screen.

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Figure 2-19: ‘FUNCTION’ selection menu map(Issue 5 software

BATTERY TEST MENU SCREEN


BATTERY TEST SETUP MENU SCREEN

GENERATOR MENU SCREEN




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4. From the default screen press ‘ ENTER ’ to display the option selection screen. 5. Select and enter ‘FUNCTION’. 6. The password screen will now be shown. 7. If the password has not yet been set, pressing ‘ENTER ’ will step forward to the maintenance selection screen shown in Figure 2-19. 2.4.7.2

Setting the Batt ery Test parameters

1. From the function menu screen, select and enter ‘ BATTERY TE ST’ to access the battery test menu. 2. Three selections are available: ‘ NOW ’, ‘AUTOMATIC’ and ‘SETUP’.

‘NOW’ Selection: When ‘ NOW ’ is set to ‘ YES ’, it initiates an immediate battery test by switching off the UPS rectifier s ection. This is not required at this time but is used later in the commissioning during the “power checks”. 3. From the battery test menu, select and enter ‘ NOW ’. 4. Press ‘ENTER ’ to step to the selection screen and, using the ‘ UP’ menu button, select NO (‘ N’). 5. Press ‘ENTER ’ to save the settings, then press ‘ESC ’ to return to the battery test menu screen.

‘AUTOMATIC’ Selection: ‘AUTOMATIC’ initiates a battery test cycle at a predefined set time and date (as entered in the setup selection menu below). 6. From the battery test menu, select and enter ‘ AUTOMATIC’. 7. If an automatic battery test function is required, press ‘ ENTER ’ to step to the selection screen and, using the ‘ UP’ menu button, select YES (‘Y’). 8. Press ‘ENTER ’ to save the settings, then press ‘ESC ’ to return to the battery test menu screen.

SETUP Selection: ‘SETUP ’ allows the parameters to be set for the automatic testing cycle (see above). 9. From the battery test menu, select and enter ‘ SETUP’ to access the battery test setup menu screen. 10.From the battery test setup menu select and enter ‘ DURATION’. 11.Using the ‘UP’ and ‘DOWN’ menu buttons, enter the test ‘ DURATION’ time in minutes. (This would normally be set to 5 minutes). 12.Press ‘ENTER ’ to save the settings, then press ‘ESC ’ to return to the battery test setup menu screen. 13.From the battery test setup menu select and enter ‘ THRESHOLD’. 14.Using the ‘UP’ and ‘ DOWN ’ menu buttons, enter the minimum battery test voltage ‘THRESHOLD’ level. (This would normally be set to 1.9V/Cell). 15.Press ‘ENTER ’ to save the settings, then press ‘ESC ’ to return to the battery test setup menu screen. 16.From the battery test setup menu select and enter ‘ PERIOD’.

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17.Using the ‘UP’ and ‘ DOWN’ menu buttons, enter the ‘ PERIOD’ (in days) at which the test is to occur in days.(This would normally be set to 90 days). 18.Press ‘ENTER ’ to save the settings, then press ‘ESC ’ to return to the battery test setup menu screen. Note: Once the first Automatic Battery test has been actioned, the time and date will up-date according to the selected period. This will change on the display to indicate when the next battery test will be carried out.

Verification: 19.Verify that the data shown on the battery test setup menu screen is correct and repeat this procedure if necessary. 20.Step back to the battery test menu screen by pressing ‘ ESC ’. 21.Verify that the data shown on the battery test menu screen is correct and repeat this procedure if necessary. 22.Step back to the function menu screen by pressing ‘ ESC ’. 2.4.7.3

Settin g the Generator parameters

1. From the function menu screen, select and enter ‘ GENERATOR ’ to access the generator menu screen. 2. Three selections are available: ‘INV: SYNC INHIBIT ’, ‘RECT: I INHIBIT’ and ‘BAT: I I NHIBIT ’. Note: These features require external control input via the Remote Alarms Board in order to become active.

INV: SYNC INHIBIT Selection: This disables synchronisation between the UPS and generator when the generator is on-line. When selected, it helps to overcome “Sync Error” problems occurring when running on a generator whose frequency is unstable. 3. From the generator menu screen, select and enter ‘ INV: SYNC INHIBIT ’. 4. Using the ‘UP’ menu button, set the attribute to YES ‘Y’ or NO ‘ N’ as required. 5. Press ‘ENTER ’ to save the settings, then press ‘ ESC ’ to return to the generator menu screen.

BAT: I INHIBIT Selection: This restricts the maximum charge current to the batteries when the generator is on-line and is used if the generator power output is limited. 6. From the generator menu screen, select and enter ‘ BAT: I INHIB IT ’. 7. Using the ‘UP’ menu button, set the attribute to YES ‘Y’ or NO ‘ N’ as required. 8. Press ‘ENTER ’ to save the settings, then press ‘ ESC ’ to return to the generator menu screen.

RECT: I INHIBIT Selection: This reduces the maximum UPS input current by 30% of the standard factory-set current limit when the generator is on-line. This facility is used if the generator power output is limited. 9. From the generator menu screen, select and enter ‘ RECT: I INHIBIT’. 10.Using the ‘ UP’ menu button, set the attribute to YES ‘Y’ or NO ‘ N’ as required.


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11.Press ‘ENTER ’ to save the settings, then press ‘ ESC ’ to return to the generator menu screen.

Verification: 12.Verify that the data shown on the generator menu screen is correct and repeat this procedure if necessary. 13.Step back to the function menu screen by pressing ‘ ESC ’.

2.4.7.4

Setting the Panel Setup selecti ons

1. From the function menu screen, select and enter ‘ PANEL SETUP’ to access the panel setup menu screen. 2. Four selections are available: ‘LANGUAGE ’, ‘TYPE (STATE) ’, ‘GROUP’ and ‘PASSWORD’.

TYPE & STATE Selection: These parameters register the equipment type number and Master/Slave paralleling configuration. 3. From the panel setup menu screen, select and enter ‘ TYPE’ _(‘STATE’). Note: The first selection, ‘LANGUAGE ’, was completed earlier in this procedure – (See paragraph 2.4.4) . 4. Using the ‘UP’ and ‘DOWN ’ menu buttons: a) Enter the ‘TYPE’ of UPS system – in this case enter ‘7200’. b) Enter the UPS system ‘STATE’ – in the case of a “single module” system enter the word ‘ MASTER ’. 5. Press ‘ENTER ’ to save the settings, then press ‘ ESC’ to return to the panel setup menu screen.

GROUP & UPS Selection: This selection sets the communications address for the UPS Module. 6. From the panel setup menu screen, select and enter ‘ GROUP’ _ ‘UPS ’. 7. Using the ‘UP’ and ‘DOWN ’ menu buttons: a) Enter the ‘UPS ’ address – in the case of a “single module” system enter ‘ 1’ unless instructed otherwise. b) Enter the ‘ NODE ’ address – in the case of a “single module” system enter ‘1’ unless instructed otherwise. 8. Press ‘ENTER ’ to save the settings, then press ‘ ESC’ to return to the panel setup menu screen.

PASSWORD Selection: This selection sets the password which will give restricted entry to certain screens once set – i.e. access to a password protected screen is possible but no data can be entered or changed. Until now, the default password (00000000) has been used. 9. From the panel setup menu screen, select and enter ‘ PASSWORD’.

