Emerson NXr, Liebert NXr User Manual

Download

Liebert NXLiebert NXr

8VHU0DQXDO

Modular NXr UPS 30kVA ~ 200kVA (parallelable to 800kVA)

User Manual

Version V1.2 ENPAu Revision date 2011 0401 (ENPAu 2011 1108) BOM 31012244

Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China

Homepage: www.emersonnetworkpower.com.cn

E-mail: support@emersonnetwork.com.cn

Safety Precaution

This manual covers the installation and use of Emerson NXr UPS.

Please read this manual before installation.

The NXr UPS must be commissioned and maintained by the engineers designated by the manufacturer or its agent. Failure to observe this could result in personnel safety risk, equipment malfunction and invalidation of warranty.

The NXr UPS is only used for commercial or industrial purpose and cannot be used as life support equipment.

This is a C2 type UPS product. In a domestic environment, this product may cause radio frequency interference, in which case, the user may be required to take additional measures.

Conformity and standards

This product complies with CE 2006/95/EC (low voltage safety) and 2004/108/EC (EMC), EMC standards of Australia and New Zealand (C-Tick), and the following UPS product standards: * IEC62040-1-1-General and safety requirements for use in operator access area * IEC/EN62040-2 EMC requirements CLASS C2 * IEC62040-3 Performance requirements and test methods For more details, refer toChapter 8 Product Specifications. Continued compliance requires installation in accordance with these instructions and the use of manufacturer approved accessories only.

Warning: high earth leakage current

Earth connection is critical before connecting the input supply (including both mains supply and battery). Earth leakage current exceeds 3.5mA and is less than 1000 mA. Transient and steady state earth leakage currents, which may occur when the equipment is started, should be taken into account in the selection of instantaneous residual current circuit breakers (RCCBs or residual current detector (RCD devices. Note also that the earth leakage currents of the load will be carried by the RCCBs or RCDs. The equipment must be earthed in accordance with the local electrical authority codes of practices.

Warning: backfeeding protection

This UPS is fitted with a voltage-free contact closure signal for use with an external automatic disconnect device (supplied by others), to protect against backfeeding voltage into the incoming termninal through the static bypass circuit. If this signal is not used by the installer, a label must be added at the external incoming bypass supply disconnect device to warn service personnel that the circuit is connected to a UPS. The text has the following meaning or is equivalent to: Isolate the UPS before working on this circuit.

User serviceable components

All the equipment maintenance and servicing procedures involving internal access need special tools and should be carried out only by trained personnel. The components that can only be accessed by opening the protective cover with tools cannot be maintained by the user. This UPS fully complies with the general and safety requirements for use in operator access area. Dangerous voltages are present within the UPS and battery enclosure but out of reach of non-service personnel. Contact of these voltages is minimized, because live parts are housed behind protective covers that require a tool for their removal. No risk exists if you operate the equipment in the normal manner, following the recommended operating procedures in this manual.

Battery voltage higher than 400Vdc

All the battery physical maintenance and servicing procedures need special tools or keys and should be carried out only by trained personnel. Take special care when working with the batteries associated with this UPS. When the batteries are connected together, the battery terminal voltage exceeds 400vdc and is potentially leathal. Battery manufacturers supply details of the necessary precautions to be observed in working on, or in the vicinity of, a large bank of battery cells. These precautions should be followed implicitly at all times. Particular attention should be paid to the recommendations concerning local environmental conditions and the provision of protective clothing, first aid and fire-fighting facilities.

Contents

Chapter 1 Installation Of single UPS cubicle ....................................................................................................................... 1

1.1 Brief Introduction ................................................................................................................................................... 1

1.2 Initial Check .......................................................................................................................................................... 1

1.3 Location Selection ................................................................................................................................................. 2

1.3.1 UPS Room ................................................................................................................................................. 2

1.3.2 External Battery Room............................................................................................................................... 2

1.3.3 Storage ...................................................................................................................................................... 2

1.4 Positioning ............................................................................................................................................................ 3

1.4.1 System Cabinet ......................................................................................................................................... 3

1.4.2 Moving Cabinet .......................................................................................................................................... 3

1.4.3 Clearance .................................................................................................................................................. 3

1.4.4 Front Access .............................................................................................................................................. 3

1.4.5 Final Positioning And Fixing ...................................................................................................................... 3

1.4.6 Cable Entry ................................................................................................................................................ 5

1.5 External protective device ..................................................................................................................................... 5

1.5.1 Rectifier And Bypass Input ........................................................................................................................ 6

1.5.2 External Battery Circuit Breaker ................................................................................................................ 6

1.5.3 UPS Output ............................................................................................................................................... 6

1.6 Power Cables ....................................................................................................................................................... 6

1.6.1 Maximum Steady State AC And DC Currents Maximum steady state AC and DC currents ................... 6

1.6.2 Distance From Floor To Connection Point On The Equipment .................................................................. 7

1.6.3 Cable Connection ...................................................................................................................................... 7

1.7 Control Cables And Communication ................................................................................................................... 12

1.7.1 Input Dry Contact Port: Battery Environment (ventilation), Ground fault, Temperature ........................... 12

1.7.2 Battery Circuit-Breaker (BCB) Port .......................................................................................................... 13

1.7.3 Maintenance Switch And Output Switch State Port ................................................................................. 13

1.7.4 Backfeed protection Output Dry Contact Port .......................................................................................... 14

1.7.5 Remote Emergency Power Off (REPO) Input Port .................................................................................. 14

1.7.6 Relay and Network Interface Card ports, Service ports, .......................................................................... 15

Chapter 2 Battery .............................................................................................................................................................. 16

2.1 Brief Introduction ................................................................................................................................................. 16

2.2 Safety .................................................................................................................................................................. 17

2.3 Battery Power Cable ........................................................................................................................................... 18

2.3.1 Overview .................................................................................................................................................. 18

2.3.2 Battery Installation ................................................................................................................................... 18

2.3.3 Battery Connection .................................................................................................................................. 18

2.4 Battery Maintenance ........................................................................................................................................... 19

2.5 Battery Recycling ................................................................................................................................................ 20



2.6 Connection Of External Battery Circuit-Breaker (BCB ........................................................................................ 20

Chapter 3 Installation Of Multiple UPS cubicles ................................................................................................................ 22

3.1 Overview ............................................................................................................................................................. 22

3.2 1 + N Parallel System ......................................................................................................................................... 22

3.2.1 Cabinet Installation .................................................................................................................................. 23

3.2.2 External protective device ........................................................................................................................ 24

3.2.3 Power Cable ............................................................................................................................................ 24

3.2.4 Auxiliary Control Wiring ........................................................................................................................... 25

3.2.5 Parallel Control Cables ............................................................................................................................ 25

3.3 Dual Bus System ................................................................................................................................................ 26

3.3.1 Cabinet Installation .................................................................................................................................. 26

3.3.2 External protective device ........................................................................................................................ 26

3.3.3 Power Cable ............................................................................................................................................ 26

3.3.4 Control Cable ........................................................................................................................................... 26

Chapter 4 System Description........................................................................................................................................... 28

4.1 Brief Introduction ................................................................................................................................................. 28

4.1.1 Operating Theory ..................................................................................................................................... 28

4.1.2 Static (bypass) Transfer Switch ............................................................................................................... 28

4.2 1 + N Parallel System ......................................................................................................................................... 29

4.2.1 Parallel System Features ......................................................................................................................... 29

4.2.2 Requirements For Paralleling Of UPS Modules ....................................................................................... 29

4.3 Operation Mode .................................................................................................................................................. 29

4.3.1 Normal Mode ........................................................................................................................................... 30

4.3.2 Battery Mode ........................................................................................................................................... 30

4.3.3 Automatic Restart Mode .......................................................................................................................... 30

4.3.4 Bypass Mode ........................................................................................................................................... 30

4.3.5 Maintenance Mode (Manual Bypass) ...................................................................................................... 30

4.3.6 Parallel Redundancy Mode (System Expansion) ..................................................................................... 30

4.4 Battery Management (Set During Commissioning) ............................................................................................. 30

4.4.1 Normal Function ...................................................................................................................................... 30

4.4.2 Advanced Function .................................................................................................................................. 31

4.5 Battery Protection (Set By Commissioning Engineer) ......................................................................................... 31

Chapter 5 Operator Control And Display Panel ................................................................................................................. 32

5.1 Introduction ......................................................................................................................................................... 32

5.1.1 Indicators ................................................................................................................................................. 32

5.1.2 Audible Alarm (Buzzer) ............................................................................................................................ 33

5.1.3 Control Keys ............................................................................................................................................ 33

5.1.4 LCD And Menu Keys ............................................................................................................................... 33

5.2 LCD Screen Type ............................................................................................................................................... 34

5.2.1 Start Screen ............................................................................................................................................. 34

5.2.2 Primary Screen ........................................................................................................................................ 34

5.2.3 Default Screen ......................................................................................................................................... 35

5.3 Selecting Language ............................................................................................................................................ 35

5.4 Changing The Current Date And Time ................................................................................................................ 35

5.5 Control Password ................................................................................................................................................ 35

5.6 Detailed Description Of Menu Items ................................................................................................................... 35

5.7 Prompt Window ................................................................................................................................................... 37

5.8 Alarm List ............................................................................................................................................................ 38

Chapter 6 Operating Instructions ...................................................................................................................................... 41

6.1 Power Switches .................................................................................................................................................. 41

6.2 UPS Startup Procedures ..................................................................................................................................... 42

6.2.1 Procedures For Startup Into Normal Mode .............................................................................................. 43

6.2.2 Procedures For Startup In Battery Mode (Startup Without A.C. Input Supply) ........................................ 43

6.3 Procedures For Transfer Between Operation Modes .......................................................................................... 44

