Single Phase UPS system S i n g l e m o d u l e a n d ‘1 + N’ ( e x p a n d a b l e ) UNINTERRUPTIBLEPOWERSYSTEM User Manual EMERSON Network Power (India) Pvt. Ltd.
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IMPORTANT This manual contains information concerning the installation, operation and maintenance of the Series 7400 1Phase Uninterruptible Power System (UPS) for the single module and one plus one Systems. All relevant parts of the manual should be read prior to commencing installation. The UPS must be commissioned by an engineer approved by the manufacturer (or his agent) before being put into service. Failure to observe this condition will invalidate any implied warranty.
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Safety Procedure WARNING This is a class A UPS product. In a domestic environment, this product may cause radio interface in which case the user may be required to take additional measures. WARNING HIGH EARTH LEAKAGE CURRENT: EARTH CONNECTIONS ESSENTIAL BEFORE CONNECTING THE INPUT SUPPLY. This equipment electrical codes. must be earthed in accordance with IS local WARNING THIS UPS DOES NOT INCORPORATE AUTOMATIC BACKFEED PROTECTION.
GENERAL As with other types of high power equipment, dangerous voltages are present within the UPS and battery enclosure. The risk of contact with these is minimised as the live component parts are housed behind a hinged, lockable door. Further internal safety screens make the equipment protected to IP20 standards. No risk exists to any personnel when operating the equipment in the normal manner, following the recommended operating procedures.
INDEX 1 General Description 1 1.1 Introduction 1 1.2 Design Concept 1 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 Redundant vs Non redundant configuration 7400 Module Design Bypass Supplies UPS Power Switch Configuration Battery circuit breaker One plus one parallel control Common Battery Operator Control Panel Battery Circuit Breaker Battery cabinet/ rack 1 2 3 4 4 7 9 10 13 13 1.3 Safety Precautions 14 1.3.1 1.3.2 1.3.3 1.3.
4 Optional Equipment 35 4.1 AS400 Interface Board (#10021512003) 36 4.1.1 4.1.2 4.1.3 AS400 Interface board outputs Remote control inputs Calibration 36 36 36 4.2 4-Way AS400 Interface Board (#100201120004) 38 4.2.1 4.2.2 Remote control inputs Calibration 38 38 4.3 Output Interface (Remote alarms) Board (#100215120007 & #100215120002) 40 4.3.1 4.3.2 Alarm Outputs Remote control inputs 40 40 4.4 Remote Alarm Monitor (RAM) for Single Module and 1+1 UPS System 42 5 Maintenance 47 5.
Series 7400 Single Phase 1+N UPS Chapter 1 General Description 1.1 Introduction The Uninterruptible Power Supply system is connected between a critical load, such as digital drives & automation, distributed digital Process Control System, telecom equipment, programmable logic controller, mission critical applications, computer, and its three phase mains power supply.
Series 7400 Single Phase 1+N UPS Bypass Supply Mains Supply (a.c) RECTIFIER (d.c) INVERTER (a.c) STATIC SWITCH UPS Output Supply (d.c) BATTERY Figure 1: Series 7400 UPS Single Module Block Diagram 1.2.2 7400 Module Design As previously mentioned, each of the two modules forming the one-plus-one system is basically a standard single module 7400 series UPS.
Series 7400 Single Phase 1+N UPS Maintenance Bypass Isolator Bypass Supply Maintenance Bypass Line Bypass Isolator Static Bypass Line Mains Supply RECTIFIER Input Isolator INVERTER STATIC SWITCH Battery Breaker Output Isolator UPS Output Supply BATTERY A. BLOCK SCHEMATIC FOR 230V OUTPUT 1PH.
Series 7400 Single Phase 1+N UPS 1.2.4 UPS Power Switch Configuration Figure 2 illustrates what is known as the “Split Bypass” configuration. This is the standard configuration for all 1PH Models In the “Split Bypass” configuration the static bypass line is switched by a separate isolator to a dedicated ‘Bypass’ power source which also feeds the maintenance bypass line. The power switch locations in the various 7400 models are shown in Figure 3.