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SECTION 2 - In s t al l at i o n & Co m m i s s i o n i n g CHAPTE CHAPTER R 2 - Commi Commi ssioni ng Proc edure

Figure 2-20: ‘FUNCTION’ selection menu map ‘NEXT PAGE’ selections selections Continued from Figure 2-19


MODEM MENU SCREEN

NEXT PAGE MENU SCREEN

ON/OFF MENU SCREEN

When selected to ‘YES’ and saved, all UPS parameters are reset reset to zero. The parameparameter values will then require re-entering into the software

Important

Once the eight digit password has been selected and saved into the NVRAM further changes to the UPS parameters will be inhibited unless the correct password is entered. ENSURE THE NEW PASSWORD IS SAFELY RECORDED IN THE RELEVANT COMMISSIONING OR SERVICE DOCUMENTATION.

10.Using the ‘UP’ and ‘DOWN ’ menu buttons enter an 8-digit password. 11.Press 11.Press ‘ENTER ’ to save the settings, then press ‘ ESC’ to return to the panel setup menu screen.

s2-c2b.f m5 - Iss ue 3 Dated 09/11 09/11/98 /98

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SECTION 2 - In s t al l at i o n & Co m m i s s i o n i n g CHAPTE CHAPTER R 2 - Commis Commis sioni ng Proc edure


Verification: 12.Verify that the data shown on the panel setup menu screen is correct and repeat this procedure if necessary. 13.Step back to the function menu screen by pressing ‘ ESC ’. 2.4.7.5 2.4.7.5

Setting the NEXT PAGE selecti ons

1. Fro From the the function menu screen select and enter ‘ NEXT the next page menu screen (See Figure 2-20) .

PAGE ’

– this accesses

2. Three selections selections are available: available: ‘PC-CONN’, ‘ON/OFF UPS ’, ‘RELOAD UPS DATA’.

‘PC-CONN’ Setting: This establishes the UPS software settings to interface via a modem to a remote location. 1. Fro From the the next page menu screen select and enter ‘ MODEM CONNECTION ’ to access the modem menu screen. 2. Fro From th the modem menu screen, select and enter ‘ PC-CONN.’. 3. Selec Selectt eit eithe herr ‘LOCAL’ or ‘ REMOTE’ modem connection as appropriate. 4. Pre Press ‘ENTER ’ to save the settings, then press ‘ ESC ’ to return to the modem menu screen. 5. Fro From th the modem menu screen, select and enter ‘ RESET’. 6. Selec Selectt eit eithe herr ‘ NO’ or ‘ YES’ as appropriate. Note: Selecting ‘YES’ will enable any alarm to be reset from a connected PC. 7. Press ‘ENTER ’ to save the settings, then press ‘ ESC ’ to return to the modem menu screen. 8. Verify that the the data data shown on the modem menu screen is correct and repeat this procedure if necessary. necessary. 9. Step Step back back to to the the next page menu screen by pressing ‘ ESC ’.

‘ON/OFF UPS CONTROL’ CONTROL’ Setting: Setti ng: The on/off menu screen allows the UPS inverter, static bypass line, and rectifier sections to be switched on or off from the control panel and will be covered in the power checks.

‘RELOAD UPS DATA’ Setting : Setting this option to YES resets the micro-processor NVRAM to the default parameters and should be carried out only if a complete reprogramming sequence is required.

WARNING

DO NOT enter a ‘RELOAD UPS DATA’ selection while the UPS is on load, as it will disable the inverter, rectifier and bypass sections, and remove load power.

10.From the next page menu screen select and enter ‘RELOAD UPS DATA’. and if you wish to reset the stored data to the default parameters select ‘ YES’. 11.Using the setup menu screen locate and enter the ‘POWER ’ screen and Re-enter the units KVA rating. 12.Turn the UPS off for 5 seconds then turn it back on 13.Step back to the default screen screen by repeatedly pressing ‘ ESC’. The UPS function menu parameters have now all been stored in NVRAM

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s2-c2b.f m5 - Issu e 3 Dated 09/11/ 09/11/98 98


SECTION 2 - In s t al l at i o n & Co m m i s s i o n i n g CHAPTE CHAPTER R 2 - Commi Commi ssioni ng Proc edure

Section 2: 1

2.5

Power checks ch ecks Once the UPS parameters have been entered into the software, full power can be applied to the unit and the following power checks carried out.

WARNING

2.5.1 2.5.1

Ensure that the load is isolated or safe to receive power, before continuing with the following procedure

App lyi ng pow er to the UPS 1. Check that that the Bypass Bypass Isolator Isolator Q2 is still closed closed – close Q2 if it is open. open. a) Verify that the LCD LCD shows shows the default screen. b) Verify that the Amber ‘ Load on Bypass’ LED is flashing. 2. Close Close the UPS UPS Input Input Isolat Isolator or Q1. a) Verify that after after approximately 30 seconds the Green ‘Load on Inverter’ LED illuminates and the ‘Load on Bypass’ LED extinguishes. b) The LCD default screen indication should be: BATTERY BREAKER OPEN OUTPUT SWITCH OPEN 24-09-95

DEFAULT SCREEN

14: 33: 00

3. Close Close the Outp Output ut Isolat Isolator or Q4. Q4. 4. Close the Battery Battery Circuit Circuit Breaker (located (located in the battery battery cabinet cabinet or adjacent adjacent to any external battery racks). a) The LCD default default screen screen indicati indication on should should be: NORMAL OPERATION 24-09-95

2.5.2 2.5.2

DEFAULT SCREEN

14: 33: 00

Monito ring & recordi ng the UPS UPS operating parameters parameters 5. Using the menu screen navigati navigation on techniques techniques described described earlier in this section section,, access the main menu screen and then access the measurement menu screen – a menu map is shown in Figure 2-21. 2-21. 6. Fro From the the measurement menu screen select and enter ‘INPUT’ then note and record indicated input voltage in the appropriate commissioning documentation. 7. Fro From th the measurement menu screen select and enter ‘ BATTERY’ then note and record in the appropriate commissioning documentation the battery voltage, current, and percentage charge. 8. Fro From the the measurement menu screen select and enter ‘ TEMPERATURE’ then note and record the indicated temperatures in the appropriate commissioning documentation:

s2-c2c.f m5 - Issu e 3 Dated 09/11 09/11/98 /98

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SECTION 2 - In s t al l at i o n & Co m m i s s i o n i n g CHAPTE CHAPTER R 2 - Commis Commis sioni ng Proc edure


Figure 2-21: Menu tree for the MEASUREMENT parameters (Issue 5 software) software)

INITIALISATION SCREEN MAIN MENU SCREEN DEFAULT MENU SCREENS

MEASUREMENT MENU SCREEN

9. Fro From th the measurement menu screen select and enter ‘ OUTPUT ’ then further select and record in the appropriate commissioning documentation: – output voltage – output current – output power – output frequency. frequency.

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s2-c2c.f m5 - Issu e 3 Dated 09/11/ 09/11/98 98



Figure 2-22: Menu tree for the ‘FUNCTON’- ‘NEXT PAGE’ test selections Continued from Figure 2-19


MODEM MENU SCREEN


ON/OFF MENU SCREEN

10.Navigate back to the default screen by repeatedly pressing the ‘ ESC ’ button.

