Elgar 2400A-104 User Manual

GLOBAL

UNINTERRUPTIBLE

POWER SUPPLY

Model GUPS 2400A–104

Operation Manual

ELGAR ELECTRONICS CORPORATION

9250 Brown Deer Road
San Diego, CA 92121-2294
1-800-73ELGAR (1-800-733-5427)
Tel: [phone]
Fax: [phone]
Email: [e-mail]
www.elgar.com

©2004 by Elgar Electronics Corporation
This document contains information proprietary to Elgar Electronics Corporation. The information contained herein is
not to be duplicated or transferred in any manner without prior written permission from Elgar Electronics Corporation.

January 23, 2004 Document No. M152332-01 Rev B

.

ELGAR ONE–YEAR WARRANTY

Elgar Electronics Corporation (hereinafter referred to as Elgar) warrants its products to be free from defects in
material and workmanship. This warranty is effective for one year from the date of shipment of the product to
the original purchaser. Liability of Elgar under this warranty shall exist provided that:

• the Buyer exposes the product to normal use and service and provides normal maintenance on the

product;

• Elgar is promptly notified of defects by the Buyer and that notification occurs within the warranty period;

• the Buyer receives a Return Material Authorization (RMA) number from Elgar’s Repair Department prior to

the return of the product to Elgar for repair, phone 800-73-ELGAR (800-733-5427), ext. 2295;

• the Buyer returns the defective product in the original, or equivalent, shipping container;

• if, upon examination of such product by Elgar it is disclosed that, in fact, a defect in materials and/or

workmanship does exist, that the defect in the product was not caused by improper conditions, misuse,
or negligence; and,

• that Elgar QA seal and nameplates have not been altered or removed and the equipment has not been

repaired or modified by anyone other than Elgar authorized personnel.

This warranty is exclusive and in lieu of all other warranties, expressed or implied, including, but not limited
to, implied warranties of merchantability and fitness of the product to a particular purpose. Elgar, its agents,
or representatives shall in no circumstance be liable for any direct, indirect, special, penal, or consequential
loss or damage of any nature resulting from the malfunction of the product. Remedies under this warranty
are expressly limited to repair or replacement of the product.

CONDITIONS OF WARRANTY

• To return a defective product, contact an Elgar representative or the Elgar factory for an RMA number.

Unauthorized returns will not be accepted and will be returned at the shipper’s expense.

• For Elgar products found to be defective within thirty days of receipt by the original purchaser, Elgar will

absorb all ground freight charges for the repair. Products found defective within the warranty period, but
beyond the initial thirty-day period, should be returned prepaid to Elgar for repair. Elgar will repair the unit
and return it by ground freight pre-paid.

• Normal warranty service is performed at Elgar during the weekday hours of 7:30 am to 4:30 pm Pacific

time. Warranty repair work requested to be accomplished outside of normal working hours will be subject to
Elgar non-warranty service rates.

• Warranty field service is available on an emergency basis. Travel expenses (travel time, per diem expense,

and related air fare) are the responsibility of the Buyer. A Buyer purchase order is required by Elgar prior to
scheduling.

• A returned product found, upon inspection by Elgar, to be in specification is subject to an inspection fee and

applicable freight charges.

• Equipment purchased in the United States carries only a United States warranty for which repair must be

accomplished at the Elgar factory.

Committed to Quality...Striving for Excellence

iii

SAFETY NOTICE

Before applying power to the system, verify that the GUPS 2400A–104 is configured properly for the user’s
particular application.

WARNING
Hazardous voltages in excess of 232 VRMS, 328V peak may be present

when covers are removed. Qualified personnel must use extreme caution
when servicing this equipment. Circuit boards, test points, and output
voltages also may be floating above (below) chassis ground.

Installation and servicing must be performed by qualified personnel who are aware of dealing properly with
attendant hazards. This includes such simple tasks as fuse verification.