6.3.1 Transfer From Normal Mode To Battery Mode ........................................................................................ 44

6.3.2 Transfer From Normal Mode To Bypass Mode ........................................................................................ 44

6.3.3 Transfer From Bypass Mode To Normal Mode ........................................................................................ 44

6.3.4 Transfer From Normal Mode To Maintenance Mode ............................................................................... 44

6.4 Procedures For Completely Powering Down The UPS ....................................................................................... 45

6.5 Procedures For Completely Powering Down The UPS While Maintaining he Power Supply To The Load ........ 45

6.6 Isolation Procedures (Of One UPS In A Parallel System) ................................................................................... 45

6.7 Insertion Procedures (Of One UPS In A Parallel System) .................................................................................. 46

6.8 Emergency Power Off (EPO) Procedures ........................................................................................................... 46

6.9 Automatic Restart ............................................................................................................................................... 46

6.10 UPS Reset Procedures ..................................................................................................................................... 47

Chapter 7 Service ............................................................................................................................................................. 48

7.1 Service Procedures Of Power Module And Bypass Module ............................................................................... 48

7.1.1 Notes ....................................................................................................................................................... 48

7.1.2 Service Procedures Of Power Module ..................................................................................................... 48

7.1.3 Service Procedures Of Bypass Module ................................................................................................... 48

7.2 Replacement Procedures Of Air Filter ................................................................................................................ 49

Chapter 8 Product Specification.. ...................................................................................................................................... 51

8.1 Conformity And Standards .................................................................................................................................. 51

8.2 Environmental Characteristics ............................................................................................................................ 51

8.3 Mechanical Characteristics ................................................................................................................................. 51

8.4 Electrical Characteristics (Input Rectifier) ........................................................................................................... 52

8.5 Electrical Characteristics (Intermediate DC Circuit) ............................................................................................ 52

8.6 Electrical Characteristics (Inverter Output) ......................................................................................................... 53

8.7 Electrical Characteristics (Bypass Input) ............................................................................................................. 53

8.8 Efficiency, Heat Losses And Air Exchange ......................................................................................................... 54



Appendix 1 Option List ...................................................................................................................................................... 55

Appendix 2 List Of Abbreviations ...................................................................................................................................... 56

Chapter 1 Installation Of UPS Module 1

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 1 Installation Of single UPS cubicle

This chapter introduces the installation of Emerson NXr 30kVA ~ 200kVA UPS (hereinafter referred to as UPS) module, including the initial check, location selection, positioning, external protective device and cable connection.

1.1 Brief Introduction

This chapter briefs the relevant requirements that must be considered in the location selection and cabling of the UPS and relevant equipment.

Because each site has its particular characteristics, this chapter does not provide detailed installation steps, it only acts as a guide for the general procedures and practices that should be observed by the installing engineer, so that they can properly handle the specific situation of the site.

Warning: professional installation required

1. Do not apply electrical power to the UPS without permission of the commissioning engineer.

2. The UPS should be installed by a qualified engineer in accordance with the information contained in this manual. All the equipment not referred to in this manual is shipped with details of its own mechanical and electrical installation information.

Note: 3-phase 5-wire input power required

The standard UPS can be connected to TN, TT and IT AC distribution systems (IEC60364-3) of 3-phase 5-wire (A, B, C, N, PE).

Warning: battery hazards

1. Take special care when working with the batteries associated with the UPS. When the battery is connected, the battery terminal voltage exceeds 400Vdc and is potentially lethal.

2. Wear eye protection to prevent injury from accidental electrical arcs.

3. Remove rings, watches and all metal objects.

4. Use tools with insulated handles only.

5. Wear rubber gloves.

6. If a battery leaks electrolyte, or is otherwise physically damaged, it must be replaced, stored in a container resistant to sulfuric acid and disposed of in accordance with local regulations.

7. If electrolyte comes into contact with the skin, the affected area should be washed immediately with water.

1.2 Initial Check

Check the following items prior to UPS installation:

1. Visually examine if there is any damage inside and outside the UPS and battery due to transportation. Report any such damage to the shipper immediately.

2. Verify the UPS label and confirm the correctness of the UPS. The UPS label is attached on the back of the door. The UPS model, capacity and main parameters are marked on the label.

2 Chapter 1 Installation Of UPS Module

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1.3 Location Selection

1.3.1 UPS Room

The UPS is designed for indoor installation. It should be installed in a clean environment with adequate ventilation to keep the environmental parameters within the specified operating range (see Table 8-2). For example, the UPS should not be installed in an environment outside the specified operating range, like in thruway tunnels or outdoor places without air-conditioning.

The UPS uses forced cooling by internal fans. Cooling air enters the UPS through the ventilation grills at the front of the cabinet and exhausted through the ventilation grills in the rear of the cabinet. Do not obstruct the ventilation holes.

If necessary, install a system of extractor fans to aid cooling-air flow to avoid room temperature buildup. An air filter should be used when the UPS is to operate in a dirty environment.

Note

The UPS should be installed on a cement surface or other surface that is not combustible.

1.3.2 External Battery Room

Batteries generate some amount of hydrogen and oxygen at the end of charge, so the fresh air volume of the battery installation environment must meet the EN50272-2001 requirements.

The ambient temperature of the battery must be stable. Ambient temperature is a major factor in determining the battery capacity and life. The nominal operating temperature of the battery is 20°C. Operation above this temperature will reduce the battery life, and operation below this temperature will reduce the battery capacity. If the average operating temperature of the battery rises from 20ºC to 30ºC, the service life of the battery will be reduced by 50%. If the operating temperature of the battery is above 40ºC, the battery service life will be decreased in exponent rate. In a normal installation, the battery temperature is maintained between 15°C and 25°C. Keep batteries away from heat sources and ventilation holes.

If external battery is used, a battery protective device (for example, fuse or circuit breaker) shall be installed. The battery protective device shall be installed as close to the battery as possible, and the cabling distance between the battery protective device and the battery shall be minimized.

1.3.3 Storage

Should the UPS not be installed immediately, it must be stored in a room for protection against excessive humidity and heat sources (see Table 8-2). The battery needs to be stored in a dry and cool place with good ventilation. The most suitable storage temperature ranges from 20ºC to 25ºC.

Warning

During storage, periodically charge the battery according to the battery manufacturer instructions. In the charge process, temporarily connect the UPS to the mains and activate the battery for the time required for recharging the battery.

Chapter 1 Installation Of UPS Module 3

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1.4 Positioning

To prolong the service life, the place chosen should offer:

 convenient wiring

 space for easy operation on UPS

 sufficient air exchange to dispel heat produced by UPS

 protection against atmospheric agents

 protection against excessive humidity and heat sources

 protection against dust

 compliance with fire prevention requirements

 operating environment temperature between 20°C and 25°C (the typical temperature range for max. battery life)

The UPS is of steel frame structure wrapped by removable panels. The top and side panels are fixed by screws.

Opening the UPS door reveals the power terminals, auxiliary terminal block and power switch. The UPS has an operator control and display panel located on its front door, which provides the basic operating status and alarm information. The UPS provides air inlet in the front and air outlet at the back.

1.4.1 System Cabinet

Depending on the design requirement of each UPS system, a UPS system may include certain equipment cabinets, such as UPS cabinet, external battery cabinet, external bypass cabinet, and so on. All the cabinets should be installed side by side to achieve an aesthetic effect.

1.4.2 Moving Cabinet

Warning

1. The lifting equipment for moving the UPS cabinet shall have enough lifting capacity. For the UPS weight, refer to Table 8-3.

2. Ensure that adequate personnel and lifting aids are available when removing the shipping pallet.

Note

Take special care when moving the battery cabinet fitted with batteries, in which case, the moving distance shall be minimized.

The UPS can be moved by means of a fork lift or similar equipment.

1.4.3 Clearance

As the UPS has no ventilation grills at either side, no clearances are required for either side.

To enable routine tightening of the power terminations within the UPS, it is recommended that clearance around the front of the equipment should be sufficient to enable free passage of personnel with the door fully open. Meanwhile, maintain, for full 200kVA applications a rear clearance of at least 350mm to permit adequate circulation of air coming out of the UPS, and advisably more than 500mm to facilitate maintenance.

1.4.4 Front Access

The component layout of the UPS supports front access and top access for servicing, diagnosing and repairing the UPS, thus reducing the space requirement for side and rear access.

1.4.5 Final Positioning And Fixing

Figure 1-1 and Figure 1-2 provide the UPS installation dimensions. After final positioning, fix the UPS directly on the installation surface through the anchor holes on the UPS base. If the UPS is mounted on raised floor, a suitable pedestal should be designed, which should be able to bear the UPS weight. When designing the pedestal, refer to the bottom view in Figure 1-1 and Figure 1-2.

4 Chapter 1 Installation Of UPS Module

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

600

1396

843

586

794

1397

476

645

445

102

A amplified view

145

Anchor hole

Front view

Side view

Top view

Bottom view

1400

843

1400

800

100

Figure 1-1 30kVA

～

160kVA UPS installation dimensions (unit: mm)

350

Chapter 1 Installation Of UPS Module 5

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1598

600

843

586

1400

803

侧视图

474

645

445

146100

前视图

顶视图

600

843

1598

586

Front view

Side view

Top view

Anchor hole

Bottom view

A amplified view

1600

825

Figure 1-2 200kVA UPS installation dimensions (unit: mm)

1.4.6 Cable Entry

The UPS uses top cable entry and bottom cable entry.

1.5 External protective device

External circuit breakers or other protective devices must be fitted at the input AC supply of the UPS. This section provides a general guide for qualified installation engineers. The installation engineers should have the knowledge of the local wiring regulations on the equipment to be installed.