2.5.3

Power mod ule ON/OFF fun cti onal checks The UPS power sections can be independently switched off and on from the Operator Control Panel, as checked below, which enables each section to be tested individually.

2.5.3.1

Acc essin g the ON/OFF menu scr een

The following functional checks are carried out from the ON/OFF menu screen. To gain access to this screen:

s2-c2c.f m5 - Issu e 3 Dated 09/11/98

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1. Using the menu navigation methods described previously, step from the default screen via the main menu screen (‘FUNCTION’), password screen, function menu screen (‘ NEXT PAGE ’) and next page menu screen (‘ ON/OFF UPS CONTROL’) to the ON/OFF menu screen. Refer to the menu maps in Figure 2-18, Figure 2-19 and Figure 2-22 for assistance if necessary. 2.5.3.2

Inverter test

1. Gain access to the ON/OFF menu screen (See paragraph 2.5.3.1) . 2. From the ON/OFF menu screen, select and enter ‘ INVERTER ’. 3. Using the ‘UP’ menu button, select ‘ INVERTER OFF ’, then press ‘ ENTER ’ to save the selection. 4. On the UPS mimic, verify that the inverter has turned off and the load has transferred to the static bypass supply. a) The green ‘Load on Inverter’ LED is extinguished and the amber ‘Load on Bypass’ LED is flashing. 5. Step back to the default screen, by continually pressing the ‘ESC’ button, and verify that: a) The ‘INV: OFF VIA DI SPLAY’ and ‘LOAD ON BYPASS ’ alarms are present. 6. Repeat steps 1 and 2 to return to the ON/OFF menu inverter selection screen. then select ‘INVERTER ON’ and press ‘ ENTER ’ to save the selection. 7. On the UPS mimic, verify that the inverter has turned on and the load has transferred back to the inverter from the static bypass supply. a) The green ‘load-on-inverter’ LED is illuminated and the amber ‘load-on bypass’ LED is extinguished. 8. Step back to the default screen, by continually pressing the ‘ ESC’ button, and verify that: a) The ‘ NORMAL OPER ATION ’ status indication is present. 2.5.3.3

Byp ass test

1. Gain access to the ON/OFF menu screen (See paragraph 2.5.3.1) . 2. From the ON/OFF menu screen, select and enter ‘ LINE’. 3. Using the ‘UP’ menu button, select ‘ BYPASS OFF ’, then press ‘ENTER ’ to save the selection. 4. Step back to the default screen, by continually pressing the ‘ ESC’ button, and verify that the ‘ BYP: OFF VIA DISPLAY ’ (bypass remotely inhibited), is displayed. 5. Repeat steps 1 and 2 to return to the ON/OFF menu line selection screen. then select ‘BYPASS ON’ and press ‘ ENTER ’ to save the selection. 6. Step back to the default screen, by continually pressing the ‘ ESC’ button, and verify that the ‘ NORMAL OPER ATION ’ status indication is present. 2.5.3.4

Rectifi er and battery autonomy test

1. Gain access to the ON/OFF menu screen (See paragraph 2.5.3.1) .

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2. From the ON/OFF menu screen, select and enter ‘ RECTIFIER ’. 3. Using the ‘UP’ menu button, select ‘ RECTIFIER OFF ’, then press ‘ ENTER ’ to save the selection. 4. Verify that the rectifier has turned off and the inverter is still operating from battery power. 5. Step back to the default screen, by continually pressing the ‘ESC’ button, and verify that: a) The ‘RECT: OFF VIA DISPLAY ’ and ‘ON BATTERY’ alarms are present. b) The green battery bargraph LEDs indicate the remaining battery time. Note: If the UPS is allowed to run in this condition the battery bargraph LED’s will progressively turn off indicating the r emaining autonomy time. 6. Step forward to the measurements menu screen (See paragraph 2.5.2) , then enter and select ‘BATTERY’, and note and record the indicated remaining autonomy time. Each illuminate bar-graph segment is equivalent to 2 minutes remaining. All 5 will be illuminated for greater than 10 minutes. 7. Step back to the default screen, by continually pressing the ‘ESC’ button. 8. Repeat steps 1 and 2 to return to the ON/OFF menu rectifier selection screen. then select ‘RECTIFER ON’ and press ‘ ENTER ’ to save the selection. 9. Verify that the rectifier turns on. 10.Step back to the default screen, by continually pressing the ‘ ESC’ button, and verify that the ‘ NORMAL OPER ATION ’ status indication is present. 11.Step forward to the measurements menu screen (See paragraph 2.5.2) , then enter and select ‘ BATTERY’, and note and record the indicated capacity charge. 12.Step back to the default screen, by continually pressing the ‘ ESC ’ button.

2.5.4

Batt ery test A software-controlled battery test facility can be initiated from the Operator Control Panel on an “immediate” or “periodic” basis. This test turns off the rectifier and runs the inverter (and load) from the battery for a predetermined period. If the battery voltage falls below a preset minimum level prior to the termination of the test period a ‘BATTERY FAIL ’ alarm is annunciated and the rectifier is immediately turned on to prevent the load transferring to bypass – and recharge the battery. The instructions given below initiates an immediate battery test. For the following test to be ‘meaningful’ as part of the UPS commissioning procedure, the batteries should be fully charged prior to the test being carried out. The UPS rectifier section must therefore be allowed to operate with the battery connected for several hours to provide the battery with an adequate initial charge.

Caution

Do not continue with this procedure if the battery has not yet been charged

1. Using the menu navigation methods described previously, step from the default screen via the main menu screen (‘FUNCTION’), password screen, function menu screen (‘BATTERY TEST’) to the battery test menu screen. Refer to the menu map in Figure 2-23 for assistance if necessary. 2. From the battery test menu screen, select and enter ‘ SETUP’.


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Figure 2-23: Menu tree for the ‘FUNCTON’- ‘BATTERY TEST’ selections (Issue 5 software)

BATTERY TEST MENU SCREEN


BATTERY TEST SETUP MENU SCREEN

Date & Time of NEXT periodi c test

3. Verify that the parameters entered in the battery test setup menu are appropriate. If not then enter the correct setup parameters (See paragraph 2.4.7.2) . 4. Press ‘ESC ’ to return to the battery test menu screen. 5. From the battery test menu screen, select and enter ‘ NOW ’. 6. Using the ‘UP’ menu button, select Yes (‘ Y’), then press ‘ ENTER ’ to initiate an ‘immediate’ battery test. 7. Verify that the rectifier enters the test mode by confirming that LED H1 (Amber) is illuminated on the Rectifier Logic Board. (The inverter will continue its operation and discharge the battery.) 8. Step back to the default screen, by continually pressing the ‘ ESC ’ button and verify that the ‘ ON BATTERY ’ and ‘ RECT: SOFTWARE B LOCK ’ alarms are displayed. The green LED battery bargraph will indicate the remaining battery time. Note: If the UPS is allowed to run in this condition the battery bargraph LED’s will progressively turn off indicating the remaining autonomy time. 9. The battery will be tested for the selected ‘DURATION’ time after which the UPS will revert to normal operation. – the rectifier will return to the Float mode. – LED H3 (green) will be illuminated on the Rectifier Logic Board. Note: If the battery fails the test (i.e. falls below the ‘ THRESHOLD’ value before the ‘DURATION’ time expires), the rectifier will immediately return to the float

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mode and the ‘ BATTERY FAIL’ alarm will be displayed on the default screen. This alarm can be reset by pressing the ‘ RESET’ Button (S1) on the UPS Logic Board.