Series 7400 Single Phase 1+N UPS I2 Output Isolator I3 Maintenance Bypass Isolator I4 Static Bypass Isolator I1 Input Isolator I4 Output Isolator 10/ 40 kVA I3 Maintenance Bypass Isolator I2 Static Bypass Isolator I1 Input Isolator 900 830 I4 Output Isolator I3 Maintenance Bypass Isolator I2 Static Bypass Isolator 1250 60/ 80 kVA 50 kVA I1 Input Isolator I4 Output Isolator I3 Maintenance Bypass Isolator I2 Static Bypass Isolator I1 Input Isolator 1400 105 kVA Figure 3A: Power Isolato
Series 7400 Single Phase 1+N UPS I2 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator I4 Output Isolator 830 I3 Maintenance Bypass Isolator 50 kVA I1 Input Isolator 1250 60/ 70 kVA I1 Input Isolator 900 10/ 40 kVA I4 Output Isolator I3 Maintenance Bypass Isolator I4 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 1400 105 kVA Figure 3B: Power Isolator identification for 110V output system 6
Series 7400 Single Phase 1+N UPS 1.2.6 One plus One Parallel Control When two of the standard 7400 modules just described are connected together to form a one-plus-one system, each module is fitted with an additional circuit board which allows the two modules to communicate with each other. Communication takes place via a single ribbon cable connected between the modules as illustrated in figure 4.
Series 7400 Single Phase 1+N UPS Bypass Supply Mains Supply RECTIFIER INVERTER STATIC SWITCH 1+1 PARALLEL CONTROL BATTERY UPS Output Supply BATTERY 1+1 PARALLEL CONTROL Mains Supply RECTIFIER INVERTER STATIC SWITCH Bypass Supply Figure 4: Parallel control in a one-plus-one system Battery charge current sharing: The illustration in figure 4 shows a dedicated battery installation for each module; however, it is possible to fit an option kit which allows the two modules in a one-plus-one system to
Series 7400 Single Phase 1+N UPS Bypass Supply Mains Supply RECTIFIER INVERTER STATIC SWITCH 1+1 PARALLEL CONTROL UPS Output Supply Control Logic BATTERY Common Batt. Panel 1+1 PARALLEL CONTROL Mains Supply RECTIFIER INVERTER STATIC SWITCH Bypass Supply Figure 5: ‘Common Battery’ configuration 1.2.7 Common Battery A “Common battery” option kit contains a DCCT (DC Current Transformers) which are fitted to the battery power lines and monitored by the parallel control logic.
Series 7400 Single Phase 1+N UPS Uninterruptible Power System MEASUREMENTS = ALARM Vo Io f B INVERTER EMERGENCY OFF = ((•)) ON Figure 6: Operator Control Panel 1.2.8 Operator Control Panel The operator control panel is divided into three functional areas; ‘Mimic indications’, Control switches’, and ‘LCD display panel’.
Series 7400 Single Phase 1+N UPS MEASUREMENTS S1 ALARM Vo Io f B S2 S3 INVERTER EMERGENCY OFF ((•)) S4 S5 ON LS7 S7 LS8 S6 S8 Figure 8: Control Panel Switches LS5 - Load on bypass: This led illuminates when the output isolator is closed and the load is connected to the bypass via the static switch. LS6 - Load on Inverter: This led illuminates when the output isolator is closed and the load is connected to the inverter via the static switch.
Series 7400 Single Phase 1+N UPS Switch S7 - Inverter ON: Pressing this switch activates the inverter and causes the load to be transferred to the inverter side of the static switch after the inverter voltage has had time to stabilise. Switch S8- Emergency Stop: When the emergency stop switch is pressed it disables the static switch block entirely (so removing load power). It also disables the rectifier and inverter, and trips the battery circuit breaker.