350

6 Chapter 1 Installation Of UPS Module

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1.5.1 Rectifier And Bypass Input

Over currents

Install suitable protective devices in the distribution of the incoming mains supply, considering the power cable current-carrying capacity and overload capacity of the system (see Table 8-6). Generally, magnetic circuit breaker with IEC60947-2 tripping curve C (normal) at 125% of the current listed in Table 1-1 is recommended.

Split bypass: In case a split bypass is used, separate protective devices should be installed for the rectifier input and bypass input in the incoming mains distribution panel.

Note

1. The rectifier input and bypass input must use the same neutral line.

2. For IT power systems, four-pole protective devices must be used upstream of the input distribution panel and output distribution panel, external to the UPS.

Earth leakage

The residual earth current introduced by the radio frequency interference (RFI) suppression filter inside the UPS is greater than 3.5mA and less than 1000mA. It is recommended that the sensitivity of all differential devices be verified upstream of the input distribution panel.

1.5.2 External Battery Circuit Breaker

The UPS and its associated battery are protected against the effect of overcurrents through a DC circuit breaker provided by the external battery cabinet.

The rated voltage of the external battery overcurrent protective device is more than 500Vdc, and its DC breaking current is more than 8kA.

1.5.3 UPS Output

The UPS output distribution shall be configured with a protective device. The protective device shall be different from the input distribution protection switch and able to provide overload protection (refer to Table 8-6).

1.6 Power Cables

The cable design must comply with the instructions provided in this section, follow local wiring practices, take the environmental conditions into consideration, and refer to IEC60950-1 Table 3B.

1.6.1 Maximum Steady State AC And DC Currents Maximum steady state AC and DC currents

UPS rating (kVA)

Rated current (A) Busbar stud size

Input mains

current

1，2

(at full

load with battery

recharging)

Output current

at full

load

Battery

discharge

current at

EOD

Main input,

output, bypass

input cables

Battery cables

380V 400V 415V 380V 400V 415V Bolt

To rq u e

(N.m)

Bolt Torque (N.m)

200 330 316 302 303 290 278 630

150, 160 280 265 255 225 215 205 525

120 224 212 204 180 172 164 420

90、100

168 159 153 135 129 123 315

60 112 106 102 90 86 82 210

40 75 71 68 60 57 55 140

30 56 53 51 45 43 41 105 M6 4.8

30-B 56 53 51 45 43 41 105 M6 4.8

Note:

1. Input mains current for common rectifier and bypass AC input.

Chapter 1 Installation Of UPS Module 7

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

2. Non-linear loads (switch mode power supplies) affect the design of the output and bypass neutral cables. The current circulating in the neutral cable may exceed that of the nominal phase current by up to 70%.

3. Values shown for 30 x 6-cell 12V blocks per battery string. Each string may contain from 30 to 40 x 6-cell 12V blocks. Inverse proportional values apply with more blocks per battery string. E.g. The max discharge current from a 40 x 6-cell 12V battery applied to a 30kVA NXr is 105A x (30/40) = 78A

1. Protective earth cable: Follow the most direct route possible to connect the earth cable to the cabinet. The earth cable shall be sized in accordance with the AC supply fault rating, cable lengths and type of protection. E.g. typical cross sectional area (CSA) is 70mm

(150kVA) according to AS/IEC60950-1 Table 2D.

2. When sizing the battery cables, a maximum volt drop of 4Vdc is permissible at the current ratings given in Table 1-1. The load equipment is generally connected to a distribution board containing individually protected busbars rather than connected directly to the UPS output. The output cables from paralleled units to the parallel distribution bus should be of the same length to optimise the sharing of current. Do not form coils, so as to minimize the formation of electromagnetic interference.

3. For terminal location, refer to Figure 1-4 ~ Figure 1-6.

Warning

Failure to follow adequate earthing procedures may result in electromagnetic interference or in hazards involving electric shock and fire.

1.6.2 Distance From Floor To Connection Point On The Equipment

Table 1-1 Distance from floor to connection point on the equipmen

UPS connection point Minimum distance (mm)

30kVA (NXr 30K-B) 30kVA (NXr 30K) ~ 160kVA 200kVA

Rectifier AC input supply 780 284 284

Bypass AC input supply 685 284 284

UPS AC output 530 369 251

Battery power 375 369 320

Auxiliary cable: to monitoring board (U2) 1104 1104 1304

1.6.3 Cable Connection

Important

The operations described in this section must be performed by authorised personnel. If you have any questions, please contact the local customer service center of Emerson immediately.

Warning

1. Before cable connection, ensure that you are aware of the location and state of the breaker that connects the UPS input to the mains distribution panel. Check that this breaker is off, and post any necessary warning sign to prevent inadvertent operation of the breaker.

2. The power cables should be routed through cable tunnel or metallic cable trough to avoid being damaged under mechanical stress and reduce electromagnetic interference to the environment.

Once the equipment has been finally positioned and secured, refer to Figure 1-3 to connect the power cables as described in the following procedures:

8 Chapter 1 Installation Of UPS Module

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

J10

1 2

12 34

324

1 2

3 4

To user safety earth

Power cable

Bypass module

UPS

External EPO

Input

Output

BFP_O BFP_S

BFP_C

BPS

ENV BIG

12V EXT_Q3

EXT_OUT

IN_S

GND

EPO_NC 12V

12V EPO_NO

DRV

FBOLGND

+12V

BAT_OUT

GND

BAT+

BAT-

Battery input

1 2

UPS output

Main input

Bypass input

BAT

EXT

Figure 1-3 UPS electrical connection

1. Verify that the UPS equipment is isolated from its external power source and all the UPS power isolators are open. Check that these supplies are electrically isolated and post any necessary warning signs to prevent their inadvertent operation.

2. Open the UPS door and remove the protective cover at the lower part in the front to gain access to the power terminals, as shown in Figure 1-4 to Figure 1-6.

Chapter 1 Installation Of UPS Module 9

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Figure 1-4 30kVA (NXr 30K-B) UPS power terminals

10 Chapter 1 Installation Of UPS Module

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

mNmCmBmA

BAT+ BAT N BAT-

bA bB bC

oB oC

Note:

1. Main input: mA, mB, mC, mN

2. Bypass input: bA, bB, bC, mN

3. UPS output: oA, oB, oC, oN

4. Battery input: BAT+, BAT-, BAT N

5. Earth: PE

Figure 1-5 30kVA (NXr 30K) ~ 160kVA UPS power terminals

oN bA

＋

－

Note:

1. Main input: mA, mB, mC, mN

2. Bypass input: bA, bB, bC, mN

3. UPS output: oA, oB, oC, oN

4. Battery input: + , - , N

5. Earth: PE

Figure 1-6 200kVA UPS power terminals

Chapter 1 Installation Of UPS Module 11

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

3. Connect the protective earth cable and all other necessary earth cables to the earth terminals (PE).

Note

The earth cables and neutral line connection must be in accordance with local and national codes of practice.

4. Identify and make power connections for the input cables according to one of the following two procedures, depending on the type of installation.

Common input connections

1) In common bypass and rectifier input configuration, for 30kVA ~ 160kVA UPS, connect the AC input cables to the main input terminals (mA-mB-mC-mN); for 200kVA UPS, connect the AC input cables to the bypass input terminals (bA-bB-bC-mN). Refer to Table 1-1 for the torque. Ensure correct phase rotation.

Split bypass connections

2) If a split bypass configuration is used, connect the main input cables to the main input terminals (mA-mB-mC-mN), and connect the bypass input cables to the bypass input terminals (bA-bB-bC-mN). Refer to Table 1-1 for the torque. Ensure correct phase rotation.

Warning

For split bypass operation, ensure that the linking busbars between the bypass input and maiin input are removed. The main input and bypass input must be referenced to the same neutral point.

System output connection

5. Connect the system output cables between the UPS output terminals (oA-oB-oC-oN) and the critical load. Refer to Table 1-1 for the torque. Ensure correct phase rotation.

Warning

If the load equipment will not be ready to accept power on the arrival of the commissioning engineer then ensure that the system output cables are safetly isolated at their ends.

Warning: hazardous battery terminal voltage 400Vdc

1. Ensure correct polarity of batter string end connections to the UPS terminals, that is, (+) to (+), (–) to (–) and (N) to (N). But do not make these connections before authorized by the commissioning engineer.

2. Ensure correct polarity of battery string end connections to the battery circuit breaker (BCB) and from the BCB to the UPS terminals, that is, (+) to (+) and (–) to (–), but disconnect one or more battery cell links in each tier. Do not reconnect these links and do not close the BCB before authorized by the commissioning engineer.

6. For frequency converter applications ensure the bypass links are removed.

7. Replace the protective cover.

12 Chapter 1 Installation Of UPS Module

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1.7 Control Cables And Communication

As shown in Figure 1-7, the bypass module provides dry contact ports (J5 ~ J10), service and communication ports (RS485 port, RS232 port and three Intellislot (Network Interface/Relay ports) on the front panel.

J8 J5

J10 J7

J6 J9

RS232 Intellislot 1RS485

Intellislot 2

Intellislot 3

Figure 1-7 Dry contact ports and communication ports

The UPS accepts external signalling from voltage-free (dry) contacts connected to push-in input dry contact terminal. Subject to prior software programming, the signalling is accepted by the UPS when relevant terminals and the +12V terminals are shorted. All control cables must be routed separately from the power cables and parallel cables, double-insulated and of a typical 0.5mm

to 1.5mm2 CSA for maximum runs between 20m and 30m respectively.

1.7.1 Input Dry Contact Port: Battery Environment (ventilation), Ground fault, Temperature

The input dry contact ports J7 and J8 provide environmental and battery ground and temperature fault contacts. The ports are shown in Figure 1-8 and described in Table 1-2.

