AEG PROTECT 1. M User Manual

UPS OPERATING INSTRUCTIONS

PROTECT 1. M

PROTECT 1.040

Thank you for deciding to purchase the PROTECT 1.M UPS from AEG Power Solutions. The following safety instructions are an important part of the operating instructions are will protect you against problems from operating errors and possible dangers. Please read these instructions carefully prior to commissioning!

1 Notes on these Operating

Instructions

Duty to provide information

These operating instructions help you to install and operate the Uninterruptible Power Supply (UPS) PROTECT 1.M as well as its USV modules PROTECT 1.040 and associated external battery units PROTECT 1.M BP (referred to below jointly as PROTECT 1.M) in accordance with its designated use, safely and correctly. These operating instructions contain important information for avoiding dangers.

Please read these instructions carefully prior to commissioning!

These operating instructions are an integral part of PROTECT 1.M.

The operator of this unit is obliged to communicate these operating instructions to all personnel transporting or starting up PROTECT 1.M or performing maintenance or any other work on the unit.

Validity

These operating instructions comply with the current technical specifications of PROTECT 1.M at the time of publication. The contents do not constitute a subject matter of the contract, but serve for information purposes only.

Warranty and liability

We reserve the right to alter any specifications given in these operating instructions, especially with regard to technical data and operation.

Claims in connection with supplied goods must be submitted within one week of receipt, along with the packing slip. Subsequent claims cannot be considered.

The warranty does not apply for damage caused by noncompliance with these instructions (such damage also includes damage to the warranty seal). AEG will accept no liability for consequential damage. AEG will rescind all obligations such as

warranty agreements, service contracts, etc. entered into by AEG or its representatives without prior notice in the event of maintenance and repair work being carried out with anything other than original AEG parts or spare parts purchased from AEG.

Handling

PROTECT 1.M is designed and constructed so that all necessary steps for start-up and operation can be performed without any internal manipulation of the unit. Maintenance and repair work may only be performed by trained and qualified personnel.

Illustrations are provided to clarify and facilitate certain steps. If danger to personnel and the unit cannot be ruled out in the

case of certain work, it is highlighted accordingly by pictographs explained in the safety regulations of chapter 3.

Hotline

If you still have questions after having read these operating instructions, please contact your dealer or our "Hotline":

Tel: +49 (0)180 5 234 787 Fax: +49 (0)180 5 234 789 Internet: www.AEGpartnerNet.com

No part of these operating instructions may be transmitted or reproduced by any electronic or mechanical means without the express prior written permission of AEG.

Table of Contents

1 Notes on these Operating Instructions.............................3

Introduction.......................................................................7