Series 7400 Single Phase 1+N UPS LCD Display *** ALARM *** EMERGENCY STOP *** ALARM *** INVERTER OFF OR FAILED *** ALARM *** OVER TEMPERATURE *** ALARM *** OVERLOAD *** ALARM *** BATTERY CB OPEN *** ALARM *** OUTPUT CB OPEN *** ALARM *** BYPASS CB OPEN *** ALARM *** RECTIFIER OFF OR FAILED *** ALARM *** UPS ON MAINTENANCE BYPASS *** ALARM *** INVERTER UNSYNCHRONISED *** ALARM *** BATTERY ON LOAD *** ALARM *** BYPASS OFF OR FAILURE *** ALARM *** LOAD ON BYPASS *** ALARM *** LOW BA
Series 7400 Single Phase 1+N UPS 1.3 Safety Precautions 1.3.1 General In common with other types of high power equipment, dangerous voltages are present within the UPS and battery enclosure. The risk of contact with these voltages is minimised as the live component parts are housed behind a hinged, lockable door. Further internal safety screens make the equipment protected to IP20 standards.
Series 7400 Single Phase 1+N UPS Chapter 2 Operating Instructions 2.1 Introduction Starting and stopping the one-plus-one system is straightforward, however the modules’ response depends on whether it is configured as a Redundant or Non-Redundant system. The operating procedures are the same irrespective of the selected redundancy mode; in simple terms you start (stop) one module and then repeat the operation on the second module.
Series 7400 Single Phase 1+N UPS How to turn ON the System from a Shut down condition (Complete this actions on one module at a time) This procedure should be followed when turning on the one-plus-one system from a fully powered down condition - i.e. where the load is not being initially supplied through the internal Maintenance Bypass supply. Step Action 1. Close the module’s Output Isolator and check that the UPS input mains supply (and bypass supply if separate) is turned on externally. 2.
Series 7400 Single Phase 1+N UPS How to turn ON the System from a Maint. power-down condition (Complete this action on module at a time) This procedure should be followed to start the one-plus-one from a MAINTENANCE power-down condition - i.e. where the load is being initially powered through the internal maintenance bypass supply. Step Action 1. Check that the UPS mains supply (and bypass supply, if separate) is turned on externally. 2. Close the input isolator (and static bypass isolator if separate.
Series 7400 Single Phase 1+N UPS How to turn OFF the System but continue to provide Load power through the Maintenance Bypass This procedure should be followed if one-plus-one is to be powered-down while continuing to supply load through the maintenance bypass line. Note that during this procedure the load will be unprotected against mains supply disturbances once the inverter(s) has been switched off. Step Action Response 1.
Series 7400 Single Phase 1+N UPS How to totally Power down the System This procedure should be followed only if the one-plus-one AND LOAD are to be completely powered down. Step Action 1. Response Press the Inverter OFF switch (S6) on both modules. Mimic panel LEDs - LS4 and LS6 should extinguish and LS5 should illuminate to show that the load has been transferred to the static bypass line. (Note: In a Non- Redundant Module system LS5 and LS6 will also changeover on the second module) 2.
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Series 7400 Single Phase 1+N UPS Chapter 3 Installation Procedure 3.1 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 Ø Special care should be taken when working with the batteries associated with this equipment.
Series 7400 Single Phase 1+N UPS 3.1.1 Equipment positioning and environmental considerations The UPS cabinets can be moved by fork lift or crane. Fork lift apertures are provided in the sides of the base plate and are accessible after removing blanking covers fitted to the side panel ventilation grills. Roof - mounted eye- bolts are fitted to enable the cabinet to be crane-handled. These can be removed once the equipment has been finally positioned.
Series 7400 Single Phase 1+N UPS 3.1.3 Battery Location In 25kVA to 125 kVA module installations the batteries associated with the UPS equipment are usually contained in a purpose-built battery cabinet/ rack which sits alongside the main UPS equipment. Sealed, maintenance-free batteries are normally used in this type of installation.
Series 7400 Single Phase 1+N UPS Note: If ‘side’ cable entry is to be used ensure that the blanking plates are removed before finally fixing the cabinet position. 5. All UPS models have a stabilising bar fitted to the output transformer T1 and input choke L1 during shipment. This should be removed when the UPS has been placed in its final position. Also PCB door is fixed with z-type clamps which should be removed.