12 V

BtG

ENV

+12V

GND

BAT_OUT

12V

BAT_IN

Figure 1-8 Input dry contact ports J7 and J8

Table 1-2 Description of input dry contact ports J7 and J8

Position Name Description

J7.1 ENV* Battery room environment detection (normally closed)

J7.2 BtG Battery ground fault

J74 +12V +12V power

J8.1 BAT_IN

Internal battery temperature detection

J8.2 +12V +12V power

J8.3 BAT_OUT External battery temperature detection

J8.4 GND Power ground

Note*: Activating this feature turns off the battery charger

Chapter 1 Installation Of UPS Module 13

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1.7.2 Battery Circuit-Breaker (BCB) Port

J6 is the BCB port. The port is shown in Figure 1-9 and described in Table 1-3.

12V

GND

DRV

12V

Figure 1-9 BCB port

Table 1-3 BCB port description

Position Name Description

J6.1 DRV BCB driver signal – for BCB UV coil when used

J6.2 FB BCB aux contact closed to J6.3 when BCB is open

J6.3 GND Power ground

J6.4 OL BCB on line – enables J6.1 and J6.2 (when J6.4 is closed to J6.3)

The connection between the BCB port and BCB is shown in Figure 1-10.

电池开关

BCB

J10

GND

DRV

Aux-N.O. Aux-N.O.

Aux_N.O.

BCB

Figure 1-10 Connection between BCB port and BCB

1.7.3 Maintenance Switch And Output Switch State Port

J9 is the maintenance switch and output switch state port. The port is shown in Figure 1-11 and described in Table 1-4.

EXT-S

CAB-S

EXT_Q3

IN_S

GND

EXT_OUT

Figure 1-11 Maintenance switch and output switch state port

Table 1-4 Description of maintenance switch and output switch state port

Position Name Description

J9.1 EXT_Q3 External maintenance bypass (EBP) switch – Aux Contact closed to J9.4 when

EBP is open.

J9.2 IN_S J9.2 shorted to J9.4 when Internal maintenance switch is closed

J9.3 EXT_OUT

External output isolator (EOI) Aux Contact closed to J9.4 when EOI is closed.

J9.4 GND Power ground

Aux contact is open when BCB is closed

14 Chapter 1 Installation Of UPS Module

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1.7.4 Backfeed protection Output Dry Contact Port

J5 is the output dry contact port, providing two relay output dry contact signals. The port is shown in Figure 1-12 and described in Table 1-5. The shunt trip coil of the external circuit breaker can be driven directly through this dry contact rated for 24Vdc/5A.

BFP_C

BFP_S

BFP_O

Figure 1-12 Output dry contact port

Table 1-5 Description of output dry contact port

Position Name Description

J5.2 BFP_O

Bypass feedback protection relay (normally open), closed when bypass silicon-controlled rectifier (SCR) is shorted

J5.3 BFP_S Bypass feedback protection relay center

J5.4 BFP_C

Bypass feedback protection relay (normally closed), open when bypass SCR is shorted

1.7.5 Remote Emergency Power Off (REPO) Input Port

The UPS has an EPO function that operates by a button on the operator control and display panel of the UPS or by a remote contact provided by the user. The EPO switch is under a hinged, plastic shield.

J10 is the remote EPO input port. The port is shown in Figure 1-13 and described in Table 1-6.

J10

+12V

EPO_NO

+12V

EPO_NC

Figure 1-13 Remote EPO input port

Table 1-6 Description of remote EPO input port

Position Name Description

J10.1 EPO_NC

EPO activate when J10.1 and J10.2 are open

J10.2 +12V

J10.3 +12V

EPO activate when J10.1 and J10.4 are closed

J10.4 EPO_NO

Notes

1. The UPS EPO action disables the UPS a.c. output by shuting down the rectifiers, inverters and static bypass.

2. The UPS EPO action does not disconnect any input power supply. To disconnect all power from the UPS, open the upstream input breaker(s) and the battery breaker when EPO is activated.

3. Pins 1 and 2 of J10 are supplied factory-shorted.

4. If the UPS EPO function is not used, pins 1 and 2 of J10 must remain shorted and pins 3 and 4 of J10 must remain open .

Chapter 1 Installation Of UPS Module 15

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1.7.6 Relay and Network Interface Card ports, Service ports,

Optional Intellislot cards

a) with Global Velocity Protocol

(On UPS display, select Protocol Velocity in “Settings”)

b) with Asia-Pacific YDN23 Protocol

(in use prior to 2012 - On UPS display, select Protocol YDN23 in “Settings”)

For details, refer to the user manuals of the each specific network interface card.

Service ports

J2 and J3: Parallel connection ports - used for control of two or more NXr UPS cabinets operating in

parallel.

J4: Load Bus Synch (LBS) interface - used to synchronize the outputs of two NXr UPS systems operating in

dual bus mode.

RS232 / RS485: maintenance ports - used for programming, commissioning and investigation by service engineers.

ModBus Card p/n IS-485L (preferred location: port 3)

SNMP/WebBrowser Card

p/n IS-WEBL (preferred loc: port 2)

Relay Card p/n IS-Relay (preferred location: port 1)

Relay Card p/n 02351874 (preferred location: port 1)

SNMP/Web SIC (Site Interface Card) p/n 02351817 2, (preferred loc: port 2)

ModBus Card p/n 02354066 (preferred location: port 3)

16 Chapter 2 Battery

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 2 Battery

This chapter introduces the relevant information of the battery, including the brief introduction, battery safety, battery power cables, battery maintenance and recycling, reference current and connection of external BCB.

2.1 Brief Introduction

The UPS battery string consists of battery cells (or blocks) connected in series to provide a d.c. input voltage for the UPS inverter to operate. The required battery backup time (that is, the time during which the battery can maintain supply to the load in the event of a mains failure) is subject to the ampere-hour capacity of the battery. To achieve the capacity required, subject to recommendation from the battery manufacturer, several battery strings may be connected in parallel. Batteries of different brand, model and age should nottbe used together.

Except for the NXr 30K-B model that contains internal batteries, all UPS batteries are located external to the UPS cabinet and is normally housed in a battery cabinet or located on stands/racks.

The NXr 30K-B UPS provides a battery compartment to accommodate internal batteries. Up to 40 x 24Ah/12V battery blocks can be accommodated.

Chapter 2 Battery 17

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

2.2 Safety

Take special care when working with the batteries associated with the UPS. When all the cells are connected together, the battery string voltage can be up to 576Vdc and is potentially lethal. Please follow the precautions for high voltage operation. Only qualified personnel are allowed to install and maintain the battery. To ensure the safety, the external batteries shall be installed inside a key-lockable cabinet or in a purpose-designed, dedicated battery room, so that they are segregated from all but qualified maintenance personnel.

During battery maintenance, pay attention to the following items:

 Place the maintenance switch in the ON position

 The battery cell number setting in the background software must be consistent with the actual battery cell

number

Note

Full safety instructions concerning the use and maintenance of UPS batteries are provided in the appropriate battery manufacturers manuals. The battery safety inforamtion contained in this section relates to key considerations that must be taken into account during the installation design process and might affect the design outcome depending on localised conditions.

Warning: hazardous battery voltage present behind covers

1. No user-serviceable parts are located behind covers that require a tool for their removal. Only qualified service personnel are authorised to remove such covers.

2. Before operating the copper bars connected with the external battery, please disenergize the copper bars.

3. Observe the following safety precautions when working on the batteries:

1) The battery shall be firmly and reliably connected. After the connection is completed, all connections between the terminals and the batteries shall be calibrated. The requirements on torque specified in the instructions or user manual provided by the battery manufacturer shall be satisfied. All connections between the terminals and the batteries shall be inspected and tightened at least once a year. Failure to observe this may cause fire!

2) Inspect the battery appearance before accepting and using the battery. If there exist any package damage, dirty battery terminal, terminal erosion, rust, or enclosure crack, deformation or electrolyte leakage, replace it with new product. Otherwise, battery capacity reduction, electrolyte leakage or fire may be caused.

3) The battery is very heavy. Please use proper method to move and hoist the battery, so as to prevent any damage to human being or the battery terminals. Severe damage to the battery may cause fire.

4) The battery terminals shall not be subject to any force, such as the pulling force or twisting force of the cable. Otherwise, the internal connection of the battery may be damaged, and severe damage may cause fire.

5) The battery shall be installed and stored in a clean, cool and dry environment. Do not install the battery in a sealed battery chamber or a sealed room. The battery room ventilation shall at least meet the requirement of EN50272-2001. Otherwise, battery bulging, fire or even personal may be caused.

6) The battery shall be kept away from heat sources like transformers, or fire sources. Do not burn the battery or the battery in fire, otherwise, electrolyte leakage, battery bulge, fire or explosion may be caused.

7) Do not directly connect any conductor between the positive and negative terminals of the battery. Remove finger rings, watches, necklaces, bracelets and other metal objects before operating the battery, and ensure that the tools (for example, wrench) are wrapped with insulating material. Otherwise, battery burning, explosion, human death or injury may be caused.

8) Do not disassemble, modify or damage the battery. Otherwise, battery short circuit, electrolyte leakage or even personal may be caused.

9) Clean the battery enclosure with wringed wet cloth. To avoid any static or arcing, do not use dry cloth or duster to clean the battery. Do not use the organic solvent, such as thinner, gasoline,

volatile oil

, to clean the battery. Otherwise, the battery enclosure

may be cracked. In worst case, fire may be caused.

10) The battery contains diluted sulfuric acid. In normal use, the diluted sulfuric acid is absorbed to the baffle plate and polar plate of the battery. However, if the battery is damaged, the acid may leak from the battery. Therefore, use personal protective equipment, such as, goggles, rubber gloves and apron, when operating the battery. Otherwise, if the diluted sulfuric acid enters the eyes, blindness may be caused; if it contacts the skin, the skin may be burnt.