2.5.5

Emergency remote pow er off check 1. Ensure that ‘ NORMAL OPER ATION ’ is displayed on the default screen. 2. Remove the link between terminals 10 & 11 on the Auxiliary Terminal Block (X3) (See Figure 2-10). Or open the remote EPO button if installed. 3. Verify that the UPS power sections shut down and ‘CUT-OFF: EMERGENCY ’ is displayed on the default screen. 4. Refit the link between terminals 10 & 11 on the Auxiliary Terminal Block (X3) (See Figure 2-10). Or close the remote EPO button if installed. 5. Press the Reset Button (S1) on the UPS Logic Board. 6. Verify that the UPS returns to normal operation – ‘ NORMAL played on the default screen.

OPERATION’

dis-

Figure 2-24: Menu tree for the ‘SETUP’- ‘BATTERY’ selection Continued from Figure 2-16


BATTERY BOOST SETUP MENU SCREEN

2.5.6

Battery boos t test (if appli cable) A software-controlled battery boost facility can be initiated from the Operator Control Panel on an ‘immediate’ or ‘periodic’ basis. This increases the rectifier output (dc bus) to the selected boost voltage level for a predetermined period. The instructions given below initiates an immediate battery boost charge.

WARNING

DO NOT APPLY BOOST CHARGE TO SEALED BATTERIES

1. Using the menu navigation methods described previously, step from the default screen via the main menu screen (‘SETUP’), password screen, setup menu screen (‘BATTERY’) to the battery menu screen. Refer to Figure 2-15 and Figure 2-16 for assistance if necessary.


2-53



2. From the battery menu screen select and enter ‘ VOLTAGE’ to access the battery voltage menu screen. 3. From the battery voltage menu screen select and enter ‘ BOOST CHARGE’ to access the battery boost menu screen. Note: The boost parameters (accessed via ‘ SETUP’) were entered earlier in this procedure (see page 2-37). These may reviewed here if required. 4. From battery boost menu screen, select and enter ‘ NOW’. 5. Using the ‘UP’ menu button, select Yes (‘Y’), then press ‘ENTER ’ to save the selection, followed by ‘ ESC ’ to return to the battery boost menu screen. 6. The rectifier should now be in its boost charge mode. a) Verify that the boost charge indicator LED H2 (green) is illuminated on the Rectifier Logic Board. b) Step back to the main menu screen and then access the measurement menu screen (See Figure 2-21). Verify that the battery voltage has increased to the appropriate boost charge level. 7. The rectifier will revert to its float charge mode (LED H3 illuminated and LED H2 extinguished on the Rectifier Logic Board) in the event of: a) The selected ‘DURATION’ time being reached. b) The battery charge current falling below the boost ‘ THRESHOLD’ current prior to the completion of the boost ‘ DURATION’ time. c) Manual intervention turning OFF the boost charge facility. Note: this is achieved by changing the ‘ NOW ’ parameter to No (‘ N’) in the battery boost menu screen (see steps 6 & 7 above). 8. Step back to the default screen, by continually pressing the ‘ ESC ’ button.

2.5.7

On-Generator test (if applic able) The following test checks the operation of the generator parameters set-up earlier (See paragraph 2.4.7.3) in the generator menu screen (See Figure 2-19). The test is unnecessary if the generator parameters have not been selected – i.e. the function parameters for the ‘ GENERATOR ’ options must be selected to Yes (‘Y’). Any combination of the three functions can be selected. 1. To initiate this test, the generator must apply a voltage in the range 12-24Volts (ac or dc) between pins 5 and 6 of the Alarm Interface Board terminal block X5 when the generator is operating. 2. Start the generator. 3. On the default screen, check for the following alarms: a) ‘INV: UNSYNCHRONIZED ’ The UPS will not synchronise to the unstable generator supply b) ‘CHARGER INHIBITED ’ The battery current is inhibited due to the generator power being limited. c) ‘REDUCED CURRENT LIMIT ’ The rectifier current is inhibited due to the generator power being limited. 4. Stop the generator

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5. Verify that ‘ NORMAL OPER ATION ’ is displayed on the default screen.

2.6

Commissioning conclusi on (‘single module’) 1. The (‘single’) UPS module has now been commissioned and can be put into normal service. Be sure that the commissioning records are completed and filed appropriately. 2. If the password protection system is to be enabled ensure that the link is removed from jumper X26 pins 7-8 on the UPS Logic Board. Note: If the password protection system is enabled only those parameters listed below are changeable without first entering the selected password: • Time and Calendar • ON/OFF UPS CONTROL (rectifier, inverter and bypass) • Battery test (star, time/date stamp, repetition rate) • Modem configuration and operation 3. For 1+1 systems, the commissioning procedure must be repeated for each module. When both modules have been satisfactorily commissioned, continue with the commissioning procedure for the ‘1+1’ system outlined below.

1+1

2.7

Parallel System Start Up (‘1+1’ System)

Applies only to

1+1

2.7.1

The procedures contained in paragraph 2.7 and paragraph 2.8 are used to commission two ‘1+1-configured’ modules as a ‘parallel-operating’ system. It is crucial that both modules have passed the single module commissioning checks before any attempt at paralleling is carried out.

Initialisation 1. Ensure that both modules are fully powered down. 2. On each module in turn: a) Fit the 60 way flat ribbon cable between the Parallel Logic Board (4520075B) connector X1 and UPS Logic Board (4550007H) connector X7 – this cable was removed earlier in the commissioning procedure to allow the modules to operate in their ‘single module’ mode. b) Reconfigure the UPS Logic Board (4550007H) jumpers for parallel operation (See Table 2-13) – these were changed earlier in the commissioning procedure to allow the modules to operate in their ‘single module’ mode. c) Check that the Parallel Logic Board (4520075B) jumpers have been selected in accordance with Table 2-10.


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Table 2-13: UPS Logic Board jumper configuration 1-2

Inverter operation in ‘Manual’ mode (Bypass preferred) = Closed Inverter operation in ‘Auto’ mode (Inverter Preferred) = (Standard)

3-4

Inverter Bad voltage for 10 seconds Off latch enabled = Closed (Standard) Off latch disabled = Open

5-6

Not Required

7-8

Security Password Over-ride. Closed = Over-ride security Password Open = Enable security Password (standard)

1-2

*G.V.C.O. to inverter logic = parallel module

2-3

Micro V.C.O. to inverter logic = single module

1-2


2 -3


1-2


2 -3


X26

X34 X35 X36

Note: *X34 must be in position 1-2 for ‘1+1’ operation. X26 must be in position 7-8 to override the password security control.

2.7.2

Parallel log ic PCB calibr ation Complete paragraph 2.7.2 for each module in turn, ensuring that only the module under calibration is energised. 1. Ensure that switches Q1, Q2, Q3 on the UPS Logic Board are selected OFF – i.e. to disable the rectifier, inverter, and bypass operation. 2. Ensure that all power isolators are OPEN, take particular care that the bypass isolator Q2 is OPEN . 3. Close the rectifier power isolator Q1 to energise the control electronics.

Governing Voltage Controlled Oscillator (GVCO) calibration: 4. Connect a DVM to X8 pin 1 and check that the level is high (+5V) to ensure that the G.V.C.O. is free running ( 0V is available at TP10). 5. Adjust R18 to obtain a 50Hz square wave at X8 pin 2. Note: for 60Hz operation connect jumper X7 to 1-2 and adjust R18 for 60.00Hz @ X8 pin 2.