Series 7400 Single Phase 1+N UPS 3.3 Connecting UPS Power Cables WARNING Ø 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 to the mains distribution panel. Ø Check that these supplies are electrically isolated and post any necessary warning signs to prevent their inadvertent operation. 3.3.1 Cable Entry Cables can enter the UPS modules and battery cabinet either from below or through either side.
Series 7400 Single Phase 1+N UPS 3.3.3 Cable Connections In the 25-40kVA UPS 1 PH models the input mains / bypass cables, UPS output cables and battery cables are connected to busbars located behind a safety cover just below the power isolator switches -as shown in figure 11. A terminal block is used for connecting the control cables to the battery circuit breaker and the external emergency stop facility.
Series 7400 Single Phase 1+N UPS 6. Connect the safety earth and any necessary bonding earth cables to the copper earth busbar located on the floor of the equipment below the power connections. Note:- The earthing and neutral bonding arrangement must be in accordance with local and national codes of practice. 7. Connect the battery circuit breaker control cables between the UPS auxiliary terminal block and battery circuit breaker controller board as shown in figures 19 & 20. 8.
Series 7400 Single Phase 1+N UPS I2 I3 NU RU I4 NI RI I1 SI TI NS RS - + Figure 11: Cable connection 25-40kVA, 230V, 1 Ph. I4 I3 I2 I1 RI SI TI NU RU NS RS Figure 12: Cable connection 50kVA, 230V, 1 Ph.
Series 7400 Single Phase 1+N UPS I4 RU I3 NU I1 I2 RS NS RI SI TI + - Figure 13: Cable connection 60 / 80 kVA, 230V, 1 Ph. I4 U2 I3 I2 I1 N2 U3 N3 NI UI VI WI Figure 14: Cable connections for 105 kVA, 230V, 1 Ph.
Series 7400 Single Phase 1+N UPS I3 I1 I2 RU NU NS1 RS1 NS2 RS2 RI SI TI - + Figure 15: Cable connection 25-40kVA, 110V, 1 Ph. + - I3 I1 I2 RI SI TI NS RS NU RU Figure 16: Cable connection 50kVA, 110V, 1 Ph.
Series 7400 Single Phase 1+N UPS I1 I3 I2 RU NU NS RS RI SI TI + - Figure 17: Cable connection 60 / 70 kVA, 110V, 1 Ph. I1 I3 N2 I2 N3 N2 U2 U3 RI SI TI + - Figure 18: Cable connections for 105 kVA, 230V, 1 Ph.
Series 7400 Single Phase 1+N UPS 3.5 Battery Circuit 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. It is most likely used with 60–125 kVA UPS models. Several boxes of various current ratings are available and are similar in their design and content. These are listed below : 100 160 250 400 Amp Amp Amp Amp C.B. C.B.
Series 7400 Single Phase 1+N UPS Usually the ‘box’ is fitted as close as possible to the batteries. Figure 19 shows the details of the power and control cable connections between the circuit breaker box and UPS itself. These are similar to the connections made to the battery cabinet, previously described. As a safety precaution, remove the battery fuse in the UPS before making the battery circuit breaker power connections.
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Series 7400 Single Phase 1+N UPS Chapter 4 Optional Equipment Several items of optional equipment are available for fitting to the 7400 series UPS for the use by the customer as required. These o o o o o options are: IBM AS400 Interface IBM AS400 Interface with 4-way output Output Interface Board Remote Alarms Board. Input filter In addition to these options, it is possible for the customer to use an RS232 extension of the operator control panel (fitted as standard) for external indications.
Series 7400 Single Phase 1+N UPS 4.1 AS400 Interface Board (#100215120003) The AS400 Interface board connects the five most operationally critical UPS alarms to an IBM AS400 computer, which is designed to monitor such alarms and respond to their appearance: * Mains failure * Load on inverter * Low battery and/or battery circuit breaker open * Load on mains (bypass) * Load on maintenance bypass These alarm signals are provided by volt-free relay contacts.
