CP3150 Series CHLORIDE POWER PROTECTION THREE-PHASE Uninterruptible Power System Owner’sManual P/N 913-576 Rev A
User and Operating Manual Chloride Power Protection 28430 North Ballard Drive • Lake Forest • IL • 60045 Toll Free Phone 800-239-2257 • Toll Free Fax 800-833-6829 Phone 847-990-3228 • Fax 847-549-7917 ii
DECLARATION OF CONFORMITY The manufacturer: CHLORIDE POWER PROTECTION Head office at: 28430 North Ballard Drive Lake Forest, IL 60045 USA HEREBY DECLARES THAT THE PRODUCT: CP3000 CONFORMS TO THE FOLLOWING REGULATIONS: UL1778 FCC PART 15 iii
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE CP3000 SERIES THAT SHOULD BE FOLLOWED DURING INSTALLATION AND MAINTANANCE OF THE UPS, BATTERIES, OPTIONS AND ACCESSERIES iv
Table of Contents INTRODUCTION Declaration of conformity Safety Grounding the unit FCC compliance CHAPTER 1 - DELIVERY AND STORAGE Delivery Unpacking Handling Storage CHAPTER 2 - PREPERATIONS FOR INSTALLATION Environmental Conditions Access area Floor loading CHAPTER 3 - UPS INSTALLATION Installation data Specifications Suggested cable sizes Terminations Protection devices Electrical connections CHAPTER 4- BATTERY CABINET INSTALLATION Battery connections v
CHAPTER 5 - CONTROL PANEL Display panel Indicators and buttons Menu layout Menus Warnings and Faults Maintenance by-pass switch and power control unit breaker Operating modes Operational procedures CHAPTER 6- PARALLEL OPTION Introduction Theory of Operation Planning Installation CHAPTER 7 - CONNECTIVITY Interface slots Communication slot adaptability RAU/RLY/DRV AS400 RS232 ManageUPSnet Adapter LIFE 2000 Industrial contacts CHAPTER 8 - MAINTENACE vi
APPENDIX A - INSTALLATION TABLES AND ILLUSTRATIONS Table 1 - Input/Output Ratings & External Wiring Recommendations Table 2 – Input/Output and Battery Cabinet Wire Terminations for Single Input Table 3 – Input/Output and Battery Cabinet Wire Terminations for Dual Input Table 4 – Full Load Heat Rejection Table 5 – Weight Specifications Illustration A – UPS Dimensions Illustration B – Battery Cabinet Dimensions Illustration C – Battery Cabinet Top Dimensions vii
Safety (English) WARNING: This equipment services power from more than one source. UPS present a different safety issue than most electrical equipment because removing input power from the UPS puts it into backup mode. Removing the input power from the UPS does not remove the electrical charge. To ensure that the UPS is off, turn the inverter OFF before removing the input power from the UPS. CAUTION: Operating this equipment without proper grounding may present a risk of electrical shock.
Grounding the Unit CAUTION: Interruption of the protective grounding conductor or disconnection of the protective earth terminal presents a potential shock hazard that could result in personal injury and damage to the equipment.
Chapter 1 DELIVERYANDSTORAGE DELIVERY Immediately inspect upon receipt of goods to ensure that the contents are undamaged. A SHOCKWATCH label has been affixed to the packaging. The purpose of this SHOCKWATCH is to give the receiving clerk an immediate indication if the goods had experienced rough handling. If red, note on bill of lading and report immediately to the freight forwarder. If damage is found, keep all packaging materials and shipping documentation.
HANDLING The equipment must be kept upright at all times and handled with care. Damage may be caused if subjected to severe impact. The UPS and battery cabinet has been fitted with casters to allow ease of installation near the final location. It is recommended that the UPS and battery cabinets be moved with a pallet jack or fork lift over long distances. The lower side skirts have been intentionally left off to allow fork access under the UPS or battery cabinets.
STORAGE When the UPS is not used within seven days of delivery, please pay special attention to the storage requirements. If the batteries or the equipment is to be stored, they must be kept in a clean, dry environment and away from extremes of temperature. STORAGE DATA Storage temperature range: -4°F (-20°C) to 140°F (60°C); however, batteries should not be exposed to temperature above 77°F (25°C). Each increment of 15°F (8°C) above 77°F (25°C) reduces the expected battery life by 50%.
Chapter PREPARING FOR INSTALLATION 2 ENVIRONMENTAL CONDITIONS The UPS and battery cabinets must be installed vertically, on a level and even surface. The UPS and battery cabinets should be protected from extremes temperatures, water, humidity, and the presence of conductive powder or dust. Do not stack units and do not place any objects on top of the unit. Although the functional temperature range of the UPS is 32°F to 104°F (0°C to 40°C).
