User’s Guide UPS 8 – 15 kVA, 400 V 50/60 Hz output (3-phase input/output)
©2007 Eaton Corporation All Rights Reserved The contents of this manual are the copyright of the publisher and may not be reproduced (even extracts) unless permission granted. Every care has been taken to ensure the accuracy of the information contained in this manual, but no liability can be accepted for any errors or omission. The right to make design modifications is reserved.
UPS 8 – 15 kVA, 400 V 50/60 Hz User’s Guide 1023625 revision C Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Safety instructions.............................................................................................................................................................. 4 Audience............................................................................................................................................................................... 4 CE marking............
1. Safety instructions The UPS operates with mains, battery or bypass power. It contains components that carry high currents and voltages. The properly installed enclosure is earthed and IP20 rated against electrical shock and foreign objects. However, only qualified personal is allowed to install and service the UPS. Warning! Operations inside the UPS must be performed by a service engineer from the manufacturer or from an agent authorised by the manufacturer.
Warning! The user is not permitted to open of any screws excluding connectivity plates and the MBS locking plate. Failure to recognise the electrical hazards could prove fatal. Environment The UPS must be installed according to the recommendations in this manual. Under no circumstances the UPS should be installed in an airtight room, in the presence of flammable gases, or in an environment exceeding the specification.
2. Mechanical installation The UPS and accessories are delivered on a specifically designed pallet that is easy to move with a forklift or a pallet jack. Keep the UPS always in upright position and do not drop the equipment.
Check the information on the type designation label of the equipment to verify that the unit is of the correct type. The type designation label includes ratings, a CE marking, a type code, a part number and a serial number. The serial number is important when making inquiries. It allows individual recognition of the equipment. Figure 2. Type designation label.
3. Planning before installation The equipment must be installed in upright position. The equipment requires space to front and back to enable cooling airflow, service and maintenance. All cooling air enters at front and exits at unit rear. The required min. clearance from unit rear to an obstruction is 150 mm. Figure 3. Ventilation space around the equipment. It is required to arrange ventilation of the UPS room. Sufficient amount of air cooling is needed to keep the max.
4. Cabinet installation The required distance for UPS units next to each other is ten millimetres. The same applies to the optional battery cabinets that should be installed next to the UPS cabinet. Figure 5. UPS and external battery cabinets. The UPS family has several alternative battery cabinets and configurations depending on the selected back-up time and quality of batteries. Maintenance bypass switch The maintenance bypass switch (MBS) shall be mounted in back of the UPS battery compartment.
Figure 7. The maintenance Bypass Switch (MBS) when installed in the backside. Figure 8.
Transformer option The galvanic isolation transformer can be ordered as factory installed. The transformer is an integral part of the UPS unit. Alternatively the isolation transformer can be purchased as a separate item to upgrade your existing system. Figure 9. Transformer option can be ordered factory installed (integral) or separately. The overtemperature sensor cable is connected to the control input (X45 or X44) of the UPS, see the next drawing.
External battery cabinet option It’s recommended to install external battery cabinets next to the UPS unit. The external battery can be placed on either side of the UPS unit. Check before the installation that the battery voltage values in the type plate of the UPS and external battery cabinets are the same. The cables are delivered with the external battery cabinet. See External Battery Cabinet (EBC) installation procedure. Warning! The UPS contains high DC voltages.
5. Electrical installation The customer has to supply the wiring to connect the UPS to the local power source. The electrical installation procedure is described in the following text. The installation inspection and initial start up of the UPS and extra battery cabinet shall be carried out by a qualified engineer with UPS installation experience. Warning! Physical injury or death may follow, or damage may occur to the UPS, or the load equipment if these instructions are ignored. Figure 12.
The UPS unit has the following power connections: Three-phase (L1, L2, L3) and protective earth (PE) connection for the rectifier input Three-phase (L1, L2, L3), Neutral (N) and protective earth (PE) connection for the bypass input Three-phase (L1, L2, L3), Neutral (N) and protective earth (PE) connection for the load output Plus (+), minus (-) and protective earth (PE) connection for the external batteries Note! The rectifier requires a Neutral to operate.