11) The battery may have short circuit, electrolyte dry-up or positive-pole plate erosion at the end of its life. If it is still used in this state, the battery thermorunaway, bulging or electrolyte leakage may occur. Please replace the battery before it enters this state.

12) Before connecting or disconnecting the battery connection cables, please cut off the charging power.

13) Check if the battery has been unexpectedly earthed. If yes, remove the earth power. Contact with any part of the earthed battery may cause electric shock.

18 Chapter 2 Battery

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

2.3 Battery Power Cable

2.3.1 Overview

Please install and connect the batteries according to the following description and graphic presentation.

2.3.2 Battery Installation

1. Before installation, check the battery appearance to ensure that there is no damage, inspect and count the accessories, and carefully read this manual and the user manual or installation instruction provided by the battery manufacturer.

2. There shall be a clearance of 10mm between the vertical sides of the batteries for the smooth flow of the air around the batteries.

3. Certain clearance shall be maintained between the battery top and the underside of the layer above it to facilitate battery monitoring and maintenance.

4. The batteries shall be installed from the bottom layer upwards to avoid high gravity center. The battery shall be properly installed and protected from vibration or shock.

5. Measure the battery voltage, and calibrate the battery voltage after UPS startup.

2.3.3 Battery Connection

1. When the battery cabinet is installed on a raised floor, the battery power cables and optional BCB control cables can enter the UPS cabinet through the cabinet bottom. If the UPS and battery cabinet are installed side by side on a solid floor, these cables can be led into the UPS cabinet through the cable entry holes on the lower part of the battery cabinet.

2. When multiple battery strings are used, they shall be connected in series and then in parallel. Before applying load and power-up, be sure to measure the total voltage of the battery strings and make sure that it is correct. The negative and positive terminals of the battery must be connected to the corresponding negative and positive battery terminals of the UPS according to the labels on the battery and UPS. Reverse battery connection may cause explosion, fire, battery damage, UPS damage, and personal injury.

3. After connecting the battery cables, install an insulating shroud for each terminal.

4. When connecting the cables between the battery terminals and the BCB, connect from the BCB side first.

5. The bending radius of the cable shall be larger than 10D, where D is the outer diameter of the cable.

6. After cable connection, it is prohibited to pull the battery cables or the cable terminals.

7. Do not cross the battery cables during connection, and do not tie the battery cables together.

8. Refer to Figure 2-1 and Figure 2-2 for the battery cable connection.

9. For NXr 30K-B UPS, it is required to install the factory supplied separators between the two rows of batteries on each layer of the battery compartment, as shown in Figure 2-2.

Chapter 2 Battery 19

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Figure 2-1 External battery cable connection

46.7

46.746.7

46.7

126.5

384

Battery

Battery Battery

Lead out the battery neutral cable from here on the third layer

Separator

Red

Battery compartment

Black

Blue

Red

Black

Blue

Figure 2-2 Internal battery cable connection (NXr 30K-B)

2.4 Battery Maintenance

The battery supplied by Emerson complies with the safety requirements of IEC 62040-1:2008. For the battery maintenance and maintenance precautions, refer to the relevant manual provided by the battery manufacturer and observe applicable local regulation e.g. AS2676:1993, IEEE-Std-1188-2005.

Note

1. Periodically check the screws of the battery terminals for loose connection. If there is any loose screw, tighten it immediately.

2. Check that all safety devices are present and that their functions are normal. Check that the battery management parameters are set correctly.

3. Measure and record the air temperature inside the battery room.

4. Check the battery terminals for damage and heating. Check the battery enclosure and terminal covers for damage.

20 Chapter 2 Battery

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

2.5 Battery Recycling

If the battery leaks electrolyte, or is otherwise physically damaged, it should be placed in a container resistant to sulfuric acid and disposed of in accordance with local regulations.

Disused lead-acid storage battery belongs to dangerous waste, and it is a key item for disused battery pollution control. The storage, transportation, use and disposal of the battery shall comply with the national and local laws and regulations on dangerous waste and disused battery pollution prevention and other standards.

According to the relevant national regulations, the disused lead-acid storage battery must be recycled and shall not be disposed of with other methods. Random discard or any other improper disposal of the disused lead-acid storage battery may cause severe environment pollution and the relevant person will be investigated of corresponding legal responsibilities.

As a lead-acid storage battery supplier, Emerson has built a perfect service network and disused battery recycling system to help the customer legally and properly dispose of the lead-acid storage battery. For detailed information about the disused battery recycling system of Emerson, please consult the local customer service center or sales office of Emerson. If the customer refuses to accept this special note or does not use the disused battery recycling system of Emerson. Emerson will not undertake any environment responsibility caused by the improper disposal of the disused battery products.

2.6 Connection Of External Battery Circuit-Breaker (BCB

Table 2-1 provides recommended BCB rated current and minimum connection cable Cross Sectional Area (CSA).

Table 2-7 Reference table for selection of BCB rated current and connection cable CSA (minimum recommended)

Note: the minimum CSA is adequate for batteries located up to 5 meters from the UPS. For longer cable runs, the CSA shall be increased so

that the voltage drop remains less than 1% in order not to affect the battery run time significantly.

Item Unit UPS rating (kVA)

30 40 60 90, 100 120 150, 160 200

30-cell battery

Maximum battery discharge current at full load

A 105 140 210 315 420 525 630

Reference rated current of BCB A 150 175 250 350 450 550 700 Connection cable CSA mm

35 50 70 120 150 185 240 32-cell battery

Maximum battery discharge current at full load

A 100 133 200 300 400 500 590

Reference rated current of BCB A 150 150 250 350 450 550 630 Connection cable CSA mm

35 50 70 120 150 185 240 34-cell battery

Maximum battery discharge current at full load

A 94 125 186 282 376 470 556

Reference rated current of BCB A 100 150 200 300 400 500 630 Connection cable CSA mm

35 50 70 95 120 185 200 36-cell battery

Maximum battery discharge current at full load

A 88 118 176 264 352 440 525

Reference rated current of BCB

A 100 125 200 320 400 500 550

Connection cable CSA

25 35 50 95 120 150 200 38-cell battery

Maximum battery discharge current at full load

A 84 112 168 252 336 420 498

Reference rated current of BCB A 100 125 200 260 350 450 550 Connection cable CSA mm

25 35 50 95 120 150 200 40-cell battery

Maximum battery discharge current at full load

A 80 106 160 240 320 400 473

Reference rated current of BCB

A 100 125 200 250 320 400 500

Connection cable CSA

16 25 35 70 95 120 180

Note:

-It is recommended to use a DC moulded-case circuit breaker (MCCB) appropriately rated to open the kA fault current of the battery at the nominal battery voltage. Applicable connections between the battery, BCB and UPS are shown in Figure 2-3, 2-4 and 2-5.

Chapter 2 Battery 21

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual









UPS

Figure 2-3 Connections between battery, 4-pole BCB and UPS (4 wires at battery side)

UPS

Figure 2-4 Connections between battery, 3-pole BCB and UPS (3 wires at battery side,









UPS

Figure 2-5 Connections between battery, 4-pole BCB and UPS (3 wire at battery side

Figure 2-6 below shows connections to be carried out when using the UV trip controlled BCB box (containing a BCB and a BCB control board) made by Emerson Network Power.

X104

X105 X106

OUT

-P OUT-N AUX1 AUX2

X101

X108

X102

X103

X100

220VDC

BCB

Battery

+12V

+12V BAT-T

BAT-

GND GND2

USE

GND1

AUX

DRV

GND

FB DRV

12V

OUT

GND

TPM2

+ N

Temp sensor

BCB control board

Bypass module

J8J6

Auxiliary

contactor

UPS

UHW241C2

Figure 2-6 Connections between UPS, BCB and BCB control board (option)

22 Chapter 3 Installation Of Parallel System

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 3 Installation Of Multiple UPS cubicles

This chapter details the installation and wiring of a system containing more than one UPS cubicles installed in either parallel and / or dual bus configuration.

3.1 Overview

Up to four UPS units can be connected in parallel to form a parallel system. Further, single or parallel configurations can form systems with independent output buses (“dual bus systems”). The parallel and dual bus system installation shall be carried out according to the installation procedures contained in chapter 1 for the single UPS cubicle and to the applicable requirements of this chapter.

In addition to the Emergency Power Off (EPO switch provided on the operator control and display panel of each UPS module for controlling the EPO of each module respectively, the parallel system also provides remote EPO function for controlling all UPS modules to shut down simultaneously from a remote terminal, as shown in Figure 3-1.

Note

1. The remote EPO switch must provide dry contact signal, which is normally open or closed.

2. The open circuit voltage provided is 5Vdc, <20mA.

3. The external EPO device can be composed of another control system which can disconnect the UPS mains supply or the bypass input.

4. Pins 1 and 2 of the normally closed EPO-J10 port on the bypass module have been linked in factory.

UPS 1

J10: 3

J10: 4

J10: 3 J10: 4

UPS 2

UPS 1

Bypass module

J10: 3

J10: 4

Bypass module

Figure 3-1 EPO circuit diagram (single and parallel UPS)

3.2 1 + N Parallel System

The basic installation steps of parallel system are the same as those of the single UPS cubicle. The following sections describe the differences between the parallel system installation and single UPS installation.

Chapter 3 Installation Of Parallel System 23

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

3.2.1 Cabinet Installation

Position the UPS cubicles side by side and make connection as shown in Figure 3-2. The output distribution consisting of external UPS output switches and maintenance bypass must be installed, as shown in Figure 3-2, to facilitate maintenance and system testing.