Ensure that the AC power line ground is connected properly to the GUPS 2400A–104 input connector
or chassis. Similarly, other power ground lines including those to application and maintenance equipment

be grounded properly for both personnel and equipment safety.

must
Always ensure that facility AC input power is de-energized prior to connecting or disconnecting the power

cables. Similarly, the GUPS 2400A–104 circuit breaker must be switched off prior to connecting or
disconnecting output power.

In normal operation, the operator does not have access to hazardous voltages within the chassis. However,
depending on the user’s application configuration, HIGH VOLTAGES HAZARDOUS TO HUMAN SAFETY
may be generated normally on the output terminals. The customer/user must ensure that the output power
lines are labeled properly as to the safety hazards and that any inadvertent contact with hazardous voltages
is eliminated.

Guard against risks of electrical shock during open cover checks by not touching any portion of the electrical
circuits. Even when power is off, capacitors may retain an electrical charge. Use safety glasses during open
cover checks to avoid personal injury by any sudden component failure.

Always disconnect the AC input power and allow three minutes, minimum, before performing any internal
servicing.

Neither Elgar Electronics Corporation, San Diego, California, USA, nor any of the subsidiary sales
organizations can accept any responsibility for personnel, material or consequential injury, loss or damage
that results from improper use of the equipment and accessories.

SAFETY SYMBOLS

CAUTION
Risk of Electrica l Shock

Off (Suppl y )

Standby (Supply)

On (Supply)

CAUTION
Refer to Accompanying Documents

Direct Current (DC)

Alternating

Three–Phase

Curre n t (AC)

Alterna ti ng Current

iv

Protective Conductor Terminal

Fuse

Earth (G round) Ter m inal

Chassis Ground

CONTENTS

SECTION 1 OVERVIEW AND SPECIFICATIONS................................1-1

1.1 Introduction...................................................................................................... 1-1

1.2 General Description......................................................................................... 1-1

1.3 Specifications...................................................................................................1-1

SECTION 2 INSTALLATION ..............................................................2-1

2.1 Introduction...................................................................................................... 2-1

2.2 Unpacking and Inspection ...............................................................................2-1

2.3 Installation........................................................................................................2-2

2.4 Air Intake and Exhaust.....................................................................................2-2

2.5 Input/Output Connectors .................................................................................2-2

2.6 Wire Gauge Selection......................................................................................2-6

SECTION 3 OPERATION....................................................................3-1

3.1 Introduction...................................................................................................... 3-1

3.2 Control and Indicator Panel.............................................................................3-1

3.2.1 Indicators.............................................................................................3-1

3.2.2 Pushbutton Switches...........................................................................3-2

3.3 Circuit Breakers...............................................................................................3-3

3.4 Audible Alarm .................................................................................................. 3-3

3.5 Control Signals ................................................................................................ 3-3

3.6 Connectors ...................................................................................................... 3-4

3.7 Start-Up and Shutdown Sequences ................................................................ 3-5

3.8 Battery Operation.............................................................................................3-5

3.8.1 Battery Care and Handling ..................................................................3-6

GUPS 2400A–104 Operation Manual v

Contents

3.9 RS-232 Data Communications Port.................................................................3-7

3.9.1 Hardware Interface...............................................................................3-7

3.9.2 Software Interface................................................................................3-7

3.9.3 RS-232 Protocol...................................................................................3-8

3.9.4 Test Data Request Commands............................................................3-8

3.9.5 Elgar Terminal Interface (ETI) Data Request Commands....................3-10

3.9.6 Status Words......................................................................................3-11

3.9.7 AC Line Loss Signal...........................................................................3-16

SECTION 4 MAINTENANCE.............................................................. 4-1

4.1 Introduction ......................................................................................................4-1

4.2 Service Information..........................................................................................4-1

4.3 Spare and Repair Parts....................................................................................4-1

4.4 Periodic Maintenance.......................................................................................4-1

4.5 Troubleshooting ...............................................................................................4-2

LIST OF FIGURES

Figure 2–1. GUPS 2400A–104 (Front View)............................................................... 2-3