Series 7400 Single Phase 1+N UPS Control Inputs TB - M2 AS400 INTERFACE BOARD Part No.
Series 7400 Single Phase 1+N UPS 4.2 4-WAY AS400 Interface Board (#100201120004) The 4-way AS-400 Interface board connects fiver critical UPS alarms to four output terminal blocks M1 - M4 as shown in figure 22. These alarm signals can be connected to a IBM AS 400 computer designed to monitor such alarms, or to a Remote Alarm Monitor panel.
Series 7400 Single Phase 1+N UPS CN1 Control Inputs AS400 INTERFACE BOARD Part No.
Series 7400 Single Phase 1+N UPS 4.3 Output Interface (Remote Alarms) Board (100215120007 & 100215120002) 4.3.1 Alarm Outputs Two remote alarm boards, shown in figure 23 & 24, similar in function and differing only in their connections to the terminal blocks M1 - M3, enable the alarm signals generated within the UPS to be connected by means of volt-free changeover relay contacts to a remote monitoring device.
Series 7400 Single Phase 1+N UPS M1 MAINS VOLTAGE OK RECTIFIER ACTIVE BATTERY OK PRE-ALARM END OF DISCHARGE INVERTER OK M2 SYNCHRO OK LOAD ON UPS LOAD ON BYASS OVER TEMPERATURE OVERLOAD M3 MAINT, BYPASS ENABLED STATIC BYPASS ISOLATOR CLOSED (SPLIT BYPASS) OUTPUT SWITCH CLOSED SYNCHRO INHIBIT INVERTER ON/OFF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 RELAY RELAY Figure 24: Output Interface Board #10021512002 41
Series 7400 Single Phase 1+N UPS 4.4 Remote Alarm Monitor (RAM) for Single Module & “1 + 1” UPS System. This will contain following items: 1. Remote Alarm Monitor for Single Module #270154000001. 2. Remote Alarm Monitor for 1+1 Module #270154000003. This unit is always used in conjunction with Alarm interface PCB #100215120002, only. Remote Alarm Monitor enables the auxiliary alarm signals to be displayed at a remote station upto 200 meters from the main equipment.
Series 7400 Single Phase 1+N UPS Figure 25: Remote alarm monitors for single module and 1+1 configuration 43
Series 7400 Single Phase 1+N UPS OUTPUT INTERFACE PCB MOUNTED IN UPS SYSTEM REMOTE ALARM MONITOR LOCATED AT REMOTE PLACE M1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 MAINS OK (BYPASS) RECTIFIER ACTIVE BATTERY OK END OF DISCHARGE INVERTER OK MIMIC STATUS LED – MAINS (BYPASS) VOLTS OK MIMIC STATUS LED – LOAD ON BYPASS MIMIC STATUS LED – RECTIFIER ACTIVE MIMIC STATUS LED – INVERTER OUTPUT OK MIMIC STATUS LED – BATTERY OK MIMIC STATUS LED – LOAD ON INVERTER (UPS) M2 ALARM SIGNAL LED – PREALARM END OF DISCHARGE
Series 7400 Single Phase 1+N UPS OUTPUT INTERFACE PCB MOUNTED IN MODULE 1 OUTPUT INTERFACE PCB MOUNTED IN MODULE 2 M1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT SWITCH CLOSED SYNCHRO INHIBIT RELAY INVERTER ON/OFF RELAY TERMINALS OF INTERFACE PCB STATUS LED LOAD ON BYPASS RM2 RM1 TEST RESET + 24 V TERMINAL CONNECTION ARE GOING TO M1 M2 M2 M3 M1 M1 M1 M1 M1 M1 M2 M1 M2 M1 M1 M1 - 11 -1 - 14 -2 - 4 MODULE 1 - 4 MODULE 2 -13 MODULE 1 -13 MODULE 2 - 7 MODULE 1 - 7 MODULE 2 -8 -2 -5 - 14 -5 -8 M
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Series 7400 Single Phase 1+N UPS Chapter 5 Maintenance 5.1 Introduction This chapter contains the procedures necessary to effect general maintenance of the UPS module and battery. Certain procedures entail gaining internal access to the UPS, and should only be undertaken by a competent engineer who is familiar with the operation and layout of the equipment and understands the areas of potential hazard.