Reverse/Forward current detector calibration: . 6. Connect a DVM to the lower end of R68. 7. Adjust R19 to obtain the appropriate voltage for the expected nominal output current as shown in Table 2-14. Table 2-14: UPS Rated Voltage

R68 L ower End Value

220/380V

5.90V

230/400V

6.20V

240/415V

6.45V

Software re-configuration:

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8. Using the software driver menu display screens enter the ‘ SETUP’ menu (See Figure 2-15). 9. Select and enter the ‘CONFIG’ screen. 10.Using the ‘ROTATE ’ button select ‘PAR 1+1’ and press ‘SAVE’ to store the parameters into memory. 11.Using the ‘ESCAPE’ button return to the ‘ DEFAULT’ alarms screen. 12.Ensure the procedures detailed in paragraph 2.7.2 are carried out individually on both modules.

2.8 2.8.1

Testi ng the Compl ete Parallel Syst em Module starti ng 1. Ensure that the bypass input isolator Q2 remains OFF on both modules. 2. Ensure that the switches Q1, Q2 & Q3 on the UPS Logic Board are OFF. 3. Close the rectifier input isolator Q1 on each module. 4. Start the rectifier in each module by closing the UPS Logic Board switch Q3 and check for the correct battery float voltage on each modules’ ‘ MEASUREMENT’ screen. 5. Close the appropriate battery isolators for the system configuration. 6. Start a selected inverter by closing switch Q2 on the module UPS Logic Board and then close the module output isolator Q4 – the inverter should run up and its output contactor K1 close. Check for correct output voltages on the ‘ MEASUREMENT’ screen. 7. Start the inverter in the second module by closing switch Q2 on the UPS Logic Board – the second module’s inverter should run up and its output contactor K1 close. Check for correct output voltages on the ‘ MEASUREMENT’ screen. 8. Using the current ‘MEASUREMENT’ screens or current clamp CTs on the output critical busbar interconnecting cables, check for circulating currents between the paralleled inverters. d) The measured circulating current should be less than 10% of the modules’ kVA rating – e.g. 6 amps for a 60kVA unit. e) Adjust the inverter φ displacement using R247 on the Inverter Logic Board (4530025T) on one module to minimise the circulating current. 9. Close the bypass input isolators Q2 on each module. 10.Enable the static bypass on each module by closing the switch Q1 on each UPS Logic Board. The inverters should now synchronise to the bypass supply. 11.Allow the system to stabilise. Check for ‘ NORMAL OPERATION’ indicated on the ‘ DEFAULT’ screen of each module.


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2.8.2


Inverter bypass re-transfer checks The UPS system can be configured to operate in two ways, i.e.: Redundant module

Where the proposed rated load level is less than or equal to the nominal kVA of one module. Either module operating is therefore capable of sustaining the load. Non-redundant module

Where the proposed rated load level is greater than the nominal kVA of one module but less than the sum of both. Both modules are therefore required to sustain the load. 2.8.2.1

Redundant confi guration system power checks

This paragraph applies to a ‘Redundant’ module syst em only. If the system under test is configured as ‘Non-redundant’ then jump to paragraph 2.8.2.2. The static bypass thyristor switches contained within each module will operate together, always opening and closing in unison. However it is possible to have one in a ‘BLOCKED’ state by selecting switch Q1 of the relevant UPS Logic Board to OFF – simulating a ‘bypass disabled’ condition. 1. Ensure that jumper X6 0-1 is open on the Parallel Logic Board (4520075B) for redundant operation. 2. Start both modules and ensure they operate as expected, with the inverters paralleled and ‘ NORMAL OPERATION’ displayed on both modules’ ‘ DEFAULT’ screen. 3. Stop one module’s inverter by selecting OFF Q2 on its UPS Logic Board. a) The inverter should stop and the module’s output contactor K1 open – thereby disconnecting the module from the critical bus. b) The remaining module should continue to operate and support the critical bus supply. 4. Stop the second module’s inverter by selecting OFF Q2 on its UPS Logic Board. a) The second module’s inverter should stop and its output contactor K1 open, – thereby disconnecting the second module from the critical bus. b) Critical bus power should now transfer to the bypass supply, without a break – i.e. both modules’ bypass static switches should close. 5. Check for the appropriate default alarms on each module mimic display. 6. Start the inverter on one module by selecting ON Q2 on the relevant module’s UPS Logic Board. a) The inverter should run up and achieve synchronisation. b) The critical bus should transfer to the inverter – i.e. the output contactor (K1) should close in the running module only, and the static switches should open in both modules. 7. Start the remaining module’s inverter by selecting ON Q2 on its UPS Logic Board. a) The inverter will run up and achieve synchronisation.

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b) Check that the LED H3 illuminates on the Parallel Logic Board during ‘slave’ mode operation. c) The second module’s output contactor (K1) should close connecting the inverter to the critical bus. d) Check that the LED H3 extinguishes on the Parallel Logic Board, indicating ‘master’ mode operation. 2.8.2.2

Non-redundant config uration system power checks

This paragraph applies to ‘Non-redundant’ configured systems only. If the system under test is configured as a ‘Redundant’ system then jump to paragraph 2.9. The static bypass thyristor switches contained within each module will operate together, always opening and closing in unison. However it is possible to have one in a ‘BLOCKED’ mode by selecting OFF switch Q1 of the relevant UPS Logic Board, simulating a ‘bypass disabled’ condition. 1. Ensure that link X6 0-1 is closed on the Parallel Logic Board (4520075B) for ‘Non-redundant’ operation. 2. Start both modules and ensure they operate as expected, with the inverters paralleled and ‘ NORMAL OPERATION’ displayed on both modules’ ‘ DEFAULT’ screen. 3. Stop one module inverter by selecting OFF switch Q2 on the UPS Logic Board. a) The inverter should stop and the module output contactor K1 open – thereby disconnecting the module from the critical bus. b) The output contactor (K1) should also open in the remaining module. c) If available both modules’ static switches should close to connect the critical bus to the bypass supply. d) Check on the appropriate module mimic displays for verification. 4. Turn OFF the remaining inverter by selecting OFF switch Q2 on its UPS Logic Board. a) The second module’s inverter should stop – the load is already on bypass. 5. Start the inverter on one module by selecting ON switch Q2 on the relevant module’s UPS Logic Board. a) The inverter should run up but its output contactor (K1) should remain open. b) The load will remain connected to the bypass waiting for the start of the second module. 6. Start the second module’s inverter by selecting ON switch Q2 on its UPS Logic Board. a) The inverter will run up in slave mode – i.e. led H3 on the Parallel Logic Board will illuminate until the module achieves synchronisation and parallels with the existing inverter. b) Both modules should now transfer the critical bus supply to inverter by closing the output contactor (K1) and turning off the static switch in both modules simultaneously.


2-59



7. Check on the appropriate module mimic displays for verification. 8. Allow the system to stabilise. Check for ‘ NORMAL OPERATION’ indicated on the mimic ‘ DEFAULT’ screen for each module.

