INSTALLATION & OPERATING MANUAL GRAVITAS SABRE SERIES MODULAR INVERTER SYSTEM WWW.UNIPOWERTELECOM.COM Manual No. SABRE-4 11/27/07 sabre-man © 2007 UNIPOWER Corp. All Rights Reserved UNIPOWER Telecom, Division of UNIPOWER Corporation NORTH AMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: +1 954-346-2442 • Fax: +1 954-340-7901 • sales@unipower-corp.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Contents 1 System Information & Description .............................................................................................................................. 4 1.1 Inverter Module Specification........................................................................................................................... 4 1.1.1 Electrical Specification ...............................................................................................
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1 System Information & Description The UNIPOWER Telecom SABRE Series Inverter System utilizes Digital Signal Processing controlled, 1000/1500VA, modular inverters, contained in a 19/23inch shelf, to supply 120/230VAC to telecom equipments when 48VDC (nominal) is supplied.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Output Item Waveform Output power Power factor Nominal output voltage Output voltage variation Output Frequency Frequency variation Crest factor THD Capacitive/inductive load Efficiency Current limitation Isolation AC-enclosure Surge protection Dynamic response Over load protection Control Load sharing Display Status/alarm information Communication (internal to system) Runtime info.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.1.3 Mechanical Specification Items Specification Depth: 10.63” (270mm) Height, body: 1.59” (40.5mm) Height, front panel: 1.72” (43.8mm) (1U) Width: 8.46” (215mm) (5U) Inverter module can be changed in a live system No wires need to be connected or tools required for installation of inverter into shelf Smart control, easy replacement 50A with STS, 100A without STS, see below.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Fault LED Warning LED Power On LED Lock Switch Figure 1 Inverter module dimensions (mm) Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL BAT- in: DC Cathode BAT+ in: DC Anode CN11: Not used UC3: AC Neutral out UC4: AC Ground UC5: AC Line out CN9 : Power Connector to Controller CN20/CN21 : Inter-Parallel Connectors CN7: COM/SYNC port with STS module CN13: Not used CN8 : CAN COM port with controller module Figure 2 Inverter shelf Gimensions (mm) JP2 : Matching resistor selector Jumper installed positions 1-2 for single inverter shelf installations, removed or installed positions 2-3
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2 STS Module Specification 1.2.1 Electrical features 1.2.1.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.3 Alarm Information Item STS Alarms Information Specification CAN communication failure Back-feed relay open SCR1 short circuit SCR2 short circuit Output short Over load Over temperature Mains unavailable Inv unavailable Output abnormal STS fan failure MBS position error EEPROM fault 1.2.1.4 Interface Item Human Interface LED Indicator Communication Interface Communication Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.5 Operating status for the various positions of the MBS The operation mode of STS is closely linked with the position of MBS. The MBS has two main contacts and three auxiliary contacts, signals generated by the three auxiliary contacts are passed to STS for position detection. Once an auxiliary contact is closed, the signal is logic 0, in reverse it will be logic 1. The combination of logic 0 and 1 can produce five valid position statuses.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL MBS Status Schematic operation principle of STS Description Normal Operation(NORM) MBS Main Contact1 Mains priority: Mains AC powers the load through the static switch MBS can be switched from P3 to P2 and P4 position SCR2 open, SCR1 and Back-feed Relay closed When the mains voltage or frequency is abnormal, and the inverter is normal, the STS transfers to on-line mode When SCR2 is short, the STS will keep the off-line mode SCR1 Backfeed Relay Mai
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL MBS Status Schematic operation principle of STS Description MBS Main Contact1 Mains Maintenance(ISS): SCR1 Mains Mains Maintenance (P4) Backfeed Relay Bypass Relay Load Inverter SCR2 Inverters power the load through the STS AC mains is disconnected from the system, and the STS cannot be removed from the system MBS can be switched from P4 to P3 and P5 Back-feed Relay and SCR1 open, and SCR2 closed MBS Main Contact2 MBS Main Contact1 Inverter