Contact the manufacturer’s authorised agent or the local office for assistance at fuse and cable sizing. Refer to the recommended cable and fuse ratings in the below table. UPS rating 8 kVA 10 kVA 3-phase 3-phase 3-phase 12 kVA 3-phase 15 kVA 3-phase 3-phase Maximum 3-phase Input Fusing 3x16 A 3x16 A 3x20 A* 3x25 A 3x25 A* 3x32 A 3x63 A Bypass Cable Fusing 4x2.5 mm² 3x16 A 4x2.5 mm² 3x16 A 4x4 mm² 3x20 A* 4x6 mm² 3x25 A 4x6 mm² 3x25 A* 4x10 mm² 3x32 A 4x16 mm² 3x63 A Load Cable Cable 4x2.5 mm² 4x2.
Figure 15. Wiring diagram of UPS N-model with integral MBS. Figure 16. Wiring diagram of UPS N-model.
Figure 17.
External Battery Cabinet (EBC) installation procedure The installation procedure is as follows: 1. The EBC is recommended to place next to the UPS unit. Note! Do not place EBC on the UPS unit. 2. The required minimum distance for UPS unit and EBC is ten millimetres, which is also required distance between two EBCs. 3. Turn F1 battery breaker from the UPS unit in OFF position. 4. Check that the circuit breaker F3 of the EBC is in the OFF position.
Figure 18. Connection of UPS and External Battery Cabinets Figure 19. To minimise safety risk remove + or - cable from battery string before connecting UPS and EBCs.
6. Software and connectivity The software Suite CD-ROM that is bundled with the UPS contains software distributions and documentation in CD format. Furthermore, the comprehensive connectivity option portfolio includes Web/SNMP adapters for networked environments, Modem card for 24/7 remote monitoring, ModBus/Jbus card for building management system integration, relay interface cards for industrial and facilities use and RS-232 cards for serial communication to one or multiple computers.
Figure 21. Identification of the interface port pins. LanSafe software The LanSafe software shuts down computers and whole networks in case of an extended power failure. It provides basic monitoring, data logging, notification and event actions for a single UPS solution. The software is bundled free of charge in Software Suite CD. The connection procedure for the RS-232 interface port is following: 1. Connect the RS-232 communication cable to the computer. 2.
Figure 22. External control cable connections to the UPS. Note! Pay attention to proper polarity if one is using a semiconductor switch type. A relay or other mechanical control is a preferred method. Emergency Power Off (EPO) This input is used to shut down the UPS from a distance. This feature can be used for emergency power down. There are two modes of operation, normally closed at X52 and normally open at X12. Remote shut down terminal X52 pins 1 and 2 are as factory default linked (X12 is open).
Warning! The relay contacts must not be directly connected to mains related circuits. Reinforced insulation to the mains is required. Programmable signal inputs The UPS incorporates two programmable inputs (X44, X45). Use of a non-polar (relay) control input is recommended. The pins must be shorted with maximum resistance of 10 ohm in order to activate the specific input. Note! Please note the polarity of the inputs as indicated in the external control connections if used with a polarity control.
XSlot communication (option) XSlot modules allow the UPS to communicate in a variety of networking environments and with different types of devices. The UPS incorporates two (2) empty XSlot communication bays. Figure 23. Location of empty XSlot bays. The UPS supports two serial communication devices according to the table below. Configuration Default #1 Default #2 Default #3 Table 24.
AS400 Relay Module (optional) The Relay Module provides potential free relay interface for AS/400 connected computers and industrial applications. The relay interface supports both 15-pin D-sub connector and terminal block connections up to four (4) potential free relays. The relay contacts are rated for 1 A, 30 Vac or 200 mA, 60 Vdc, and they have a galvanic isolation from the other circuits of the UPS unit. Figure 26. AS400 Relay Module.
7. User operations The UPS has a four-button graphical LCD with backlight. It provides useful information about the unit itself, load status, events, measurements, and settings. The LCD backlight is switched on by pressing any button. It has a timeout that automatically switches off after 15 minutes of inactivity. Display functions As default and after 15 minutes of inactivity the UPS is showing the selectable start screen: 1. Logo screen 2.
User Settings The UPS has the following typical settings that are user configurable. Note that some of the settings become effective at the next start-up of the UPS. User settings can be configured via LCD menu.
