CP3000 Series CHLORIDE THREE-PHASE Uninterruptible Power System Owner’sManual P/N 913-537 REV D
User and Operating Manual CHLORIDE 27944 N. Bradley Rd.
DECLARATION OF CONFORMITY The manufacturer: CHLORIDE Head office at: 27944 N. Bradley Rd.
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 iii Safety vii Grounding the unit viii FCC compliance xi CHAPTER 1 DELIVERY AND STORAGE Delivery 1 Unpacking 1 Handling 2 Storage 3 CHAPTER 2 PREPERATIONS FOR INSTALLATION Environmental Conditions 4 Access area 5 Floor loading 6 CHAPTER 3 INSTALLATION Installation data 7 Specifications 8 Suggested cable sizes 9 Terminations 10 Protection devices 11 Electrical connections 12 v
Chapter 4 BATTERY Battery connections 16 Chapter 5 OPERATION Display panel 20 Indicators and buttons 21 Menu Structure 23 Menus 24 Warnings and Faults 29 Maintenance by-pass switch and power control unit breaker 30 Operating modes 31 Operational procedures 32 Chapter 6 COMMUNICATIONS Interface slots 33 Communication slot adaptability 34 RAU/RLY/DRV 35 AS400 36 RS232 37 Manage UPSnet 38 LIFE 2000 39 Industrial contacts 40 Chapter 7 MAINTENANCE 41 vi
Safety (English) WARNING: This equipment services power from more than one source. The convenience receptacles may have voltage even when the unit is off. UPSs 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: DO NOT dispose of batteries in a fire. The battery may explode. Do not open or mutilate the battery or battery cabinet. Released electrolyte is harmful to the skin and eyes and is toxic. WARNING: Only AUTHORIZED SERVICE PERSONNEL should perform maintenance on or service the UPS system.
FCC Compliance ATTENTION: Changes or modifications to this unit not expressly approved by the party responsible or in FCC compliance could void the user’s authority to operate the equipment. This equipment was tested and complies with the limits for a Class A digital device, pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the UPS is operating in a commercial environment.
Chapter 1 DELIVERY AND STORAGE DELIVERY The goods have been checked thoroughly before dispatch. Immediately inspect upon receipt of the packaging and ensure that the contents are undamaged. A SHOCKWATCH label has been affixed to the packaging. Red indicator indicates rough handling. If red, Note on Bill of Lading and report immediately to the freight forwarder. UNPACKING Care should be taken when removing the packaging in order to avoid damaging the equipment.
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. It is recommended that the UPS and Battery cabinets be moved with a pallet jack or fork lift over long distances. The side skirts have been intentionally left off to allow fork access under the UPS or battery cabinets. See figure 2.
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 2 PREPERATIONS FOR INSTALLATION ENVIRONMENTAL CONDITIONS The UPS and battery cabinets must be installed vertically, on a level and even surface. The UPS and battery cabinets must 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).
ACCESS AREA The area must have sufficient space for the installation to be carried out. Access doors must be sufficiently large to permit passage of the unit. The UPS has been designed to provide front access for maintenance purposes. See figure 3. TOP ENTRY PLATE TOP FAN EXHAUST 38.6’ 27.6’ 69.
FLOOR LOADING It is necessary that the floor in the chosen location be capable of supporting the weight of the UPS and battery cabinets. The weight of these cabinets can be found in table 1. To ease movement over short distances the UPS is fitted with casters. See figure 4.
Chapter 3 INSTALLATION Installation must be carried out only by qualified electricians and in conformity with the applicable safety standards. UNLESS MANUFACTURER’S SPECIFICATION STATES OTHERWISE INSTALLATION DATA Ambient temperature 32°F to 104°F (0°C to 40°C) Relative humidity (w/o condensing at 20°C) 0 – 95% Max. Altitude (w/o de-rating) 5000 ft a.s.l.