Figure 2–2. GUPS 2400A–104 (Rear View)............................................................... 2-4

Figure 2–3. GUPS 2400A–104 Dimensions (Top, Side, and Front Views)................. 2-5

Figure 3–1. GUPS 2400A–104 Control and Indicator Panel....................................... 3-2

LIST OF TABLES

Table 2–1. GUPS 2400A–104 Input/Output Connectors............................................ 2-2

Table 2–2. Recommended Wire Gauge Selection Guide........................................... 2-6

Table 3–1. GUPS 2400A–104 Connector Pin Assignments.......................................3-4

Table 3–2. Battery Storage Times.............................................................................. 3-6

Table 3–3. RS-232 Connector Pin-Out....................................................................... 3-7

Table 3–4. RS-232 Communications Port Protocol.................................................... 3-8

Table 3–5. Status Word 1 Data Format....................................................................3-11

Table 3–6. Status Word 2 Data Format....................................................................3-14

Table 4–1. GUPS 2400A-104 Troubleshooting Guide................................................ 4-2

vi GUPS 2400A–104 Operation Manual

SECTION 1

OVERVIEW AND SPECIFICATIONS

1.1 Introduction

The Elgar Model GUPS 2400A-104 is a 2400 VA Global Uninterruptible Power Supply (GUPS)
that provides regulated 115 VRMS, 60 Hz output power at up to 20.9 Amps RMS load current.
The GUPS 2400A-104 accepts 3-phase AC input line voltages from 159V to 232V at
frequencies from 370 Hz to 430 Hz. A battery backup of five minutes at 2400 VA output is
provided by a removable battery pack. Output power is continuous when transferring from AC to
battery or battery to AC.

1.2

The GUPS 2400A-104 is contained in a rack-mount enclosure. All input and output connections
are made at the rear panel. Cooling air is drawn in through a filter on the front panel and
exhausted out the rear panel. Operational and input/output power status is indicated by front
panel LEDs. An AC input circuit breaker and control pushbutton switches also are located on
the front panel. There are no operator adjustments.

General Description

1.3 Specifications

(Specifications Subject to Change Without Notice)

AC Input Voltage: 115/200V, 3-phase, 3-wire plus ground, neutral not used;

159V to 232V, line voltage;
92V to 134V, phase voltage

AC Input Current: 9.8A, maximum at 200V, 2400VA/1920W load, fully charged battery;

12.5A, maximum at 159V, 2400VA/1920W load, charging battery

AC Input Frequency: 370Hz to 430Hz

Batteries: 192VDC, sealed, maintenance-free, lead-acid

Battery Hold-Up Time: 5 minutes with a 2400VA/1920W load at 25°C

GUPS 2400A–104 Operation Manual 1-1

Overview and Specifications

Battery Recharge Time: 4 hours to 90% full charge following discharge

at 2400VA/1920W and 25°C

Output Voltage: 115V, ±2%

Output Frequency:

Output Current: 20.9A(RMS)

Output Distortion: 2% THD, maximum with linear load

Output Power: 1920W with resistive load;

Efficiency: 77%

AC to Battery Crossover: 159V, maximum low-line voltage;

Battery to AC Crossover: 169V, maximum low-line voltage;

AC Input Voltage Unbalance: 7V (RMS) maximum difference in line voltages

Temperature: 0°C to 40°C (32°F to 104°F), operating;

Humidity: 5% to 95% non-condensing, operating

Altitude: 0 to 10,000ft, operating;

0 to 40,000ft, 2000ft/min, maximum, non-operating

Dimensions: 7"H x 19"W x 25.1"D,

Weight: 75lb (34kg), UPS enclosure;

48lb (22kg) battery module;
123lb (56kg) total weight

60Hz, ±0.1%

2400VA/1920W with a reactive load or a non-linear load

232V, minimum high-line voltage

232V, minimum high-line voltage

-40°C to 65°C (-40°F to 149°F), non-operating

excluding protrusion of handles, controls, and connectors;
fits standard RETMA rack

1-2 GUPS 2400A–104 Operation Manual

SECTION 2

INSTALLATION

2.1 Introduction

The Elgar Model GUPS 2400A–104 has been aligned, calibrated, and tested prior to shipment.
The instrument is ready for immediate use upon receipt. However, the following checks should
be made to ensure that the instrument was not damaged during shipment.