2.1 Product description.....................................................7

2.2 Technical Data..........................................................10

3 Safety Regulations .........................................................14

3.1 Important Instructions and Explanations ..................14

3.2 Accident Prevention Regulations .............................14

3.3 Qualified Personnel ..................................................15

3.4 Safety Instructions for PROTECT 1.M .....................15

3.5 CE certificate ............................................................18

4 Set-up.............................................................................18

4.1 Unpacking and Inspection ........................................19

4.2 Transport to Installation Site.....................................21

4.3 Set-Up ......................................................................22

5 External View .................................................................23

5.1 Front and Rear View of PROTECT 1.M (chassis)....23

5.2 Front/Rear and 3D View PROTECT 1.040 (module)... 24

5.3 Front and Rear View (communication module)........24

5.3 Front and Rear View (communication module)........25

5.4 Front View of LCD Panel..........................................25

5.5 Display Panel............................................................26

6 Installation ......................................................................27

6.1 Installation Notes......................................................27

6.2 Set-up and Installation of the Modules.....................31

Adding/Removing Modules ......................................33

7.1 Active Redundancy ..................................................33

7.2 Installing and Removing UPS Modules....................33

7.2.1 Basic procedure

for installing a PROTECT 1.040 UPS module... 34

7.2.2 Basic procedure

for removing a PROTECT 1.040 UPS module..34

8 Operating and Maintenance...........................................35

8.1 Operation..................................................................35

8.1.1 Start-up..............................................................37

8.1.2 Shutting down....................................................37

8.1.3 Inquiries .............................................................38

8.1.4 Setup..................................................................39

8.2 Maintenance.............................................................41

8.3 Shutdown and UPS Management Software.............42

9 Communication Interfaces .............................................43

10 Troubleshooting and Fault Rectification.........................44

11 Reference Table for the Display and UPS Operating .....45

11.1 Normal operation......................................................45

11.2 Battery Operation .....................................................45

11.3 Bypass Operation.....................................................45

11.4 Warning Signal if Battery System Not Connected....46

11.5 Warning Signal

for Phase Loss or Phase Sequence Error................46

11.6 Overload Protection..................................................47

12 Minimum Number of Battery Packs ...............................48

13 List of terms....................................................................51

13.1 Technical terminology ..............................................51

2 Introduction

2.1 Product description

PROTECT 1.M ("M" for modular structure) is an

ninterruptible Power Supply (UPS) for

The PROTECT 1.M connection to the mains can be either three or one-phase. The load connection, i.e. the UPS output, is always one-phase. The online-/double-converter technology guarantees the highest levels of reliability and performance. This standard product is designed as a highly intelligent module construction with a rack-type design. One module of the AEG USV PROTECT 1.040 corresponds to an UPS with full functions. Depending on the requirements for output power and serviceability, the user can increase or reduce the number of modules in the AEG UPS PROTECT 1.M to achieve an optimum price/ performance ratio.

important loads such as small data centres, servers, network components, telecommunication facilities and the like.

Module for UPS

communikation

& LCD display

Connection terminals

Fig.: Diagram in principle of the PROTECT 1.M

L2 L3

UPS INPUT

PROTECT

UPS module

PROTECT

UPS module

PROTECT

UPS module

Battery system

1.040

UPS OUTPUT

The PROTECT 1.M has been designed for operating up to six UPS modules. Depending on the output power required, the unit is operated in normal mode with between one and six modules installed. These modules can easily be installed, removed or replaced under a very wide range of operating conditions.

PROTECT 1.M uses a high-performance communication module to collect information from the individual UPS modules via the internal network within the unit and displays this information on an LC display. This greatly facilitates operation of the UPS.

PROTECT 1.M protects your systems against numerous power supply problems such as mains failures, voltage and frequency fluctuations, under and overvoltage, voltage distortions, voltage harmonics, etc.

SBS

PFC

Input

Fig.: Component diagram of an individual PROTECT 1.040 UPS module

Filter

Battery

charger

Rectifier

Battery system

Inverter

DC/DC Booster

Control logic

(external)

Mains

filter

DSP

Output

The UPS is connected between the public utility mains and the loads to be protected.

The power sections of the UPS module rectifier convert the mains voltage to DC voltage for supplying the inverters. The circuit technology used (PFC) enables sinusoidal current consumption and therefore operation with little system

disturbance. Separate battery chargers configured with switch mode power supply technology are responsible for charging or trickle-charging the battery connected in the intermediate circuit. The configuration of these charging rectifiers means the harmonic content of the charging current for the battery is almost zero, which increases the service life of the battery even more. The inverters are responsible for converting the DC voltage into a sinusoidal output voltage. A microprocessordriven control based on a pulse-width modulation (PWM) integrated in each UPS module guarantees, in conjunction with digital signal processor technology and extremely fast pulsating IGBT power semiconductors of the inverters, a voltage system of the highest quality and availability on the secured busbar.

In the event of mains faults (e.g. current failures), the voltage continues to be supplied from the inverters to the load without any interruption. From this point onwards, the inverters draws their power from the battery instead of the rectifiers. Since no switching operations are necessary, there is no interruption in the supply to the load.

The greatest possible supply reliability of connected loads is attained by the parallel connection of up to max. six PROTECT

1.040 UPS modules. The n+x technology thus guarantees maximum reliability through up multiple active redundancy on the one hand as well as on the other hand the possibility of increased power with simple redundancy or even only higher UPS power without any redundancy.

The automatic electronic bypass serves to increase the reliability of the supply further. It switches the public mains directly through to the load without any interruption, e.g. when there is a system overload. As a result, the automatic bypass represents an extra passive redundancy for the load.

An integrated, manually operated bypass unit ensures an uninterrupted supply to the connected loads in the case of maintenance and/or service work. The internal electronic part (with the exception of the metal-clad manual bypass) can be disconnected via the mains input miniature circuit breakers.

Load

Number of UPS modules

4 kV

12 kV

16 kV

20 kV

24 kV

module

redundancy

---

modules

n+1

(4 kVA)

redundancy

- --

modules

n+2

(8 kVA)

n+1

(4 kVA)

redundancy

- - -

modules

n+3

(12 kVA)

n+2

(8 kVA)

n+1

(4 kVA)

redundancy

- - -

modules

n+4

(16 kVA)

n+3

(12 kVA)

n+2

(8 kVA)

n+1

(4 kVA)

redundancy

---

Fig.: Table showing the level of redundancy depending on the installed

modules and available output power

modules

n+5

(20 kVA)

n+4

(16 kVA)

n+3

(12 kVA)

n+2

(8 kVA)

n+1

(4 kVA)

redundancy

2.2 Technical Data

Type rating

PROTECT 1.M (system) max. 24 kVA (cos ϕ = 0.7 lag.)