Chapter 3 UPS INSTALLATION WARNING: Dangerous voltages are present within this unit! There are no user-serviceable parts inside. Any repairs or modifications by the user may result in out-of-warranty repair charges, unsafe electrical conditions, or violation of electrical code. Do not remove the cover. All repairs should be done by qualified service personnel. Voltages inside the UPS may be lethal. Internal components are powered even when the power switch is in the OFF position.
UPS ELECTRICAL CONNECTIONS In order to gain access to the electrical connections Refer to Figure 5 & 6 – Electrical Terminations, it will be necessary to remove the protection panel located on the front of the UPS behind the front doors. On the UPS and Transformer cabinet, power cables can be brought in from the top or bottom through the access plates and routed through the cable raceway.
UPS ELECTRICAL TERMINATIONS Figure 5 – UPS Electrical Terminations Electrical connections 1. 2. 3. 4. 5. 6. Connect the ground wire to the GND terminal. For dual input connect the MAIN AC wires to the INPUT A,B,C, and BY-PASS AC wires to BY-PASS A, B ,C, and N For single input the mains input and bypass will be supplied with jumpers between them. Connect the output AC wires to the output A,B,C, and N Connect the optional battery cabinet positive (+) terminal to the positive (+) terminal in the UPS.
Figure 6 – Input Transformer Cabinet 208/480V 8
Chapter 4 BATTERY CABINET INSTALLATION BATTERY CONNECTIONS Connections must be carried out only by qualified electricians and in conformity with the applicable safety standards. Both the UPS and battery cabinet are similar in appearance. However the battery cabinet houses the backup power required to provide the energy needed during a power disturbance or outage. The batteries in the battery cabinet have been pre-wired on each shelf.
Figure 8 – Battery Cabinet Electrical Connections 10
Figure 9 – Multiple Cabinet Connections As can be seen in Figure 9 – Multiple Cabinet Connections each cabinet will be connected in parallel. The DC connections between the UPS and battery cabinet must be connected with the most positive of the battery cabinet connected to the positive termination in the UPS. The most negative of the battery cabinet must be connected to the negative termination of the UPS. See Figure 6 – UPS Electrical Connections for DC connection within the UPS.
Chapter 5 CONTROL PANEL The control panel serves as the interface to the UPS allowing the user to obtain the status of the system and to control as needed. LED’s (Light Emitting Diode) inform the user about three operating parameters of the UPS (1, 2 & 3 below). The LCD (Liquid Crystal Display) will provide detail on messages, alarms, values and operating conditions of the UPS. And finally buttons that control the inverter and shutdown the entire system.
INDICATORS AND BUTTONS 1 ON BATTERY - when this LED is illuminated, the battery supplies the inverter 2 ON BY-PASS - When this LED is illuminated, the load is supplied by the By-pass AC power 3 SUMMARY ALARM - When this LED is solid, the UPS is operating with a fault condition. When blinking, it indicates a warning condition.
9 LEFT ARROW - This button allows the user to scroll left on the LCD 10 RIGHT ARROW - This button allows the user to scroll right on the LCD 11 DOWN ARROW - This button allows the user to scroll down on the LCD 12 UP ARROW - This button allows the user to scroll up on the LCD 14
Using the Liquid Crystal Display BY-PASS INPUT INVERTER RECTIFIER INPUT BATTERY 13 LCD Screen – Shows graphical and functional parameters The LCD provides a graphical user interface providing power blocks representing the Rectifier, Battery, Inverter and By-Pass. The power path will be highlighted providing the user with an understanding of which power blocks are active and that which is supplying the critical load.
Menu Structure Main Menu Screen Actual Values By-Pass Input Rect. Input UPS Output Rectifier Alarms No Faults/ No Warnings Battery Values Displayed Values Displayed Values Displayed Values Displayed Voltage L1 Voltage L2 Voltage L3 Frequency Voltage L1 Voltage L2 Voltage L3 Current L1 Current L2 Current L3 Frequency Total Real Pwr Real Power L1 Real Power L2 Real Power L3 Total App. Pwr App. Power L1 App. Power L2 App.
MENUS MAIN MENU 1 Actual Values Inverter Alarms Rectifier Alarms The Main Menu screen’s function is to provide the user the selection options for viewing various information about the UPS. This is the highest level for menu. To return to previous screen, press ESC button. Parameters displayed are: Actual Values, Inverter Alarms, and Rectifier Alarms Display Settings and About. Press the ENTER button to select screen. Use the UP and DOWN arrows to toggle through current screen.