CAUTION!

The GUPS 2400A–104 weighs 75 pounds (34 kg) without the
battery pack. The battery pack adds an additional 48 pounds
(22 kg). A minimum two–person lift is required!

WARNING!
Hazardous voltages are present when operating this equipment.

Please read the SAFETY NOTICE on page iv prior to installation,
operation, or maintenance.

2.2 Unpacking and Inspection

Perform a visual inspection of the shipping container prior to accepting the package from the
carrier. If extensive damage is evident, a description of the damage should be noted on the
carrier's receipt and signed by the driver of the carrier agent.

If damage is not apparent until the instrument is unpacked, a claim for concealed damage
should be placed with the carrier. Check for shipping damage such as dents, scratches,
distortion, and damaged connectors. If the instrument or container(s) show signs of rough
handling, remove the covers from the instrument to ensure that the circuit boards are securely in
place and that no loose or broken components are evident.

In addition, the shipping container(s) and filler material should be saved for inspection. Forward
a report of damage to the Elgar Service Department. Elgar will provide instructions for repair or
replacement of the instrument.

GUPS 2400A–104 Operation Manual 2-1

Installation

When returning the instrument to Elgar, suitable shipping containers and packing material must
be used. If the instrument needs to be shipped and proper packing material is not available,
contact Elgar to provide containers and shipping instructions.

2.3

The Model GUPS 2400A–104 is 7" (178 mm) high and is designed to be installed in a standard
19" (483 mm) wide cabinet enclosure or a transit case.

Refer to Figure 2–1 through Figure 2–3 for information on outline and mounting dimensions.

2.4

The air intake is located on the front panel of the instrument and the exhaust is through the rear
panel. Care must be taken not to block the air intake and exhaust. No special vertical
separation is required when stacking instruments. However, a 1¾" (44.5 mm) vertical spacer
above and below the instrument may improve cooling.

Installation

Air Intake and Exhaust

CAUTION!

Avoid blocking the instrument air intakes or exhaust.

2.5 Input/Output Connectors

Table 2–1 provides a listing of the GUPS 2400A–104 input and output connectors.

J1: AC Input Connector

Panel Connector

Mating Connector

J2– J7: AC Output Connectors

Panel Connector PT02CE-12-3SY

Mating Connector PT06CE-12-3PY (SR)

J8: Data/Alarm Port Connector

Panel Connector PT02CE-12-8S

Mating Connector PT06CE-12-8P (SR)

Table 2–1. GUPS 2400A–104 Input/Output Connectors

PT02CE-14-5P
PT06CE-14-5S (SR)

2-2 GUPS 2400A–104 Operation Manual

Installation

S

)

O

O

O

(4.000)

(1.485

DULE

VABLE BATTERY M

WARNING

REM

INACTIVE STOR AGE OF 30 DAYS O R M ORE

REMOVE BATTERIES BEFORE SHIPMENT OR

BATTERY MODULE

VABLE AIR FILTER

(19.00)

(INTAKE)

REM

PLAY PANEL
DI

ON

TEST

OUTPUT

AC INPUT

BATT

ON

GLOBAL UPS

GUPS 2400A-104

BATT

-AB -AC -BC

ALARM

SILENCE

LOAD

TEMP

TEST

AC INPUT

PUSHON/PULL OFF

AC INPUT CIRCUIT BRKR

4 x .50

4 x .25

(6.968)

4X HANDLE

Figure 2–1. GUPS 2400A–104 (Front View)

GUPS 2400A–104 Operation Manual 2-3