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.7 Voltage and frequency mode The STS has two inputs and one output. The two inputs are from Mains Utility and Inverters; the output is the system output. The STS will continuously detect Mains voltage and Inverter voltage in order to decide the system’s supply mode. If both Mains and Inverters are normal, the Mains has priority to decide the operation status of the system.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.8 Fan control 1.2.1.8.1 Fan speed control The speed of STS fans is decided by the output current and the NTC temperature, with the NTC temperature taking priority. When the temperature of the NTC is above 80ºC, the fan will operate at maximum speed according to the valid fan number, otherwise, the fan will operate according to the load current. The following tables show the relationship between the fan speed and load current.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.9.1 Off-line mode Figure 6 Off-line mode relay bypass transfer Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.9.2 On-line mode Figure 7 On-line mode relay bypass transfer Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.10 SCR short protection/Back-feed protection 1.2.1.10.1 On-line mode The SCR1 on the mains side will be detected when the STS operates in on-line mode. If SCR1 is short, the back-feed relay will be open, and the system continues to power the load from the inverters. At this time, “SCR1 short alarm” will be sent to the controller via the CAN bus.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.10.2 Off-line mode The SCR2 that is on the inverter side will be detected when the STS operates in off-line mode. When SCR2 is short, the system will continue to power the load from the Utility. An “SCR2 short alarm” will be sent to the controller via the CAN bus.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.1.11 Overload/output short circuit protection 1.2.1.11.1 Overload protection <1> Method one When the STS is operating in either On-line or Off-line mode, the load current will be calculated in the firmware automatically. This calculation will be used in the overload protection function.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.2.2 STS Module Environmental Specification Item Noise Operating temperature Storage temperature Operating humidity Operating Attitude Specification 55 dB, ETS 300 753, class 3.1 -20°C (-4°F) to 70°C (158°F) -5°C (23°F) to 50°C (122°F) with full performance -40°C (-40°F) to 85°C (185°F) 90% RH (non condensing) 1500m 1.2.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Fault LED Warning LED Power On LED Lock Switch Figure 11 STS module dimensions (mm) Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL CN1:Connector to UC5: MBS UC4: AC Input Cathode AC Output Cathode CN12 : Power CN3 : CN4: Connector of CAN COM port other Bat Control (future option) controller module Controller CN2: Signal Port Between STS & Inverter UC3: AC Neutral UC2: AC Ground UC1: AC Line CN7~CN11: Dry Contact CN2,CN6: CN13: RS232 RS485 Figure 12 STS/Controller shelf dimensions (mm) Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.3 Maintenance Bypass Switch Module Specification 1.3.1 Electrical Specification Item AC Input Selectable Input Frequency Rating Power Type (mechanical switch, 5 positions) Specification 110/115/120 VAC or 208/220/230/240VAC 50/60 Hz 6kW for 110/115/120 VAC 12kW for 208/220/230/240 VAC MBP (mains bypass) Position The load is powered through the maintenance bypass switch by the mains AC. The STS can be removed from the system.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.4. Controller Module Specification 1.4.1 Input Specification Item Nominal voltage Operating range Over Current Protection Specification Remarks Specification Resolution :Line * Array: 4 * 16 Green LED Red LED Yellow LED Enter Esc PgUp PgDn AlarmÆ Beep continuously Remarks 48Vdc 30Vdc -72Vdc 2A Fuse 1.4.2 Human Interface Specification Item LCD LED Indicator Function Keys Buzzer Press ENTER to defeat 1.4.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Alarm Type STS Controller Alarm Name Bypass unavailable STS priority Alarm Back-feed relay open SCR1 short circuit SCR2 short circuit STS running in fault mode Level Major Major Major Critical Critical Critical STS fan fault EEPROM fault STS operation mode alarm Inverter unavailable Mains unavailable Output over load Output short circuit Inverter capacity limit Inverter bypass mode STS temperature high MBS in abnormal position Control power fail STS