RECT. INPUT 5 Voltage L1 Voltage L2 The Rectifier Input screen displays parameters regarding the Main Input. Parameters displayed are: Voltage L1, Voltage L2, Voltage L3, Current L1, Current L2, Current L3, Frequency, Total Real Power, Real Power L1, Real Power L2, Real Power L3, Total App. Power, App. Power L1, App. Power L2, App. Power L3. Press down or up arrows to view other entries. Press ESC to exit. .
BATTERY 9 The Battery screen displays parameters regarding the inverter’s DC bus. Parameters displayed are: Voltage, Current, Residual Capacity, Expected RUN Time, and Temperature C. Press down or up arrows to view other entries. Press ESC to exit. 10 The Actual Values screen’s function is to allow access to various parameters at different locations of the UPS. Parameters displayed are: By-pass Input, Rectifier Input UPS Output, Battery, and DC Bus.
INVERTER ALARMS 13 No Faults ... The Inverter Alarms information screen displays parameters regarding the alarms. (Shown for No Faults and No Warnings) To return to previous screen, press ESC button. No Warnings ... OR INVERTER ALARMS 14 Message 1 of 3 The Inverter Alarms Information screen is showing message 1 of 3 and specific information on alarm. Using the cursor will display any active alarm messages. To return to previous screen, press ESC button.
RECTIFIER ALARMS 17 The Rectifier Alarms Information screen is showing message 1 of 3 and specific information on alarm. Using the cursor will display any active alarm messages. To return to previous screen, press ESC button. 18 The Main Menu screen’s function is to provide the user the selection options for viewing various information about the UPS. This is the highest level for menu. To return to previous screen, press ESC button. Press the ENTER button to select screen.
DISPLAY SETTINGS 21 Language Contrast Press to select CONTRAST 22 Press The Display Settings screen displays sub menus regarding display settings. The display sub menus displayed are: Language and Contrast. To return to previous screen, press ESC button. (Shown for the Contrast sub menu) The Contrast screen is used to adjust the contrast of the display for ease of readability. Use the left and right arrow to adjust the contrast of the screen. To return to previous screen, press ESC button.
TABLE OF WARNINGS AND FAULTS Warnings Over-temperature inverter By-pass mains failure Rectifier mains failure Load too high Under-voltage VDC Overload False By-pass Phase Sequence Service By-pass is on Battery Operation Battery Rest time Exceeded Battery Under-Voltage Commissioning or Test Mode Battery Switch not Engaged Ventilator Lifetime Exceeded Connection to charger lost Battery Charge Inhibit Battery Temperature Output Switch Open Faults Over temperature Converter Internal fault Incorrect Power Clas
OPERATING MODES On-Line Operation CB1, SW1, SW2 and the Battery CB are in the on position and SW3 is in the off position. The loads are supplied by the mains through the inverter. The batteries are charged by the rectifier as necessary. The Inverter filters mains interruptions, disturbances and provides a stable, interference-free supply to the load. Path of Current The summary alarm LED on the control panel is not illuminated in this mode.
Battery Operation CB1, SW1, SW2 and the Battery CB are in the on position and SW3 is in the off position. In the event of a mains power failure the load is automatically transferred to the batteries, without interruption. In this mode, the load is supplied entirely by the batteries, via the inverter. If the power fails, the UPS indicates a fault condition. Path of Current In Battery operation, the On Battery and Summary Alarm LEDs on the control panel are illuminated.
Battery Recharge Operation CB1, SW1, SW2 and the Battery CB are in the on position and SW3 is in the off position. The UPS returns automatically to On-Line operation once the mains supply has been restored. The batteries are charged according to the specific battery model provided by the battery manufacturer’s specifications. Within the battery autonomy period, the UPS provides information regarding the remaining battery autonomy via the Liquid Crystal Display.
By-pass Operation CB1, SW1, SW2 and the Battery CB are in the on position and SW3 is in the off position. In this mode, the load is supplied by the mains through the static switch. This mode of operation does not condition the incoming power. The by-pass further ensures the supply to the load in the event of an overload condition, manual inverter shut off or the unlikely event that the inverter should fail.
Maintenance By-pass Operation CB1, SW1, SW2 and the Battery CB are in the off position and SW3 is in the on position. The load is supplied directly by the mains supply. The Maintenance Bypass is used to supply the load during maintenance operations. CB1 and SW1 can be used to supply power to the UPS for testing or startup without affecting the output. In the Maintenance By-pass Position, all power is removed except for the fans and power transformers in some models.