UPS with standard autonomy Table 1 – SPECIFICATONS Unit DESCRIPTION INPUT BY-PASS OUTPUT UPS power rating kVA 10 15 20 kW 8 12 16 Voltage Vrms 208 480 480 208 480 480 208 480 480 Max Current Arms 40 17 17 53 23 23 66 29 29 Frequency Hz Voltage Vrms 208 208 480 208 208 480 208 208 480 Current Arms 28 28 12 42 42 18 56 56 24 Frequency Hz 60 Wave form - SINUSOIDAL 60 Maxi dissipation @ nominal load and battery in recharge BTU/Hr 4443 6118 815
SUGGESTED CABLE SIZES • Input and output conductors are based on NEC 310-16 for insulated copper conductors rated at 75°C in ambient temperature of 104°F. • Grounding conductors are based on NEC 250-95 for copper wire. • UPS input and output cables should be run in separate conduits. • It is recommended that the external cables and protection be selected for the highest possible rating of UPS kVA. • • • Connect the mains supply cables to the UPS input terminals A, B, C, N.
TERMINAL CONNECTIONS Table 3 – Recommended terminal connections table TERMINATION TERMINAL WIRE SIZE OF CLAMP TERMINATION TIGHTENING TORQUE lb – in TYPE SCREW INPUT A, B, C #6 – 1/0 50 SLOTTED BY-PASS A, B, C, N #6 – 1/0 50 OUTPUT A, B, C, N #6 – 1/0 50 INTERNAL BATTERY BATTERY (+) (-) #8 – 1/0 45 EXTERNAL BATTERY BATTERY (+) (-) #8 – 1/0 45 CUSTOMER GROUND GROUND #14 – 2/0 45 10 SLOTTED SLOTTED SLOTTED SLOTTED SLOTTED
RECOMMENDED PROTECTION DEVICES The following table indicates the protection devices (circuit breakers or fuses), which must be installed by the user for the protection of both the cables and the equipment. For recommended fuses /circuit breakers, see table 4. It is recommended that the protection be selected for the highest rated UPS kVA for future kVA upgrades.
ELECTRICAL CONNECTIONS In order to gain access to the electrical connections see figure 5, it is necessary to remove the lower right protection panel situated on the front of the UPS figure 2. Cables can be brought in from the top through the access plate and routed through the channels or bottom through an access plate. See figure 3 for the electrical connections.
UPS Top Plate (template) 13
UPS Bottom Plate (template) 14
TERMINATIONS Jumpers will be provided between the By-pass and the input connections. These jumpers should be removed if there is a requirement for connection of two separate AC input supplies. Refer to table 2 for correct wire size and table 3 for torque requirements. The BY-PASS is phase rotation sensitive. Clockwise phase rotation is required for this connection. Note: This UPS may be considered a separately derived source.
Chapter 4 BATTERY BATTERY CONNECTIONS Connections must be carried out only by qualified electricians and in conformity with the applicable safety standards. The batteries have been pre-wired on each shelf. The battery tray interconnects should only be connected by a factory trained and authorized service representative. As seen in figure 7, the standard battery configurations consist of batteries located in the front lower-left section of the UPS. Optional extended run-times can be purchased or added.
Optional Battery Cabinet The battery runtime can be increased by employing either one or two optional battery cabinet.
Figure- 9 GCAB 18
Battery Cabinet Conduit Plate (Template) 19
Chapter 5 OPERATION DISPLAY PANEL The control panel serves as the UPS user interface. LED’s (Light Emitting Diode) inform the user about three operating parameters of the UPS, LED 1, 2 & 3. The LCD (Liquid Crystal Display) will provide detail on messages, alarms, values and operating conditions of the UPS.
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.
7 8 9 CANCEL AUDIBLE ALARM - This button silences current alarm EQUIPMENT POWER OFF - This button turns off the entire UPS in 0 seconds.