Figure 3-2 Typical “1+N” system schematic diagram (with common input, separate battery and output/bypass distribution cabinet)

24 Chapter 3 Installation Of Parallel System

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Qout of all UPSs

Rectifier

Inverter

Mains input L1, L2, L3, N

Qout UPS 1

Supplied by others

Qin UPS 1

STS

Qout UPS 2

Qout UPS 3

Output distribution

Qout Byp

Bypass input L1, L2, L3, N

Mains input L1, L2, L3, N

Bypass input L1, L2, L3, N

Mains input L1, L2, L3, N

Bypass input L1, L2, L3, N

L1, L2, L3

Rectifier

STS

Inverte r

UPS 1 output

UPS 2 output

L1, L2, L3, N

L1, L2, L3, N UPS 3 output

STS

Rectifier

Inverter

Qin UPS 2 Qin UPS 3

Qin Ext Byp

Figure 3-3 1 + N UPS system with external maintenance switch

Note

For 1+N installations an external bypass rated for the total system load must be installed and the UPS internal maintenance bypass must be locked off to prevent operation.

1. For parallel systems designed for redundancy with 3 or more UPSs, it is recommended to install bypass load sharing inductors to optimize current sharing during static bypass operation.

2. For parallel systems designed for capacity, with 2 or more UPSs, it is recommended to install bypass load sharing inductors to optimize current sharing during static bypass operation.

3.2.2 External protective device

Refer to Chapter 1 Installation Of single UPS cubicle .

3.2.3 Power Cable

The wiring of the power cable is similar to that of UPS module. The bypass and main input supplies must use the same neutral line input terminal. If the input has a current leakage protective device, the current leakage protective

device must be fitted upstream of the common neutral sinking point. Refer to Chapter 1 Installation Of single UPS cubicle .

Note

The length and specification of power cables including the bypass input cables and UPS output cables should be the same. This facilitates load sharing in bypass mode.

Chapter 3 Installation Of Parallel System 25

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

3.2.4 Auxiliary Control Wiring

Auxiliary wiring must be installed as shown in Figure 3-4 to protect the system and enable a single UPS to be isolated

and tested during service. Refer to 1.7.3 Maintenance Switch And Output Sw itch State Port for auxiliary contact

details.

Input dist ribution

UPS 3

143

UPS 2

143

UPS 1

143

Q1Ext

Q2Ext

QByp

QUPS

Q2Ext

Dis tribut ion panel

To load

Figure 3-4 Auxiliary control wiring

3.2.5 Parallel Control Cables

Shielded and double-insulated parallel control cables available in lengths 5m, 10m and 15m must be interconnected in a ring configuration between the UPS modules, as shown in Figure 3-5. The parallel ports J2 and J3 are provided on the front panel of the bypass module, as shown in Figure 3-6. The ring connection ensures the reliability of the control of the parallel system. Be sure to verify the reliable cable connection before starting up the system.

UPS 1

UPS 2

UPS 3

UPS 4

Figure 3-5 Connection of parallel control cables of 1+N parallel system

26 Chapter 3 Installation Of Parallel System

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Figure 3-6 Locations of ports J2, J3 and J4 on bypass module

3.3 Dual Bus System

3.3.1 Cabinet Installation

A dual bus system consists of two independent UPS systems, each containing one or more (maximally 4) parallel UPS modules, as shown in Figure 3-7. The dual bus system has high reliability and is suitable for load with multiple input terminals. For single-input load, an optional static transfer switch can be fitted to start the load bus synchronizer (LBS supplied in standard configuration.

UPS 1

Bypass

UPS 1

LBS

To load

Main input

UPS4 UPS4

Main input Main inputMain input

Parallel control cable

Bypass

STS

Figure 3-7 Typical dual bus system (with static transfer switch and LBS)

The dual bus system uses the LBS to keep the output of the two independent UPS systems (or parallel systems) in synchronization. One system is designated as the master, the other is designated as the slave. The operation modes of the parallel system comprise master and/or slave operation in normal or bypass mode.

Place the UPS modules side by side and interconnect the UPS modules according to the following instructions.

3.3.2 External protective device

Refer to Chapter 1 Installation Of single UPS cubicle .

3.3.3 Power Cable

The wiring of power cables is similar to that of single module system. The bypass and the main input sources must be referenced to the same neutral potential and input earth leakage monitoring devices, if installed, must be located

upstream of the common neutral sinking point. Refer to Chapter 1 Installation Of singl e UPS cubicle .

3.3.4 Control Cable

For NXr-to-NXr dual bus system, connect the optional LBS cables between the LBS ports (J4) of the two parallel systems, as shown in Figure 3-8. The LBS port (J4) is provided on the front panel of the bypass module, as shown in Figure 3-6.

Chapter 3 Installation Of Parallel System 27

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

UPS 1

Bypass module

LBS cable

UPS 3 UPS 4

Bypass module Bypass module Bypass module

UPS 2

LBS cable

Figure 3-8 Connection of typical dual bus system

28 Chapter 4 Operation

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 4 System Description

This chapter introduces the information related to UPS operation, including the brief introduction, 1+N parallel system, operation mode, battery management and battery protection.

Warning: hazardous mains and battery voltage present behind covers

No user-serviceable parts are located behind covers that require a tool for their removal. Only qualified service personnel are authorised to remove such covers.

4.1 Brief Introduction

The UPS provides continuous, high-quality AC power to your critical equipment, such as telecommunications and data processing equipment. The UPS supplies power that is free of the disturbances and variations in voltage and frequency common to mains power, which is subject to brownouts, blackouts, surges and sags.

The UPS uses the latest high frequency, double-conversion pulse width modulation (PWM technology and digital signal processing (DSP technology to enhance its reliability and increase the ease of use.

4.1.1 Operating Theory

As shown in Figure 4-1, the AC mains source is converted by the rectifier into DC power. The inverter converts that DC power from the rectifier or the DC power from the battery into AC power, and provides the AC power to the load. The battery supplies the load through the inverter in the event of a mains failure. The mains source can also supply the load through the static bypass.

If UPS maintenance or repair is necessary, the load can be transferred without power interruption to the maintenance bypass.

Maintenance switch

Maintenance bypass

STS

Rectifier Inverter

Charger

UPS output

Battery

Mains input

Bypass input

Figure 4-1 Operating theory of UPS module system

4.1.2 Static (bypass) Transfer Switch

The circuit block labeled STS (static transfer switch) in Figure 4-1 contains an electronically controlled switching circuit that enables the load to be connected to either the inverter output or to the bypass power source through the static bypass line. During normal system operation, the load is connected to the inverter; but in the event of a UPS overload or inverter fault, the load is automatically transferred to the static bypass line.

During normal operating conditions, the inverter output and bypass supply must be fully synchronized so as to achieve a clean (no-break) load transfer between the inverter output and static bypass line. The synchronization between the inverter output and static bypass is achieved through the inverter control electronics, which make the

Chapter 4 Operation 29

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

inverter frequency track that of the static bypass supply, provided that the bypass remains within an acceptable frequency window.

A manually-controlled maintenance bypass supply is incorporated into the UPS design. It enables the critical load to be powered from the maintenance bypass supply while the UPS is shut down for routine maintenance and repair.

Note

When the UPS is operating in bypass mode or on maintenance bypass, the connected equipment is not protected from power failures, surges, or sags.

4.2 1 + N Parallel System

Up to four UPS modules can be parallel-connected to form a 1 + N system to increase the system capacity or reliability, or both. The load is equally shared between the paralleled UPSs.

4.2.1 Parallel System Features

1. The hardware and software of parallel system are completely the same as those of single UPS module. The parallel configuration is achieved through settings in configuration software. The parameter settings of each UPS module in parallel system should be the same.

2. Parallel control cables are connected in a ring, providing both system reliability and redundancy. Dual bus control cables are connected between any two UPS modules of each bus. The intelligent parallel logic provides the user with maximum flexibility. For example, shutting down or starting up UPS modules in a parallel system can be done in any sequence. Transfers between normal and bypass modes of operation are synchronised and self–recoverable, for example, following overloads and their clearance.

3. The total load of the parallel system can be queried from each UPS module’s LCD.

4.2.2 Requirements For Paralleling Of UPS Modules

A group of paralleled modules behave as if it were one large UPS with the advantage of presenting higher reliability. To ensure that all modules are equally utilised and to comply with relevant wiring rules, the following requirements apply:

1. All UPS modules must be of the same rating and must be connected to the same bypass source.

2. The bypass and main input sources must be referenced to the same neutral potential.

3. Any residual current detector (RCD, if installed, must be of an appropriate setting and located upstream of the common neutral bonding point. Alternatively, the device must monitor the protective earth current of the system. Refer

to Warning: high earth leakage current before Contents.

4. The outputs of all UPS modules must be connected to a common output bus.

Note

Optional isolation transformers are available for applications where sources do not share the same neutral reference or where the neutral is not available.

4.3 Operation Mode

The UPS is an on-line, double-conversion, reverse-transfer UPS that permits operation in these modes:

 Normal mode

 Battery mode (“stored energy mode”)

 Automatic restart mode

 Bypass mode

 Maintenance mode (manual bypass)

 Parallel redundancy mode

30 Chapter 4 Operation

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

4.3.1 Normal Mode

The UPS rectifier derives power from the AC mains input source and supplies DC power to the inverter, which continuously supplies the AC load to the load. Simultaneously, the charger, which derives power from the rectifier, float or boost charges the associated backup battery of the UPS.

4.3.2 Battery Mode

The UPS is operating in battery mode when the battery is supplying backup power to the load through the inverter. Upon mains failure, the UPS automatically transfers to battery mode without power interruption to the load. Upon restoration of the AC mains, the UPS automatically transfers back to normal mode without the necessity of user intervention, without power interruption to the load.