OPERATIONAL PROCEDURES STARTUP PROCEDURE 1. 2. 3. 4. 5. 6. 7. 8. With main and By-pass disconnects on wall, CB1, SW1-3 and the Battery Cabinet circuit breaker all off, turn on the main disconnect and the By-pass disconnect if present. Turn on SW3 to supply the output with power. Turn on CB1, SW1, SW2 and the Battery Cabinet circuit breaker. Check for alarms. Turn off SW3. Press and hold for more than three seconds the “INVERTER ON” button on the display.
Chapter 6 PARALLEL OPTION The parallel UPS is connected to an AC main power source and contains high current batteries for back up. Therefore safety precautions must be followed to prevent electrical hazards when operating the parallel UPS system. Introduction The CP3150 UPS system can be connected in parallel to increase power capacity or redundancy to the load. Up to 8 units of the same kVA rating may be configured in parallel.
Multiple Module Block Diagram Fig 11- Parallel Configuration Planning Special attention must be taken when planning for parallel system installation. The system power cables (input and output) should be the same length. Differences in cable length of 20% are permitted for cables up to 60ft, but for longer cables differences must not exceed 10%. Another important factor to consider is the total size of the parallel UPS configuration.
Installation Input / Output connections When installing a multiple block parallel system, the input and output connections procedures for each module use the same terminals as those for a single UPS. For more information refer to Chapter 3 of Owners Manual. Parallel Communications The individual UPS blocks communicate with each other via a 25-conductor cable. The communication cables are shielded and must be routed separately from the power cables.
Parallel communications raceway Figure 13 – Raceway for Parallel Communication Wires Note: When connecting the communication bus, the shield of the communication cable must be grounded to the UPS on each end of the cables.
. The Parallel communication terminal blocks (X130 and X140) are located at the upper right front of the UPS, behind the front door and dead plates. Parallel Communication Terminal Blocks Fig 14- Parallel Communication Terminal Blocks Location NOTE: Installation of the parallel kit must be completed by Authorized Technical Personnel.
Chapter 7 CONNECTIVITY Installation of communication card(s) The CP3000 series can be equipped with a variety of connectivity options. Five interface slots have been designed to allow installation of the AS400 card, LIFE 2000 card, R.A.U. card (Remote Alarm Unit), RS232 card and Manage UPS Net adapter card. These interface slots are located behind the front panel located in the middle right section. See Figure 5 –UPS Electrical Terminations.
Recommended Communication configuration Shown in Figure 16 – Communication Card Configuration are the recommendations of those communication options and were to insert them.
RAU/RLY/DVR CARD This card allows connection to the Remote Alarm Unit option. It also can be used to drive the Industrial Contact Card as seen in Figure 17 – RAU (Remote Alarm Unit) or Relay Card or Driver Card. The voltage-free contacts are rated at 30V .5A max.
AS400 CARD The AS400 (Relay) card is equipped with a “D”-type female 9-pin connector comprising voltage-free contacts and conforming to the requirements of IBM AS/400 and other computing systems. Figure 18 - AS400 (Relay) card The interface communication pin layout is as follows • Pin 1 is Bypass • Pin 2 is Summary Alarm • Pin 3 is Shutdown (+) • Pin 4 is Shutdown (-) • Pin 5 is the common for all contact on internal relays.
RS232 CARD The male 9-pos. SUB-D connector contains the RS 232 signals. Figure 19 - RS232 Card The interface COM is isolated from all power circuits. • • • Pin 5 GND This connection point serves as a reference for all signals. Pin 2 RXD Standard configuration of an RS 232 interface. Pin 3 TXD Standard configuration of an RS 232 interface.
ManageUPSNET CARD ManageUPSNET (formerly known as the SNMP adapter) includes a complete package allowing CP3000 SERIES to be monitored and controlled over a network using TCP/IP protocol. The adapter allows: • • • • UPS monitoring from an NMS station using SNMP UPS monitoring from a pc using a Web Browser SHUTDOWN AND MONITORING SOFTWARE The primary function of MopUPSPROFESSIONAL for Windows is to shut down the operating system of an unattended computer, safely, in the event of a power failure.
LIFE2000 MODEM CARD This option provides remote monitoring of the UPS, via a dedicated analog telephone line, to ensure maximum reliability for the duration of its operational life. The UPS automatically telephones the service center at predefined intervals, to provide detailed information, which is analyzed in order to predict any short-term failures. In addition it is possible to control the UPS remotely.
INDUSTRIAL CONTACT CARD Figure - 22 Industrial Contact Card and Bracket The contacts are rated at 120VAC, 2A.