Menu Structure 23
MENUS 1 MAIN MENU The Main Menu screen’s function is to provide the user the selection options for viewing information about the UPS. This is the highest level for menu selectibility. To return to previous screen, press ESC button. Press the ENTER button to select screen. Use the UP and DOWN arrows to toggle through current screen. Actual Values Alarm Information Display Settings About ...
5 UPS OUTPUT The UPS Output screen displays parameters regarding the UPS output. 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.
9 DC BUS The DC Bus screen displays parameters regarding the inverter’s DC bus. Parameters displayed are: Voltage Total, Voltage +, and Voltage -. Press down or up arrows to view other entries. Press ESC to exit. Voltage Total Voltage + 10 MAIN MENU The Main Menu screen’s function is to provide the user the selection options for viewing information about the UPS. This is the highest level for menu selectibility. To return to previous screen, press ESC button. Press the ENTER button to select screen.
13 MAIN MENU The Main Menu screen’s function is to provide the user the selection options for viewing information about the UPS. This is the highest level for menu selectibility. To return to previous screen, press ESC button. Press the ENTER button to select screen. Use the UP and DOWN arrows to toggle through current screen. (Shown for display settings) Actual Values Alarm Information Display Settings About ...
CONTRAST Press 17 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. (Shown for the contrast sub menu) to select 18 MAIN MENU The Main Menu screen’s function is to provide the user the selection options for viewing information about the UPS. This is the highest level for menu selectibility. 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 (2-superscript) Under-voltage intermediate circuit Overload Phase sequence incorrect in By-pass Service By-pass is on Battery operation Battery rest time exceeded Battery under-voltage Commissioning or test mode initiated Battery switch not engaged Ventilator lifetime exceeded Connection to charger lost Faults Temperature in converter too high Internal fault Illegal status of actual
MAINTENANCE BY-PASS SWITCH AND POWER CONTROL UNIT BREAKER The maintenance By-pass switch SW1 and the power control unit breaker CB1 are located on the inside lower front-right panel.
OPERATING MODES The UPS has four different Operating Modes: On-line Operation The UPS normally operates in this mode. The loads are supplied by the mains through the inverter. The batteries are charged by the battery charger as necessary. The Inverter filters mains interruptions, disturbances and provides a stable, interference-free supply to the load. The summary alarm LED on the control panel is not illuminated in this mode.
OPERATIONAL PROCEEDURES STARTUP PROCEDURE 1. 2. 3. 4. 5. 6. 7. 8. With main disconnect off, switch SW1 to position 3 and CB1 off. Turn main disconnect on. (Supplies load) Turn CB1 on. Close F1 and F2. Turn SW1 to position 2. Check for fault codes. Press interlock pin and turn SW1 to position 1. Press the “INVERTER ON” button for 3 seconds on the front panel. TRANSFER TO MAINTENANCE BY-PASS PROCEDURE 1. 2. 3. 4.
Chapter 6 COMMUNICATIONS Installation of communication card(s) The CP3000 series can be equipped with a variety of interfacing. 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 in the upper right hand corner. See figure 12.
Recommended Communication configuration The following table 5 describes in which different functions of each slot are compatible to the corresponding card types for the Chloride UPS system. These interface slots are located behind the front panel in the upper right hand corner. See figure 5.
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 18. The 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 - 14 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 - 15 RS232 Card The interface COM is galvanically separated 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 CARD This option provides remote monitoring of the UPS, via a dedicated telephone line, to ensure maximum reliability for the duration of its operational life. The UPS automatically telephones the service centre 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 - 18 Industrial Contact Card and Bracket The contacts are rated at 120V, 2A.
Chapter 7 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.
PRECAUTIONS During maintenance, disconnect the battery blocks so that no more than five batteries are connected in series. (NOTE: This cannot be achieved with internal batteries) All safety and handling instructions shall be carefully observed. Qualified personnel may only remove the access panels. Watches rings and any other metal objects must be removed before working on the batteries Rubber gloves must be used. Insulated tools only must be used.
For a number of years CHLORIDE 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.