2.9

Commissioning conclusi on (‘1+1’ system) 1. The (‘1+1’) parallel UPS system has now been commissioned and can be put into normal service. Be sure that the commissioning records are completed and filed appropriately. 2. If the password protection system is to be enabled (both modules) ensure that the link is removed from jumper X26 pins 7-8 on the UPS Logic Board. Note: If the password protection system is enabled only those parameters listed below are changeable without first entering the selected password: • Time and Calendar • ON/OFF UPS CONTROL (rectifier, inverter and bypass) • Battery test (star, time/date stamp, repetition rate) • Modem configuration and operation

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Section 2:

2.10

Voltage and Frequency Conversion The 7200 Series UPS leaves the manufacturer fully tested and adjusted t o operate at 400Vac / 50Hz with a 198 cell battery; however, but can be converted to 380V or 415V, at either 50 or 60Hz. Such a conversion is effected by: • •

changing the control power supply transformers primary tap voltages. entering the revised working parameters into the control system’s memory via the Operator Control Panel ‘ SETUP’ menus. • amending the number of batteries, if required. The module’s working voltage and frequency is set as a matter of course within the commissioning procedure: the purpose of the following paragraphs is to provide a consolidated procedure for changing these parameters post commissioning – i.e. to change the voltage/frequency of an already working module. Note: Where reference is made to the “nominal” voltage, this should be taken as the required equipment working voltage – e.g. 380/400/415 volts.

2.10.1

Rating con sideratio ns and battery sizing If the module is to operate at 415V input/output its power capacity will increase by approximately 10%. – i.e. A 60kVA unit will be increased to 66kVA. The number of battery elements required to enable the unit to meet its design specifications is shown in the table below. Note: If additional elements are required they should be of the same type and ca pacity as those already in use. Table 2-15: Number of battery elements

2.10.2

Nominal Operating Output Voltage

Specified Nº of Battery Elements

380V AC

192 Cells

400V AC

198 Cells

415 V AC

204 Cells

Hardware con version 1. Ensure that the module is completely powered down – i.e. all the UPS isolators, including the battery circuit breaker, are open (OFF or in position ‘ 0’) – if necessary transfer the load to the Maintenance Bypass supply. 2. Select the correct primary voltage tap on the Power Supply transformers T2 and T3, according to Table 2-16 below. Table 2-16: Power supply transformers T2 and T3 voltage selection. 380V Operation

400V Operation

415V Operation

A3 - B

A2 - B

A1 - B

s2-c2d.f m5 - Issue 3 Dated 09/11/98

2-61


2.10.3


Software con version – Entering new volt age / frequenc y / battery data Figure 2-25: ‘SETUP’ menu map (Issue 5.0 software) MAIN MENU SCREEN

UPS MENU SCREEN

SETUP MENU SCREEN

VOLTAGE MENU SCREEN

FREQUENCY MENU SCREEN

BATTERY MENU SCREEN


1. Inhibit the UPS power sections by selecting switches Q1, Q2, Q3 on the UPS Logic Board to OFF. 2. Close the Bypass Isolator Q2. a) The power supply and electronics will energise. b) The Operator Control Panel display will power up. c) The rectifier and inverter power sections will remain off. 3. From the default screen press ‘ENTER ’ to access the main menu screen.

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s2-c2d.f m5 - Issu e 3 Dated 09/11/98



4. Ensure that a link is fitted to jumper X26 pins 7-8 on the UPS Logic Board to override the password protection system. 5. Select and enter ‘SETUP’ – the password screen will now be shown. 2.10.3.1

Setting the UPS wor kin g vol tage parameters

1. From the setup screen, select and enter ‘ VOLTAGE’ – this will access the voltage menu screen. 2. Select and enter ‘RATED VOLTS. ’. a) Press the ‘UP’ menu button repeatedly until the desired input/output working voltage is indicated. b) Press ‘ENTER’ to save the selection and then press to the voltage menu screen.

‘ESC’ once

to move back

3. Select and enter ‘LOWER ’. a) Using the data entry method described above, enter the required input and output voltage undervoltage thresholds. Note: Standard settings are for -10% (input) and -10% (output). b) Press ‘ENTER’ to save the selection then press the voltage menu screen.

‘ESC’ once

to move back to

4. Select and enter ‘UPPER ’. a) Using the data entry method described above, enter the required input and output overvoltage thresholds. Note: Standard settings are for +10% (input) and +10% (output). b) Press ‘ENTER’ to save the selection then press the voltage menu screen.

‘ESC’ once

to move back to

5. Verify that the data shown on the voltage menu screen is correct and repeat this procedure if necessary. 6. Press ‘ESC’ again to move back to the setup menu screen. 2.10.3.2

Setting the UPS frequ ency parameters

Note: go directly to paragraph 2.10.3.3 if the frequency is not to be changed.

1. Select and enter ‘FREQUENCY’ – this will access the frequency menu screen. 2. Select and enter ‘ NOMINAL’. a) Press the ‘UP’ menu button repeatedly until the desired nominal frequency is indicated. b) Press ‘ENTER’ to save the selection then press ‘ ESC ’ once to move back to the frequency menu screen. 3. Select and enter ‘SYNC WINDOW ’. a) Enter the required sync window limit. Note: Standard setting is ‘2.0%’ – i.e. the inverter will sync to the bypass if it is ±1Hz of 50Hz nominal. b) Press ‘ENTER’ to save the selection then press ‘ ESC ’ once to move back to the frequency menu screen.


2-63



4. Select and enter ‘SLEWRATE’. a) Enter the required slew rate (range 0.1 - 1.0 Hz/s). Note: Standard setting is ‘0.10 Hz/s’ – i.e. the speed the inverter will track a change in bypass frequency. b) Press ‘ENTER’ to save the selection then press the frequency menu screen.

‘ESC’ once

to move back to

5. Verify that the data shown on the frequency menu screen is correct and repeat this procedure if necessary. 6. Press ‘ESC’ again to move back to the setup menu screen. 2.10.3.3

Setting the Batter y parameters

Figure 2-26: ‘SETUP’ – BATTERY MENU Continued from Figure 2-25

UPS 0060 kVA VOLTAGE 400 V FREQUENCY 50 Hz BATT. CELLS 198

SETUP MENU SCREEN BATTERY MENU SCREEN


W RI TE MOVE BATT. CELLS


W RI TE MOVE CAPACI TY



WRI TE MOVE END DI S.


WRI TE SAVE MOVE EXI T BAT. LOW 1. 82 v/ e


WRI TE MOVE MAX.

BATTERY VOLTAGE MENU SCREEN

SAVE EXI T 198

SAVE EXI T 052 Ah





1. From the setup menu select and enter ‘ BATT.CELLS ’ – this will access the battery menu screen (illustrated in Figure 2-26).

Setting the number of cells: 2. From the battery menu screen, select and enter ‘ BATT.CELLS ’. 3. Following the data entry method described earlier, using the ‘UP’, ‘DOWN ’ menu buttons, enter the number of cells contained in the battery string.

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4. Press ‘ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery menu screen.

Setting the Battery Capacity: 5. From the battery menu screen, select and enter ‘ CAPACITY’. 6. Using the ‘UP’, ‘ DOWN ’ menu buttons, enter the total battery A/Hr capacity. (at the 10Hr rate C 10). 7. Press ‘ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery menu screen.