REMOTE EQUIPMENT POWER OFF Figure - 24 Remote Equipment Power Off (REPO) To wire the external EPO circuit, connect a normally closed (N/C) emergency switch, which opens when activated and is held open mechanically when operated. Make sure switch is de-activated (closed) before connecting to the outer terminals of the EPO terminal block (REPO Hi and REPO Low). Remove the jumper wire between the inner terminals (Disable). It is recommended to use twisted wires for this low voltage connection.
Chapter 8 MAINTENANCE The UPS only requires that the air filters be cleaned on periodical bases and that the area around the UPS is clean and free from dust and debris. When the batteries expire, these must be replaced by the appropriate battery specifications. Exhausted accumulator batteries are classified as “harmful toxic waste” and as such, the law demands that they be disposed of by an authorized recycling center. Periodic maintenance should be performed on the UPS and batteries.
STORAGE For extended storage at ambient temperature < 77°F, the batteries should be charged for 5 hours once every 4 months; at higher storage temperatures, it is advised that this period be reduced to two months. Make sure the Power Control Unit Breaker is in the OFF position before continuing. Follow the electrical installation procedure in Chapter 3. Connect the positive and negative External Battery Cabinet Connections. See chapter 4 for battery information.
Appendix INSTALLATION TABLES AND ILLUSTRATIONS A The information in the appendix will provide you with the necessary data to install the UPS and Battery Cabinet. Following is a list of tables and drawings.
Table 1 - Input/ Output Ratings & External Wiring Recommendations Model CP3150/150kVA/125kVA Terminal Function Voltage Configurations Details Input/ Output current, Conductor size & Circuit Breaker rating Max input current (3Ph, 1 gnd) Nom input current (3Ph, 1 gnd) AC Input To UPS Rectifier 208V-208Y/120 Minimum conductor size (number per phase) Recommended input circuit breaker ratings Max input current (3Ph, 1 gnd) Nom input current (3Ph, 1 gnd) 480V-208Y/120 Minimum conductor size (number per ph
Table 1 Continued - Input/ Output Ratings & External Wiring Recommendations AC Output to Critical Load Nom output current ( 3Ph, 1 Neutral, 1 gnd) 208V-208Y/120 Minimum conductor size (number per phase) Recommended output circuit breaker ratings Nom output current ( 3Ph, 1 Neutral, 1 gnd) 480V-208Y/120 Minimum conductor size (number per phase) Recommended output circuit breaker ratings Nom output current (3Ph, 1 Neutral*, 1 gnd) 480V - 480V Minimum conductor size (number per phase) DC Input Recomme
Table 2 – Input/Output and Battery Cabinet Wire Terminations for Single Input Power Cable Terminations - Single Input Termination AC Input AC Input to UPS Input Transformer AC Output to Critical Load Wire Size of Clamp Termination Tightening Torque In.
Table 3 – Input/Output and Battery Cabinet Wire Terminations for Dual Input Power Cable Terminations - Dual Input N Positive (+) Negative (-) Wire Size of Clamp Termination 3/0-250MCM (2) 3/0-250MCM (2) 3/0-250MCM (2) 4AWG-500MCM (2) 4AWG-500MCM (2) 4AWG-500MCM (2) 6AWG-350MCM 6AWG-350MCM 6AWG-350MCM 6AWG-350MCM * 6AWG-350MCM * 6AWG-350MCM * * (2 for 208V Output) 6AWG-350MCM (4) 6AWG-350MCM (2) 6AWG-350MCM (2) Battery Cabinet Ground Only Battery Cabinet Ground Customer Ground Ground (Earth) Terminat
Table 4 – Full Load Heat Rejection Full Load Heat Rejection (BTU/Hr) Configuration Model 2X2 4X2 CP3150-150kVA 56,931 45,556 4X4 34,670 CP3150-125kVA 28,892 47,442 37,963 Table 5 – Weight Specifications Weight Specifications CP3150-150kVA/125kVA Weight (lbs) 480in/480out 2564 480in/208out 3675 208in/208out 3675 "K" Battery Cabinet 3900 Input Transformer Cabinet 1300 51 Floor Loading (lbs) 4 at 641 4 at 919 4 at 919 8 at 488 4 at 325
Illustration A 52
Illustration B 53
BATTERY CABINET TOP DIMENSIONS Illustration C 54
For a number of years CHLORIDE POWER PROTECTION has been committed to a policy of Total Quality and today devotes a great deal of resources and energy to providing the best possible after-sales service. Therefore, we value any suggestion you might make and consider it an inspiration for our continued improvement. We thank you in advance for any such suggestions that may be forwarded to the addresses listed in the last page. This document is for information only.