Battery information and settings: ABM charging cycling disable Charging temp compensation Battery size setting Number of 32 pcs. battery strings Battery low alarm level Automatic battery support test Maximum charging current Output on, automatic delay time before turning the output on Output off, automatic delay time on battery after which output is turned off [Enabled], [Disabled] [Enabled], [Disabled] Step: 1 Watts/cell 0 (no batteries), 1, 2, 3, 4... Step: 0.01 V/cell [Enabled], [Disabled] Step: 0.
Configuring user settings User settings can be configured via front panel. Select Settings from main menu and then select User Settings. Changing language Pressing and holding down the first button on the left for about 3 seconds selects the language menu. This action is possible from any LCD menu screen. The default firmware has four main languages: English, Spanish, French and German.
Normal start-up Check the mechanical and electrical installation of the UPS before start-up. Go through the checklist below together with another person. Check Read the attached safety manual before you work on the unit. The unit is fixed according to mechanical installation The ambient conditions are within specification. The cooling air will flow freely. The UPS is grounded properly. The input and bypass voltages match the UPS nominal voltage.
Shutdown The procedure to shutdown from LCD is following: 1. Push any key of the control panel to enable the functions of the LCD screen 2. Select “TURN UPS OFF” from the LCD menu (see: Display Functions) 3. Press and hold ↵ button for 5 sec. There shall be an indication sound during the hold. 4. UPS shall do a shutdown routine. 5. Turn the battery and input circuit breakers to OFF position to finalise the shutdown procedure.
8. Maintenance All operations inside the unit must be performed only by a service engineer from the manufacturer or from an agent, authorised by the manufacturer. The troubleshooting procedure gives simple remedial if a malfunction occurs in the UPS. The operator should start the trouble shooting if there is an active alarm indicated on the LCD screen. Service should be contacted if the active alarm is abnormal and displayed as a service code. Call service if you are not able to solve the problem.
Note! Do not dispose of batteries in a fire. The batteries may explode. Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic. CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECTED TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS Cooling fan The cooling fan lifespan of the UPS unit is about 60 000 operating hours. The actual lifespan depends on the environment and ambient temperature.
Figure 34. The normal positions of the three MBS switches. Turn UPS from normal mode to mechanical bypass The procedure to turn the UPS to mechanical bypass switch is described below. Figure 35. The normal (UPS supplying the load) positions of the three MBS switches. No break transfer from normal mode to Service Bypass: 1. The normal start position should be following: 2. Use LCD to turn the UPS on internal static bypass mode. Remember to verify the transfer before proceeding the next step. 3.
8. Turn OFF the S2 switch to disconnect UPS bypass input: 9. Remount the locking plate of the S1-3 switches to the position to prevent the use of them. 10. UPS is now in the mechanical bypass mode, see below: Turn UPS from mechanical bypass to normal mode The procedure to turn the UPS back to normal mode is described below. Figure 36. The service (bypass supplying the load) positions of the three MBS switches. No break transfer from Mechanical Bypass to normal mode: 1.
7. Turn ON S3 switch to connect UPS output to load: 8. Turn OFF S1 switch to disconnect bypass output: 9. Use LCD to transfer the UPS to normal mode. 10. Remount the locking plate of the S1-3 swiches to the position to prevent the use of them. 11.
9. Parallel systems Overview Parallel UPS configurations are recognised as either redundancy or capacity systems. The redundancy system is used to improve the system reliability with N+1 redundant UPS module. The capacity system for its part provides the maximum output power without focusing to the highest system reliability. A parameter selection is used to switch between the redundancy and capacity modes.
Tie cabinets The Tie Cabinets (TCs), provided by UPS manufacturer, has input connections up to three parallel UPS modules. It is also possible to use two redundant UPS modules and one bypass connection. This bypass option can be used for service or test purposes. Note! It is not allowed to feed the load simultaneously from mains (bypass) and inverter(s) of the UPS unit(s). While turning the switch, where the bypass is connected, ON/OFF, UPS should be on static bypass mode or shut down.
Figure 39 Cable routing of Tie Cabinet Figure 40. Tie Cabinet’s wiring diagram with three UPSs.