PROTECT 1.040 (module) 4000 VA (cos ϕ = 0.7 lag.)

UPS input 3ph~ or 1ph~ / N / PE

Rated connection voltage 400 V / 230 Vac (3ph~) or

Voltage range without 277 Vac – 520 Vac ±3% battery operation (Rectifier 3ph~)

160 Vac – 300 Vac ±3% (Rectifier 1ph~)

16800 W

2800 W

230 V (1ph~)

176 VAC – 264 VAC ±3% (Bypass)

Frequency 50 Hz / 60 Hz

(Automatic detection) Frequency tolerance range ±4 Hz Current consumption at full load (max.) PROTECT 1.M (system) 44 A (3ph~) or 132 A (1ph~) / 155

A (Bypass) PROTECT 1.040 (module) 7.3 A (3ph~) or 22 A (1ph~) System disturbance factor λ ≥ 0.98

UPS output

Nominal voltage output 220 / 230 / 240 Vac ±2%

(configuration via "CompuWatch"

software) Nominal frequency 50 Hz / 60 Hz ±0.2 Hz (dependent

on mains frequency) Type of voltage Sine, distortion

< 3% THD (linear load) < 6% THD (non-linear load)

Crest factor 3:1 Overload behaviour Up to 105% continuous;

with mains supply > 105% – < 130% for 30s 130% for 2

Following this, automatic,

uninterrupted switchover to

integrated bypass (SBS).

Switch-off after 1 min. if overload

continues to be present (switch

back if overload decreases = load

< 90%) Overload behaviour with Up to 105% continuous;

battery operation > 105% – < 130% for 30s 130% for 2

Short-circuit behaviour 3 x I

for 100 ms

Battery

Nominal DC voltage (intermediate circuit) 120 Vdc DC window 102 Vdc – 160 Vdc ±1% Trickle charge voltage

137 Vdc ±1%

Battery charging current (max.) 3.5 Adc per UPS module

Communication

Interfaces RS232 (Sub-D9) RS485 (Sub-D9 / RJ45)

Additionally: Communication slot for optional expansion cards (e.g. AS/400 / SNMP, etc.)

Shutdown software on CD "CompuWatch" for all common

operating systems, e.g. Windows, Linux, Mac, Unix, FreeBSD, Novell, Sun

General data

Classification VFI SS 111 acc. to IEC 62040–3

double-conversion technology Total efficiency AC-AC PROTECT 1.M (system) > 88% PROTECT 1.040 (module) > 89%

Inherent noise (1m distance) PROTECT 1.M (system) < 62 dB(A) PROTECT 1.040 (module) < 55 dB(A) Cooling type Forced air cooling through

variable-speed fans Operating temperature range 0 °C to +40 °C Battery systems

(recommended):

+15°C to +25°C Storage temperature range 0°C to +40°C Relative humidity 20% – 90%

Site altitude Up to 1000 m at nominal output

Use more than 1000 m above sea level results in the following reduction in output power:

Housing colour Blackline

Weight: PROTECT 1.M (chassis) 75 kg PROTECT 1.040 (module) 15 kg per module

Dimensions W x H x D: PROTECT 1.M (chassis) 442 mm x 965 mm x 700 mm PROTECT 1.040 (module) 405 mm x 87 mm x 530 mm

Directives

The PROTECT 1.M meets the product standard EN 50091. The CE mark on the unit confirms compliance with the EC

outline directives for 73/23 EEC – Low voltage and for 89/336 EEC – Electromagnetic compatibility if the installation instructions described in the operating instructions are observed.

For 73/23 EEC low-voltage directive reference number EN 62040-1-1 : 2003

For 89/336 EMC directive reference number EN 50091-2 : 1995

EN 61000-3-2 : 1995 EN 61000-3-3 : 1995

Height (m) 1000 1500 2000 2500 3000

Power 100% 95% 90% 85% 80%

Warning:

This is a class A generate radio interference in the domestic environment. In this case, the user can be required to employ additional interference suppression measures.