Series 7400 Single Phase 1+N UPS 5.3.2 Weekly Checks Carry out the following checks from the mimic panel and log the results: 1. Measure and record the battery float charge voltage. 2. Measure and record the battery charge current. 3. Measure and record the UPS output voltage on all three phases. 4. Measure and record the UPS output line currents.
Series 7400 Single Phase 1+N UPS 6. Carry out a thorough examination of the UPS power components and sub-assemblies, paying particular attention to the following Electrolytic capacitors - Check for signs of leakage, buckling etc. Magnetic components - Check for signs of overheating, security of fixture and signs of delamination. Cables and Connections - Check cables for chaffing, fraying or signs of overheating. Check that all printed circuit board connectors are secure.
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Series 7400 Single Phase 1+N UPS Chapter 6 Troubleshooting 6.1 Troubleshooting UPS systems The UPS contains complex electronic control circuits that require a firm understanding in order to carry out comprehensive fault diagnosis and repair of the equipment. The following information aims to provide a trained user with sufficient knowledge to understand the nature of a fault through the correct interpretation of the accompanying alarms and indications, and to carry out any necessary first aid repair.
Series 7400 Single Phase 1+N UPS Corrective Action When all the indications have been noted, you should refer to the following fault interpretation charts and carry out the actions detailed against any led whose status is abnormal. If you are unsure as to how to undertake the actions detailed - or if several LED indications are abnormal and you are unable to distinguish between the likely cause and affects - then seek immediate assistance from an approved service agent.
Series 7400 Single Phase 1+N UPS LED NUMBER LS1 NORMAL STATE ON ACTIONS TO BE TAKEN IF ABNORMAL If this led is OFF it signifies a problem either with the incoming mains supply or the rectifier section. See accompanying alarm messages. Check a) b) c) d) the following: Input isolator is closed. Input supply voltage is within 20% of nominal Input fuses are O.K. Power supply fuses are OK (Note: LS1 and LS2 on the AC Power Supply Board will be OFF if either of these fuses are ruptured).
Series 7400 Single Phase 1+N UPS LED NUMBER LS4 NORMAL STATE ON ACTIONS TO BE TAKEN IF ABNORMAL If this led is OFF it signifies that the inverter is not producing its correct output voltage. Check the following: a) If [OVERTEMPERATURE] OR [OVERLOAD] alarm messages are active then (after allowing the UPS to cool / checking that the load current on the bypass line is not excessive) press the reset switch on the UPS Logic Board.
Series 7400 Single Phase 1+N UPS 6.2 Display Panel Message Interpretation The following table lists the various messages displayed on the operator panel together with a description of their interpretation. DISPLAY MESSAGE EMERGENCY STOP INTERPRETATION This alarm indicates that the UPS was shut down by means of the local or remote (if fitted) emergency stop pushbutton which of course is normally due to operator action - investigate why the emergency stop pushbutton was pressed.
Series 7400 Single Phase 1+N UPS DISPLAY MESSAGE INTERPRETATION UPS ON MAINTENANCE BYPASS This is a status warning that the load is being powered through the maintenance bypass line and is unprotected from mains supply abbreviations. Due to the fact that the UPS power supplies are fed by the input circuit breaker, this message will disappear if the input isolator is opened (and bypass isolator opened on a split bypass system) while the load is on maintenance bypass supply.
Series 7400 Single Phase 1+N UPS ANNEXURE Inter Connection cable details Any system essentially needs UPS module. However many customers need auxiliary cubicles such as Input Isolation Transformers, Battery Current Sharing Kit, 1+1 Paralleling kit, Bypass SCVS / SVR or Bypass Line Transformers. In case any of the auxiliary cubicle or combination of them is required & ordered by the customer, we would like to recommend following sequence in which the cubicles shall be located.
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