Setting the battery voltage characteristics: From the battery menu screen, select and enter ‘ VOLTAGE’ – this will take you to the battery voltage menu, which is concerned with selecting the battery charging characteristics. Battery undervoltage trip setting

8. From the battery voltage menu, select and enter ‘ END DIS .’. a) Using the ‘UP’, ‘DOWN ’ menu buttons, enter the specified ‘end-of-discharge’ voltage – standard setting is 1.67V/cell. Note: this is the ‘end-of-discharge’ voltage and is the voltage at which the battery breaker is tripped. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery voltage menu screen. Battery low voltage warning setting

9. From the battery voltage menu, select and enter ‘ BAT LOW’. a) Using the ‘UP’, ‘DOWN ’ menu buttons, enter the specified ‘low battery voltage’ – standard setting is 1.82V/cell. Note: this is the voltage at which ‘low-battery warning’ annunciates. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery voltage menu screen. Battery overvoltage trip setting

10. From the battery voltage menu, select and enter ‘ MAX ’. a) Using the ‘UP’, ‘DOWN ’ menu buttons, enter the specified ‘max battery voltage’ – standard setting is 2.45V/cell. This sets the ‘slow’ overvoltage level which is effective only when the batteries are in the float charge mode, and is the voltage at which, after 3 minutes, the battery breaker is tripped, and the rectifier and inverter turned OFF. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery voltage menu screen.

Battery boost charge setting:

WARNING

DO NOT apply BOOST CHARGE to sealed batteries


2-65



Figure 2-27: Battery boost charge parameters Continued from Figure 2-26


11. From the battery voltage menu, select and enter ‘ BOOST CHARGE ’ – this will take you to the boost charge menu screen. 12. From the boost charge menu, select and enter ‘SETUP ’ – this will take you to the battery boost setup menu screen. 13. From the battery boost setup menu, select and enter ‘ DURATION’. a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required boost operation time (in minutes) – factory setting is 600 mins. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery boost setup menu screen. 14. From the battery boost setup menu, select and enter ‘ THRESHOLD’. a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required current changeover threshold – factory setting is 20% of the battery current limit. Note: this is the level that the battery current must reach before boost charge is enabled upon mains return. b) Press ‘ ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery boost setup menu screen. 15. It is advisable to set the ‘ NOW’ and ‘AUTOMATIC’ parameters to ‘ NO’ at this stage in the commissioning, and reset to ‘YES ’ (if required) once the rectifier has been fully commissioned.

Verification: 16. Press ‘ENTER ’ to save the data to memory, then press ‘ ESC ’ once to return to the battery voltage menu screen. 17. Verify that the data shown on the battery voltage menu screen is correct and repeat this procedure if necessary.

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Figure 2-28: Battery CHARGE MODE Selection (Issue 5.0 software) Continued from Figure 2-19



ON/OFF MENU SCREEN

CHARGE MODE SELECTION SCREEN

2.10.4 2.10.4.1

Calibration conv ersion s Recalibrating the battery charging voltages

This part of the procedure calibrates the battery charging voltages using the ap propriate potentiometers on the Rectifier Logic Board and requires the rectifier to be fully powered-up. 1. Connect a DC voltmeter across the battery cable connections (adjacent to the battery fuse).


2-67



2. Close the UPS input mains isolator (Q1). 3. Turn switch Q3 on the UPS Logic Board to ON – the rectifier should now start and ramp up to float voltage, as indicated on the voltmeter.

Float charge voltage calibration: 4. On the Rectifier Logic Board: a) Ensure led H3 (green) is illuminated. b) Adjust R21 to obtain the required float charge voltage, indicated on the DC voltmeter.

Manual charge voltage calibration: 5. Using standard screen navigation techniques, gain access to the charge mode selection screen via the FUNCTION – NEXT PAGE – ON/OFF UPS CONTROL menu path (See Figure 2-28). 6. Scroll through the menu options and select manual charge mode (‘ MAN’). 7. On the Rectifier Logic Board: a) Ensure led H4 (yellow) illuminates (H3 extinguished). b) Adjust R22 to obtain a charge voltage, indicated on the DC voltmeter, appropriate to ‘forming’ open vented cells (if applicable). If sealed cells are used then set this voltage to equal the float voltage set previously.

Boost charge voltage calibration: 8. Leave the charge mode selected to manual (‘MAN’), as instructed above. 9. On the Rectifier Logic Board: a) Link-out pins 0-2 on jumper X9 to force the charger to the ‘Boost’ mode. b) Ensure led H2 (green) illuminates (H4 should extinguish). c) Adjust R20 to obtain the required boost charge voltage, indicated on the DC voltmeter. Note: If sealed cells are used then set this voltage to equal the float voltage set previously.

Calibration completion: 10. Open the UPS input mains isolator Q1 and bypass isolator S2. 11. On the UPS Logic Board set S1, S2, S3 to ON to re-enable the UPS power sections. 12. On the Rectifier Logic Board remove the link from pins 0-2 on jumper X9. 13. Disconnect and remove the DC Voltmeter. 2.10.4.2

Compl etion of UPS SETUP con fig urati on

The setup menu parameters have now all been entered and stored in the control system’s non-volatile memory. 1. Start the UPS following the normal start-up instructions and verify that it now operates at the desired voltage and frequency. 2. If required, remove the link from jumper X26 pins 7-8 on the UPS Logic Board to re-enable the password security system.

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Section 2:

Chapter 3 - Converting single (pre Jan 1997) units to 1+1 capability

3.1

Introduction Series 7200 single module units manufactured prior to January 1997 will require upgrading before they can operate in a 1+1 system configuration. This chapter outlines the procedure to be followed before the units are commissioned. Before the 1+1 paralleling option can be fitted the upgrade procedure requires mechanical changes to be made by fitting Modification Kit Part Nº 4641030E, which then changes the unit part number as shown below. Table 2-17:

3.1.1

Model Rating k VA

Pre January 1997 unit Part Nº

Modification Kit Required

Converted Unit Part Nº

30

5410303P

4641030E

5410305R

40

5410304Q

4641030E

5410307T

60

5410308U

4641030E

5410310W

Import ant Consid erations

Caution

This modification must be carried out only by a f ully trained and authorised Liebert engineer.

Allow approximately two hours for the modification of each module. The mechanical relocation of existing PCB’s and control transformers must be carried out prior to fitting the 1+1 parallel option kit Part N º 4645004A. Step by step instructions are included with the conversion kit Part Nº 4641030E but are not in the scope of this manual. However the basic mechanical differences and repositioning of components is shown in Figure 2-29.

3.2

Conversio n Procedure 1. Fit the conversion kit Part Nº 4641030E, follow the instructions supplied with each kit. 2. Upgrade the PCB’s, refer to below. Remove PCB Pre Jan. 97

Fit New PCB Post Jan. 97

Inverter Logic

4530024S

4530025T

UPS Logic

4550004E

4550007H

Static Switch

4542041X

4542043Z

PCB Descriptio n

Units manufactured after January 1997 will have the new PCB’s factory fitted.

s2-c2d2.fm 5 - Issue 3 Dated 09/11/98

2-69

SECTION 2 - Installation & Commissioning CHAPTER 3 - Commissio ning Procedure


Figure 2-29: Pre/Post modification mechanical layouts

T 5 2 0 0 3 5 4

4550007H

Pre January 1997 unit before conversion

Pre January 1997 unit after conversion. Factory supplied units post Jan 97

3. Check the software version on the UPS Logic Board (D35/D36) and Operator Logic PCB (D8). This must be Version 3.0 or later. If the software version is incorrect, replace these devices according to the table below Table 2-18: . EEPROM

Old Part Number

New Part Number

D35

0837044A Rev x.xx

0837044A Rev D.00

D46

0837045B Rev x.xx

0837045B Rev D.00

D8

0837046C Rev x.xx

0837046C Rev D.00

On completion of the mechanical conversion, PCB replacement and software upgrade, the converted unit should be commissioned as detailed in Chapter 2.