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 1.4.5 Mechanical Specification Item Controller Dimensions WxHxD Weight Cooling & Ventilation Specification 2U x 1U x 6U (without optional interfaces) 3.15” (80mm) x 1.59” (40.5mm) x 10.63” (270mm) 2.2lbs (1kg) Natural cooling Remarks Installed in Controller/STS shelf unit. Power On LED Function Keys Warning LED Fault LED LCD Display Figure 15 Controller module dimensions (mm) 1.4.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 2. System Features Compact Design Inverter power density up to 5.24W/in³ (0.32W/cm3) for 1000VA, 7.87W/in³ (0.48 W/cm3) for 1500VA. Modular design System output capacity scaleable according to requirements. Parallel operation and N+1 redundancy Inverters operate in true N+1 redundant mode with load sharing. Hot swappable Inverter modules can be swapped in a live system.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Priority Low High Red LED Flash 1 LED Signal Status One of the alarms as follows: 1) EEPROM Fault; Inverter module cannot operate in parallel mode system, however, it can work in single mode system 2) Fan Fault Fan failed in operation One of the alarms as follows: 1) Internal DC Bus Over /Under/ Unbalance/soft start fail; The inverter will shutdown. 2) Over Temperature. The inverter will shut down.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL STS Module LED Display Priority Green LED Solid Flash 1 LED Signal Status STS operating normally Running mode not according to the setting priority. For example, STS operating in off-line mode, but the priority is set to on-line.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 2.1 Principal of Operation Rectifier System Inverter System Telecom Equipment Static Transfer Switch AC . . . . . DC Distribution . . . . . Telecom Equipment AC Distribution Telecom Equipment Telecom Equipment Telecom Equipment Telecom Equipment Low Voltage Disconnect Battery Controller Figure 16 Telecom power system The inverter system accepts 40.5 to 58VDC for normal operation; however it requires an input of at least 45VDC to start.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Configuration 2: •Controller / Communications •Inverter Modules Configuration 3: •STS Module •Inverter Modules •AC Distribution Unit •MBS Module Configuration 4: •Inverter Modules Figure17 Typical system configurations Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 3 Electrical Connections 3.1 Description This chapter provides details for the installer for the electrical connections when installing the Gravitas SABRE Series inverter system. Before making any electrical connections refer to Figure 20 below.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 3.2 DC Input Refer to Figures 20 & 21 for a pictorial view of the DC Input connections. A. Attach Bat+ cables to Bat+ Bus Bar on inverter backplane. B. Attach Bat- cables to Bat- Bus Bar on inverter backplane. Note that the maximum input current to each shelf could be as high as 67A at minimum input voltage and maximum output power when using the INV1548 or INV1548H modules.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Input Bat - Signal connector EPO connector Input Bat + CAN connector Controller Power connector Output N Output L Input Bat + Output N Output L Input Bat - Brass plate The brass plate shown above is required to act as a spacer under the interconnecting bus bars only when an odd numbered combination of inverter and STS/controller shelves is employed. Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL B. STS and Inverters installed. Attach the AC Output Line to the STS Output AC Line terminal on STS shelf backplane. Attach the AC Output Neutral to the inverter output Neutral bus bar on the inverter shelf backplane. AC Input L STS Output IP/OP N Input Bat - Input Bat + Brass Plate C. AC Distribution Unit installed. Attach the Output AC Line and Neutral to the AC bulk output terminals or the socket outlets as desired. Brass Plate Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 3.5 DC Input for controller A. Attach the supplied 3 pin cable for the Controller Input from inverter shelf backplane. 3.6 Internal Communications connections A. Attach the supplied communication cable for the Inverters and STS module on the backplane of Inverter and STS shelves. B. Attach the supplied 2 pin cable for the Controller CAN Bus. 3.7 External Communications Connections 3.7.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Figure 23 Communications interfaces on the rear of the controller 3.7.2 Dry contact Alarm Settings A. B. SettingsÆSystemÆDry contact Press ‘Enter’ entry the follow menu t : 1 m T y p e : m N O : 0 2 e r l o D r y C o A l a r A l a r I n v n o v I N a d V Press ‘Up’ or ‘Down’ to select the dry contact, then enter the menu to set the alarm mode of the dry contact.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 03 04 05 C. Controller EEPROM fault Controller CAN bus off Bat voltage high 03 04 05 06 07 08 09 10 Rectifier fuse broken Rectifier fault Fan failure EEPROM failure AC power limiting Power limitation by temperature/status value AC default SMR lost Dry Contact connection on STS/Controller shelf backplane. Dry Contact # Dry Contact 1 Dry Contact 2 Dry Contact 3 Dry Contact 4 Dry Contact 5 Manual No.