Figure 41. Tie Cabinet’s wiring diagram with two UPSs and bypass connected. UPS Module 8 kVA 10 kVA 12 kVA 15 kVA TC Module 8 kVA 10 kVA 12 kVA 15 kVA 16 kVA 20 kVA 24 kVA 30 kVA 36 kVA 45 kVA Cable A 2.5 mm2 4 mm2 6 mm2 6 mm2 Cable B 2.5 mm2 4 mm2 6 mm2 6 mm2 6 mm2 10 mm2 10 mm2 16 mm2 16 mm2 35 mm2 Cable C 4 mm2 4 mm2 6 mm2 6 mm2 Cable D 4 mm2 4 mm2 6 mm2 6 mm2 6 mm2 16 mm2 16 mm2 16 mm2 16 mm2 16 mm2 Fuse 1 16 A 20 A 25 A 32 A Cable E 2.
Required parallel system wiring length should be in accordance with the following rule, as referenced to the diagram below to ensure approximately equal current sharing when in static bypass mode (see Figure below: Total length of 1A + 1B = Total length of 2A + 2B = Total length of 3A + 3B = Total length of 4A + 4B This rule has a tolerance of approximately ± 10% for the combined input and output wire lengths.
XSlot Hot Sync card: installing and wiring To enable parallel operation all the UPSs in the system need the XSlot Hot Sync card (see Figure below) installed into an open XSlot on the front of the UPS (see chapter XSlot communication from the UPS’s User’s Guide). Figure 44. Terminal J3 1 2 Name Alarm Alarm Rtn Description 3 Alarm Relay NC 4 Alarm Relay Com 5 Alarm Relay NO 6 TX 7 TX Normally-closed contact opens when UPS is on bypass. Bypass contact return.
Note! XSlot Hot Sync card has built-in termination resistor enabled by a jumper J7. The default jumper setting without termination resistor is J7: Pin 2-3. The first and the last UPS modules should have the termination resistor enabled by connecting Pins 1 and 2 with the jumper J7. Figure 46.
1. Turn the battery and input circuit breakers to ON position. 2. UPS will enter a stand-by mode and starts to charge batteries with a cooling fan operational. Output is without the voltage in the stand-by mode. 3. Push any key of the control panel to enable the functions of the LCD screen 4. Select unit number in parallel system: Unit #1, Unit #2, Unit #3 or Unit #4. Select: SETTINGS -> USER SETTINGS -> PARALLEL OPERATION SETTINGS -> PARALLEL UNIT NUMBER 5.
10. Recycling the used UPS or batteries Before scrapping UPS or its battery cabinet, the battery bank must be removed. Local requirements must be followed in battery recycling or discard. The removal of batteries is allowed only by authorised service personnel due to high energy and voltage. Do not discard waste electrical or electronic equipment in the trash. For proper disposal, contact your local collecting/recycling/reuse or hazardous waste center and follow the local legislation.
11. Dimensional drawings Figure 47. UPS models with no battery sections. Figure 48. UPS models with (1) and (2) battery bottom sections. Figure 49. UPS models with (1) and (2) battery bottom sections plus integrated MBS.
Figure 50. External battery cabinet models with (2) and (3) sections. Figure 51. UPS models with middle battery and bottom transformer sections.
12. Technical data Standards UPS Safety EMC Product 8 kVA 10 kVA 12 kVA IEC 62040-1-1, EN 62040-1-1 and EN 60950 EN 50091-2 IEC 62040-3 and EN 62040-3 15 kVA UPS Amb. temperature Relative humidity 8 kVA 10 kVA 12 kVA 0 to +40°C (electronics), 15 to +25°C (batteries) 0 to 95%, no condensation allowed 15 kVA Altitude Vibration <1000 m above sea level at +40°C IEC 68-2-6; max. 0.3 mm (2 to 9 Hz), max.
AC input UPS Rectifier input Bypass input Voltage tolerance Frequency Power factor Input distortion Rated input current 8 kVA 12 A 10 kVA 12 kVA 3-phases 3-phases 196-253 V and 339-438 V 45 Hz to 65 Hz 0.99 < 5% THD(I) 15 A 17 A 15 kVA 22 A DC circuit UPS 8 kVA Management Nominal voltage Battery qty Float voltage Battery type Cut off voltage Battery charging 10 kVA 12 kVA 15 kVA Advanced Battery Management 384 Volts 32 /module 2.30 VPC VRLA 12 Volts 1.
13. Warranty The product is warranted against defects in design, materials and workmanship for a period of twelve (12) months from its original date of purchase. The local office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract.