Note

Battery start function is available for switching the UPS on into battery (charged) mode directly upon mains failure. Thus, the battery power can be used independently to increase the UPS utility.

4.3.3 Automatic Restart Mode

The battery becomes exhausted following an extended AC mains failure. The inverters shut down when the battery reaches the EOD voltage. The UPS can be programmed to automatic restart after EOD after a set variable delay time. This mode and any delay time are programmed by the commissioning engineer.

4.3.4 Bypass Mode

During normal mode operation, if the inverter fails, is overloaded or turned off, the static transfer switch will perform a transfer of the load from the inverter to the bypass source, with no interruption in power to the load. Should the inverter be asynchronous with the bypass, the static transfer switch will perform a transfer of the load from the inverter to the bypass, with interruption in power to the load. This is to avoid paralleling of unsynchronised AC sources. This interruption is programmable but typically set to be less than 3/4 of an electrical cycle, for example, less than 15ms (50Hz) or less than 12.5ms (60Hz).

4.3.5 Maintenance Mode (Manual Bypass)

If UPS maintenance or repair is needed, you may use the maintenance switch to transfer the load to the maintenance bypass, with no interruption in power to the load. This maintenance switch is fitted in all UPS modules and rated for full load of one module.

4.3.6 Parallel Redundancy Mode (System Expansion)

For higher capacity or higher reliability or both, the outputs of multiple UPS modules can be programmed for directly paralleling while a built-in parallel controller in each UPS ensures automatic load sharing. The parallel system can be composed of up to four UPS modules.

4.4 Battery Management (Set During Commissioning)

4.4.1 Normal Function

1. Constant current boost charge.

The charge current can be set.

2. Constant voltage boost charge.

The boost charge voltage can be set as required by the type of battery.

For valve-regulated lead-acid (VRLA batteries, the maximum boost charge voltage should not exceed 2.4V/cell.

3. Float charge.

Chapter 4 Operation 31

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

The float charge voltage can be set as required by the type of battery.

For VRLA batteries, the float charge voltage should be between 2.2V/cell and 2.3V/cell.

4. Float charge temperature compensation (optional).

The temperature compensation coefficient can be set as required by the type of battery.

5. EOD protection.

When the battery voltage drops to the EOD voltage, the battery converter shuts down automatically and the battery is isolated to avoid further battery discharge. The EOD voltage is settable from 1.6V/cell to 1.75V/cell (VRLA).

6. Battery low pre-warning time.

The battery low pre-warning time is adjustable between 3min and 60min. The default setting is 5min.

4.4.2 Advanced Function

The UPS provides an advanced function, battery maintenance test. At periodic intervals, 20% of the rated capacity of the battery will be discharged automatically, and the actual load must exceed 20% of the rated UPS (kVA) capacity. If the load is less than 20%, the automatic discharge cannot be executed. The periodic interval can be set from 30 to 360 days. The battery self-test can be disabled.

Conditions: battery at float charge for at least 5h, load equal to 20% ~ 80% of rated UPS capacity.

Trigger: manually through the command of Battery Maintenance Test in LCD or automatically.

Battery maintenance interval: 30 ~ 360 days (default setting: 60 days).

4.5 Battery Protection (Set By Commissioning Engineer)

Battery low pre-warning

The battery low pre-warning occurs before the EOD. After this pre-warning, the battery should have the capacity for three remaining minutes discharging with full load. The time can be configured from 3min to 60min.

EOD protection

When the battery voltage drops to the EOD voltage, the battery converter shuts down. The EOD voltage is adjustable from 1.6V/cell to 1.75V/cell (VRLA).

Battery disconnect device alarm

The battery disconnect device alarm occurs when the battery disconnect device disconnects.

The external battery connects to the UPS through the external BCB. The BCB is manually closed and tripped by the UPS control circuit.

32 Chapter 5 Operator Control And Display Panel

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 5 Operator Control And Display Panel

This chapter expands the functions and use of the components on the operator control and display panel of the UPS, provides LCD display information, including the LCD screen types, detailed menu messages, prompt windows and UPS alarm list, and tells how to select language and change the current data and time.

5.1 Introduction

The operator control and display panel is located on the front door of the UPS. It is the access point for operator control and monitoring of all measured parameters, UPS and battery status and alarms. The operator control and display panel is divided into three functional areas: mimic power flow chart, LCD display with menu keys, control keys, as shown in Figure 5-1. The components on the operator control and display panel are described in Table 5-1.

LCD display with menu keys

EPO

INVERTER ON INVERTER OFF

FAULT CLEAR SILENCE ON / OFF

Control keys

Mimic power flow chart

STATUS

Lieber

t NX

20 08

1 0

3 1

1 2

3 0

3 6

1 5 0

-3 X 3

单机在线

正常

旁路输入主路输入

相电压 (V) 相电流 (A) 频率 (H z ) 线电压 (V) 功率因数

A( AB )

220

20 .5 50 .1

380

0.99

B(BC)

220

20 . 5 50 . 1

380

0.99

C(CA)

220

20.5

50.1

380

0.99

主路空开闭合 01 -12 手动开机

主路逆变供电 01 - 22

交流输出

单机在

线

NXr

kVA

1 6

2 1

1 7

交流输出

A(AB) B(BC) C(CA)

相电压(V) 相电流(A) 频率(H z) 线电压(V)

功率因数

220 220 220

20.5 20.5 20.5

50.1 50.1 50.1 380 380 380

0.99 0.99 0.99

F3 F4

F5F2

Figure 5-1 Operator control and display panel

Table 5-1 Description of operator control and display panel

Part No. Function Key Function

1 Rectifier indicator

EPO EPO switch

2 Battery indicator INVERTER ON Inverter start switch

3 Bypass indicator INVERTER OFF Inverter shutdown switch

4 Inverter indicator FAULT CLEAR Fault reset switch

5 Output indicator SILENCE ON/OFF Audible alarm silencing switch

6 Status indicator F1 ~ F5 LCD menu keys

7 Buzzer

8 EPO switch cover

5.1.1 Indicators

The indicators mounted on the mimic power flow chart represent the various power paths and current UPS operational status. The indicators are described in Table 5-2.

Table 5-2 Indicator description

Indicator State Description

Rectifier indicator

Solid green Rectifier in normal operation

Flashing green Mains input normal, but rectifier not operating

Solid red Rectifier fault

Off Rectifier not operating, mains input abnormal

Chapter 5 Operator Control And Display Panel 33

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Indicator State Description

Battery indicator

Solid green Load on battery

Flashing green Battery EOD pre-warning

Solid red

Battery abnormal (failed, absent or polarity reversed) or battery converter abnormal (failed, overcurrent or overtemperature)

Off Battery and battery converter normal, battery charging

Bypass indicator

Solid green Load on bypass

Solid red Bypass power abnormal or outside specifications, or static bypass switch fault

Off Bypass normal

Inverter indicator

Solid green Load on inverter

Flashing green Inverter turning on, starting up, synchronizing

Solid red Inverter fault

Off Inverter not operating

Output indicator

Solid green UPS output on and normal

Solid red UPS output on and overloaded

Off UP output off

Status indicator

Solid green Normal operation

Solid yellow Alarm (for example, AC input failure)

Solid red Fault (for example, fuse or hardware fault)

5.1.2 Audible Alarm (Buzzer)

UPS activity is accompanied by the three kinds of sound listed in Table 5-3.

Table 5-3 Audible alarm description

Alarm sound Meaning

A short beep Any key on the operator control and display panel is pressed

Beep every other second The UPS has a general alarm, for example, AC input failure

Continuous beep The UPS has a serious fault, for example, fuse or hardware fault

5.1.3 Control Keys

The operator control and display panel provides five control keys, as described in Table 5-4.

Table 5-4 Description of control keys

Control key Silkscreen Description

EPO switch EPO

Emergency Power Off: Cuts off the load power, shuts down the rectifier, inverter, static bypass

Inverter start switch INVERTER ON Starts the inverter

Inverter shutdown switch

INVERTER OFF Shuts down the inverter

Fault reset switch FAULT CLEAR Restarts the UPS (subject to any fault being cleared)

Audible alarm silencing switch

SILENCE ON/OFF

When an alarm is active, pressing this button silences the audible alarm. Pressing this button again enables the buzzer again

5.1.4 LCD And Menu Keys

The operator control and display panel provides an LCD and five menu keys (F1 ~ F5). The menu keys are described in Table 5-5.

Table 5-5 Menu key description

Function 1

Function 2

F1 F2 F3 F4

ESC

Escape

Left

Right

Down

Enter

Key F5

HOME

34 Chapter 5 Operator Control And Display Panel

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Providing 320 × 240 dot matrix graphic display, the user-friendly and menu-driven LCD allows you to easily browse through the input, output, load and battery parameters of the UPS, learn current UPS status and alarm information, perform functional setting and control operation. The LCD also stores up to 1024 historical records that can retrieve for reference and diagnosis.

5.2 LCD Screen Type

5.2.1 Start Screen

Upon UPS start, the UPS executes self-test, and the start screen appears and remains approximately 15 seconds, as shown in Figure 5-2.

F3 F4

F5F2

Figure 5-2 Start screen

5.2.2 Primary Screen

After the UPS starts and finishes self-test, the primary screen appears, as shown in Figure 5-3. The primary screen is divided into four windows: system information window, data window, menu window and keypad window.