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 4 Mechanical Installation Installation Equipment Before installing the Inverter system, ensure the product received contains the components specified when it was ordered. Contact UNIPOWER Telecom immediately if there is a question about the configuration of the system.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 4.1.3 Inverter Module Installation When installing Inverter modules in a working plant proceed as follows referring to Figure 25. It is not necessary to shut down the system. A. Decide where the inverter module will be installed. Before installing a new inverter module, remove the dummy plate if there is any covered the selected slot. B. Set the lock switch to the unlock position. Insert the inverter module into the inverter shelf. C.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 4.2 STS/Controller Shelf, STS Module & Controller Module Installation and Removal 4.2.1 STS/Controller shelf installation When installing the STS shelf to a plant, proceed as follows referring to Figure 26. It is essential to shut down the system. A. Insert the shelf at the STS shelf position. B. Secure the shelf with the retaining screw. 4.2.2 STS/Controller shelf removal Referring to Figure 26. It is essential to shut down the system. A.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 4.2.3 Communication Interface module Installation When installing the Communication Interface Module to a working plant proceed as follows referring to Figure 27. It is essential to shut down the system. A. B. C. D. E. Remove the dummy plate where the Communication Interface Module will be inserted. Loosen the retaining screw. Connect the cable to the communication board. Insert the Communication Interface Module into the shelf.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL interlock. . Refer to Figure 28. Figure 28 MBS position when installing or removing the STS module B. Remove the dummy plates where the STS module will be inserted. C. Insert the STS module into the STS/Controller shelf. D. Push on the front of the module until it is fully home. Secure the module to the shelf by setting the lock switch to the lock position. 4.2.6 STS Module Removal A.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL B. Loosen the retaining screw. C. Insert the controller module into the controller shelf. D. Push on the front of the module until it is fully home. Secure the module to the shelf with the retaining screw. 4.3.2 Controller Module Removal A. Loosen the retaining screw. B. Remove the module from the shelf. C. Once the controller Module is removed, replace with a dummy plate or another controller to avoid exposure to a hazardous voltages.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL B. Cable Installation Install the Signal cable, Controller Can Bus cable and Controller Input cable as required. C. Communication Interface connection Connect the communication cable between the PC and rear communication interface. D. Rear Cover Installation Install the rear safety covers. 4.4.2 Inverter system Rear Removal Remove the rear cover then remove the bus bars & signal cables.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 5 Operation This section provides the procedures necessary for checking out operation of the system. 5.1 Start up Operation Follow steps 1-4 before power up: 1. 2. 3. 4. Check power wiring for errors. Measure inputs and outputs to GND for shorts. Apply 48-60VDC power to the DC input terminal of inverter system. The Inverter system will run after 20 seconds. Verify if the green LED of Inverter modules, STS module and Controller module are on.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Status Menu Waiting … … 1 minute yy-mm-dd hh:mm I NV OPV: xxx.xV SMR OPV: xxx.xV STS MOD: float Enter Main Menu Ź Status Settings Status Menu Status Ź Module Controller Alarm Module Menu Module Ź Inverter Static SW SMR Alarm Menu Controller Menu 1. HW Ver x.xx 2. SW Ver x.xx Alarm Ź Active Alarm History Alarm ź 3. Input Vol: Ÿ xx.xxV 4. Temperature: xx.x°C Alarm Status Menu Inverter Status Menu Inv: XĽ 1. Serial No. xxxxxxxxx ź 2. OPV xxx.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL Setting Menu Waiting … … 1 minute yy-mm-dd hh:mm I NV OPV: xxx.xV SMR OPV: xxx.
GRAVITAS SABRE SERIES INSTALLATION &OPERATING MANUAL 5.2.2 Hot Swap Operation 5.2.2.1 Inverter module A. Locate the lock switch at the unlock position. B. Install or remove the Inverter module from the shelf. 5.2.2.2 STS module A. WARNING: Ensure that the Maintenance Bypass Switch is set to the MBP or the IBP position (as determined by mains and inverter output status position) otherwise it will damage the STS module frame due to the mechanical interlock. . Refer to Figure 28. B.