- device. This product can

3 Safety Regulations

3.1 Important Instructions and Explanations

The instructions for operation and maintenance as well as the following safety regulations must be complied with to ensure the safety of personnel as well as to ensure the continued availability of the unit. All personnel installing/dismantling, starting up, operating or servicing the units must be familiar with and observe these safety regulations. Only trained and qualified personnel may perform the work described, using tools, equipment, test equipment and materials intended for the purpose and in perfect working condition.

Important instructions are emphasised by the words

"Caution", "Attention", "Note" and indented text.

Caution

This symbol identifies all working and operational procedures requiring absolute compliance to avoid any danger to persons.

Attention

This symbol identifies all working and operational procedures requiring absolute compliance to prevent any damage, irreparable or otherwise, to the unit and its components.

Note

This symbol identifies technical requirements and additional information requiring the operator's attention.

3.2 Accident Prevention Regulations

Compliance with the accident prevention regulations valid in the respective country of use and the general safety regulations in accordance with IEC 364 is mandatory. The following safety rules must be observed prior to performing any work on the PROTECT 1.M:

♦ Disconnect the unit from the power supply ♦ Secure the unit against being switched back on ♦ Verify that the unit is disconnected from the power

supply

♦ Earth and short-circuit the unit ♦ Provide protection by covers or barriers for any

neighbouring live parts

3.3 Qualified Personnel

The PROTECT 1.M may only be transported, installed, connected and serviced by qualified personnel who are familiar with the pertinent safety and installation regulations. All work performed must be inspected by responsible qualified personnel.

The qualified personnel must be authorised by the responsible safety officer of the installation to perform the work required.

Qualified personnel is defined as personnel

♦ having completed training and gained experience in the

respective field,

♦ familiar with the pertinent standards, rules and

regulations and accident prevention regulations,

♦ having received instruction on the mode of operation

and operating conditions of the PROTECT 1.M,

♦ capable of recognising and preventing dangers.

Regulations and definitions for qualified personnel can be found in DIN 57105/VDE 0105, Part 1.

3.4 Safety Instructions for PROTECT 1.M

The UPS is live, and the voltage can be dangerous. The unit may only be installed and

if necessary opened by trained and qualified personnel. Repairs may only be carried out by

qualified customer service staff!

The output can be live, even when the UPS is not connected to the mains supply!

For health and safety reasons, the unit must be earthed correctly!

The PROTECT 1.M may only be operated with or connected to three-phase or AC voltage power systems with protective grounding using a mains connection cable with PE conductor that has been tested according to German standards (VDE).

Risk of burning!

The battery has powerful short-circuit currents. Incorrect connection or isolation faults can lead to melting of the plug connections, sparking potential and severe burns!

The unit has a warning signal that sounds when the battery voltage of PROTECT 1.M is exhausted or when the UPS is not working in its normal mode (see also chapter 6.1 "Signalling", page 47ff and the following).

Observe the following safety instructions to ensure permanent operational safety of and safe work with the UPS and the battery modules (special accessories):

♦ Do not dismantle the UPS!

(The UPS does not contain any parts that require regular maintenance. Bear in mind that the warranty will be invalidated if the unit is opened!)

♦ Do not install the unit in direct sunshine or in close

proximity of heaters!

♦ The unit is designed to be installed inside in heated

rooms. Never install the housing in the vicinity of water or in an excessively damp environment!

♦ Condensation may occur if the UPS is brought from a cold

environment into the room where it is to be installed. The

UPS must be absolutely dry prior to start-up. As a result, leave it to acclimatise for at least two hours.

♦ Never connect the mains input and the UPS output! ♦ Ensure that no fluids or foreign bodies can penetrate the

housing!

♦ Do not block the air vents of the unit! Make sure, for

example, that children do not insert any objects in the ventilation openings!

♦ Do not connect household appliances such as hairdryers

to the UPS! Also take care when working with motor loads. It is essential to avoid back-feeding the inverter, e.g. if the load is intermittently operated in regenerative mode.

Danger! Electric shocks!

Even after the mains voltage has been disconnected, the components within the UPS remain connected to the battery and can thus cause electric shocks. It is therefore imperative to disconnect the battery circuit before carrying out any maintenance or repair work!

If it is necessary to replace the battery or carry out maintenance work, this must be done by or under the supervision of a specialist familiar with batteries and the necessary safety precautions!

Only authorised persons are allowed in the vicinity of the batteries!

When replacing the batteries, the following must be observed: Only ever use identical, maintenance-free sealed lead batteries with the same data as the original batteries.

Danger! Explosive!

Never throw batteries into open fire. Never open or damage batteries. (Electrolyte

may leak out and damage skin and eyes. It may be toxic!)

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