2-70

s2-c2d2.fm 5 - Issu e 3 Dated 09/11/98

Commissioning Report Sheet

Section 2 : Commissioning ParameterSettings

Sampl e Commis sio ning Recor dsheets Syst em Details Customer Site Details

Module Type/Rating Module Part/Serial Number

SET UP MENU Parameters Menu Selection UPS

Parameter

Max

Selected Setting

–

–

UPS TYPE

3 Phase

–

–

Single

–

–

230

220

240

INPUT UNDERVOLTAGE

–10%

–1%

–99%

INPUT OVERVOLTAGE

+10%

+1%

+99%

230

220

240

OUTPUT UNDERVOLTAGE

–10%

–1%

–99%

OUTPUT OVERVOLTAGE

+10%

+1%

+99%

NOMINAL FREQUENCY

50 Hz

50Hz

60Hz

2%

0.5%

9%

0.1 Hz/Sec

0.1

1.0

198

190

210

85 AHr

000

499

END OF DISCHARGE VOLTS

1.67 Volts/cell

1.60

1.69

LOW BATTERY VOLTAGE

1.82 Volts/cell

1.70

1.89

MAX. BATTERY OVER VOLTAGE

2.40 Volts/cell

2.30

2.70

BOOST CHARGE ENABLE

NO

–

–

BOOST CHARGE AUTO

NO

–

–

BOOST CHARGE DURATION

0000 min.

0000

9999

BOOST CHARGE THRESHOLD

00 Amps

00

99

NOMINAL INPUT VOLTAGE

SYNC WINDOW SLEW RATE (SPEED) BATTERY

Min.

60kVA

NOMINAL OUTPUT VOLTAGE

FREQUENCY

Range

KVA VALUE CONFIGURATION

VOLTAGE

Standard Factory Setting

NUMBER OF CELLS CAPACITY

S2-c2e.fm5 - Issu e 3 Dated 09/11/98




MAINTENANCE MENU Parameters Menu Selection

Parameter

Standard Factory setting

Range Min

Max

PASSWORD

PASSWORD

0000 0000

–

S.N.

SERIAL NUMBER

0000 0000

–

12.00.00

CURRENT TIME AND DATE

12.00.00 01.01.96

LAST SER.

LAST SERVICE TIME AND DATE

01.01.96

–

NEXT SER.

NEXT SERVICE TIME AND DATE

01.01.96

–


–

Selected Setting




FUNCTION MENU Parameters Menu Selection

Parameter

0000 0000

0000 0000

9999 9999

NOW

NO

–

–

AUTOMATIC

NO

–

–

00 Min

00

99

1.70 V/e

1.70

1.90

000 dd

000

999

01.01.96

–

INV: SYNC INHIBIT

NO

–

BAT: I INHIBIT

NO

–

RECT: I INHIBIT

NO

–

DURATION THRESHOLD PERIOD START AT

LANGUAGE

PANEL SETUP

Selected Setting

Max

SETUP

GENERATOR

Range Min

Input Password To Gain Access To Function Selection Screen BATTERY TEST


ITALIAN

TYPE GROUP

UPS : NODE :

PASSWORD

–

Requires an alarm inter face PCB fitted

Eng : Fr : Esp : Deu.

MASTER. 0060

–

–

1:1

–

–

0000 0000

0000 0000

9999 9999

LOCAL

–

–

MODEM CONNECTION

PC CONN RESET

NO

–

–

ON/OFF UPS BLOCK

INVERTER

ON

–

–

BYPASS

ON

–

–

RECTIFIER

ON

–

–

RECTIFIER

FLO

FLO

MAN

RELOAD DATA

NO

RELOAD UPS DATA


DO NOT perform this test as part of the normal commissioning procedure unless the UPS parameters have to be reset to factory default values.




MEASURMENT MENU Parameters Selection Screen OUTPUT

Parameter VOLTAGE

A–B

400 Volt

B–C

400 Volt

C–A

400 Volt

A – N

230 Volt

B–N

230 Volt

C–N

230 Volt

A

0 Amp

B

0 Amp

C

0 Amp

N

0 Amp

A

0 kW

B

0 kW

C

0 kW

A

0 kVA

B

0 kVA

C

0 kVA

Bypass Line

50 Hz

Inverter

50 Hz

A–B

230 Volt

B–C

230 Volt

C–A

230 Volt

CURRENT

POWER

FREQUENCY

INPUT

BATTERY

TEMPERATURE


VOLTAGE

VOLTAGE

460 Volt

CURRENT

0 Amp

CHARGE CAPACITY

100%

Tt (Transformer)

–

Ta (Input air)

–

To (Output air)

–

Tb (Batt cabinet)

–


Enter On Site Readings




Hardware Parameters Rectifier Log ic Board Potentiometer

Test Point

Factory setting

Rectifier Current Limit

R17

X8 pin 7

Proportional kVA

Battery Current Limit

R18

X8 pin 8

Proportional kVA

R121

X8 pin 5

2.98Vdc

DC Float Voltage

R21

DC Bus

449Vdc

DC Manual Voltage

R22

DC Bus

449Vdc

DC Boost Voltage

R20

DC Bus

449Vdc

DC Test Voltage

R19

DC Bus

390Vdc

Parameter

Battery Temperature Compensation

Site Setting

Inverter Logic Board Potentiometer

Test Point

Factory setting

150% Current limit

R248

X10 pin 4

0.6Vdc

Inverter Tri-wave PWM reference

R241

Scope to LHS of R27

4Vp-p (+2V to -2V)

Output Voltage R-N

R246

Inv output terminal R-N

230Vac

Output Voltage S-N

R244

Inv output terminal S-N

230Vac

Output Voltage T-N

R245

Inv output terminal T-N

230Vac

Output Voltage R-S

R242 Adjust all 3 phases together

Inv output terminal R-S

400Vac

Inv output terminal S-T

400Vac

Inv output terminal R-T

400Vac

Output Frequency R-T

–

Inv output terminal R-T

50Hz

Inverter/Bypass phase shift

R247

Scope Bypass R-phase and Inv R-phase.

0° Shift

Parameter

Output Voltage S-T Output Voltage R-T

Site Settin g

UPS Log ic Bo ard Potentiometer

Test Point

Factory setting

5V Voltage reference

R209

X20 pin 1

5.00Vdc

2.5V Voltage reference

R212

V45 anode

2.50Vdc

Parameter


Site Setting




Operator Logic Board Parameter

Potentiometer

Test Point

Factory setting

R21

LCD Display

N/A

LCD Display Contrast

Battery infor mation Parameter

On-Site notes

Battery Type Number of Cells Float Voltage

=

Ampere/Hr capacity Battery Current Limit Battery Breaker Size

ENGINEER’S NAME: SIGNATURE: DATE:

WITNESSED BY: SIGNATURE DATE:


Site Setting

Sect-2

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