#1 Liebert NXr 150 kVA

L 1-N/L2 L2-N/L3 L3-N/L1

L-N voltage (V)

OutPut

220.6 220 .0 220.0

0.0 0.0 0.0

50.1 50.1

50.1

381.5 381.0 381.5 000

16:21: 17

System information window

Data window

Menu window

Keypad window

Frequency (HZ)

L-N current (V)

L-L voltage (V)

Power factor (V)

F3 F4

F5F2

Figure 5-3 Primary screen

The functions of the menu keys F1 ~ F5 for the current screen are shown by self-explanatory icons in the keypad

window as appropriate. From any menu on the primary screen, pressing the F1 key returns to the Output menu。

Chapter 5 Operator Control And Display Panel 35

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

5.2.3 Default Screen

During UPS operation, if there is no alarm within two minutes, the default screen will appear, as shown in Figure 5-4. After a short delay, the LCD backlight will turn off. Pressing any menu keys (F1 ~ F5) restores the default screen.

按任意键返回主

菜单

LIEBERT NX

2008-10- 30 12: 30:36

150kVA-3X3 并机系统(1# ) 正常

Parallel system1(#)

Normal

Press any key to return to

the main menu

1# Liebert NXr 150KVA

10:07:55

F3 F4

F5F2

Figure 5-4 Default screen

5.3 Selecting Language

The LCD menu and data display is available in 12 languages: Chinese, Dutch, English, French, German, Italian, Japanese, Polish, Portuguese, Russian, Spanish and Swedish.

Use the following procedures to select the language:

1. On the Output menu screen, press the F3 (left) or F4 (right) key to select the Language menu.

2. Press the F5 (enter) key to move the cursor to the data window of the screen.

3. Press the F3 (up) or F4 (down) key to select the desired language.

4. Press the F5 (enter) key to confirm.

5. Press the F2 (ESC) key repeatedly to return to the Output menu. At this point, the LCD displays in the selected language.

5.4 Changing The Current Date And Time

Use the following procedures to change the system date and time:

1. On the Output menu screen, press the F3 (left) or F4 (right) key to select the Settings menu.

2. Press the F5 (enter) key to move the cursor to the data window of the screen.

3. Press the F3 (up) or F4 (down) key to select the Date & time item, and then press the F5 (enter) key to confirm.

4. Press the F3 (up) or F4 (down) key to the row displaying the date and time, and press the F5 (enter) key to confirm.

5. Use the F3 (up) or F4 (down) key to input the current date and time.

6. Press the F5 (enter) key to confirm, and press the F2 (ESC) key to return to the Output menu.

5.5 Control Password

Password protection is used to limit the control functions accessible to the operator. The default password is ‘123456’. This password provides access to UPS and battery test functions.

5.6 Detailed Description Of Menu Items

The description that follows refers to the LCD primary screen shown in Figure 5-3.

36 Chapter 5 Operator Control And Display Panel

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

System information window

The system information window displays the current time, UPS name, configuration and alarm silencing state. This window requires no user operation. For details, see Table 5-6.

Table 5-6 Item discription of system information window

Item Explanation

Liebert NXr UPS name

12:30:36 Current time (format: 24 hours, hour, minute, second)

1# Unit 1

/ Audible alarm enabled or disabled. : disabled; : enabled

Menu window and data window

The menu window provides the menus of the data window. The data window displays the items of the menu selected in the menu window. UPS parameters can be browsed and functions can be set through the menu window and data window. Details are provided in Table 5-7.

Table 5-7 Item discription of menu window and data window

Menu Item Explanation

Mains

L-N voltage (V) Phase voltage

L-N current (A) Phase current

Frequency (Hz) Input frequency

L-L voltage (V) Line voltage

Power factor Power factor

TX Input

L-N voltage (V) Phase voltage

L-L voltage (V) Line voltage

Bypass

L-N voltage (V) Phase voltage

Frequency (Hz) Bypass frequency

L-L voltage (V) Line voltage

OutPut

L-N voltage (V) Phase voltage

L-N current (A) Pahse current

Frequency (Hz) Output frequency

L-L voltage (V) Line voltage

Power factor Power factor

TX Output

L-N voltage (V) Phase voltage

L-L voltage (V) Line voltage

Load

Sout (kVA) Sout: apparent power

Pout (kW) Pout: active power

Qout (kVAR) Qout: reactive power

Load level (%) Load (expressed in percentage of the UPS rating load )

Crest factor Output current crest factor

System

Sout (kVA) Sout: apparent power

Pout (kW) Pout: active power

Qout (kVAR) Qout: reactive power

Single unit, no parallel system data

Displayed in this data window when the UPS is configured as a single unit

Battery

Battery voltage (V) Battery bus voltage

Battery current (A) Battery bus current

Battery temperature (°C) Battery temperature

Battery remain time (min) Remaining battery backup time

Battery capacity (%) Percentage of battery life when compared to a new battery

Battery boost charging Battery is boost charging

Battery float charging

Battery is

float

charging

Battery is not connected Battery is not connected

Event (active alarm)

Displays the active alarms. For the list of the alarms that may be displayed on the LCD on the UPS operator control and display panel, refer to Table 5-9

Records (alarm history)

Displays the alarm history. For the list of the alarms that may be displayed on the LCD on the UPS operator control and display panel, refer to Table 5-9

Language (language option) Provides 12 optional LCD languages

Chapter 5 Operator Control And Display Panel 37

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Menu Item Explanation

Settings (refer to Intellislot configuration procedure for recommended settings)

Display contrast Adjusts the LCD contrast

Date format set Four formats selectable: MM/DD/YYYY, DD/MM/YYYY, YYYY/MM/DD

Date & time Sets the date and time

Comm1 baud rate

Sets the RS232 communication baud rate of the RS232 service port and of Intellislot 1 port

Comm2 baud rate Sets the RS232 communication baud rate of Intellislot 3 port

Comm3 baud rate Sets the RS485 communication baud rate of Intellislot 1 ~ 3 ports

Communication address Applicable to RS485 communication

Communication mode Sets the communcation mode

Callback times

When the communication mode of Intellislot 1 port is modem, this parameter sets the number of callback attempts for each new alarm

Phone No.1

Sets the first priority telephone number to be dialled upon alarm when the communication mode of Intellislot 1 port is modem

Phone No.2

Sets the second priority telephone number to be dialled upon alarm when the communication mode of Intellislot 1 port is modem

Phone No.3

Sets the third priority telephone number to be dialled upon alarm when the communication mode of Intellislot 1 port is modem

Command password The user can modify the command password

Protocol System protocols available : Velocity, YDN23

Command (initiate, stop battery, system test or freshening charge

Battery maintenance test

This test performs a partial discharge of the battery to obtain a rough estimate of the battery capacity. Load must be between 20% and 80%

Battery capacity test

This test performs a full discharge of the battery to obtain a precise measure of the battery capacity. Load must be between 20% and 80%

System test

This is a self-test of the UPS. When the user activates this function, a window appears about five seconds later to show the test result

Stop testing Manually stops a battery maintenance test, battery capacity test or system test

Freshening charge Manually initiates a battery freshening charge

Stop freshening charge Manually stops a battery freshening charge

Modem auto-answer enabled

Manually enable the modem’s auto-answer function

Version

UPS version Provides UPS inverter, rectifier and monitoring software versions

UPS model Provides UPS model information, for example, 400V-60Hz

Keypad window

The functions of the menu keys F1 ~ F5 for the current screen is shown by self-explanatory icons in the keypad window as appropriate.

5.7 Prompt Window

A prompt window is displayed during the operation of the system to alert you to certain conditions or to require your confirmation of a command. The prompts are provided in Table 5-8.

Table 5-8 Prompts and meanings

Prompt Meaning

Transfer with interrupt, confirm or cancel

The inverter and bypass supplies are not synchronized and any load transfer between the inverters and bypass will cause a brief load interruption

The load is too high to be transferred with interrupt

The total load must be less than the capacity of one UPS to allow a parallel system to perform an interrupted transfer from bypass to inverter

This operation leads to output shutdown, confirm or cancel

The bypass is abnormal, turning off the inverters will cause the load to be dis-engergised

This operation leads to inverter overload, confirm or cancel

Turning off this inverter will lead to the overload of the remaining inverter(s) in a parallel system

Turn on more UPS to carry current load

The number of inverters already turned on is insufficient to carry the exisitng load. The user is required to turn on more inverters

Battery will be depleted, confirm or cancel

If you select battery maintenance test, the battery will discharge until the UPS shuts down. This prompt appears to require your confirmation. Cancelling the test will ends the test and transfers the UPS to Normal mode

System self test finished, everything is No action required

38 Chapter 5 Operator Control And Display Panel

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Prompt Meaning

Please check the current warnings Check the active alarm messages

Enter control password Required for battery or UPS test (default: 123456)

Battery Self Test aborted, conditions not met

Battery selt-test condition is not met. Please check whether the battery is in boost charge state and the load is more than 20%

Battery Refresh Charge aborted, conditions not met

This prompt appears when you select the Freshening charge command while the a battery freshening charge condition (such as no battery, charger failure) is not met

5.8 Alarm List

Table 5-9 provides the complete list of UPS alarm messages for display either on the Event menu or on the Records menu described in Table 5-7.

Table 5-9 Alarm list

Alarm Explanation

Comm. fail The communication of the internal monitor with the rectifier, inverter or bypass failed

Parallel Comm. Fail

The communication between the inverter of each UPS in the parallel system failed.

1.Check if any UPSs are offline. If yes, power on these UPSs and check if the alarm disappears.

2. Press the FAULT CLEAR button

Battery Overtemp. The battery temperature is over limit. Check the battery temperature and ventilation

Ambient Overtemp. The ambient temperature is over limit. Check the ventilation of the UPS room

Battery Replaced Battery test failed. The battery needs replacement

Battery Low Pre-warning

Before the EOD, battery low pre-warning will occur. After this pre-warning, the battery will have the capacity for three minutes discharging with full load. The time is user-settable from 3 minutes to 60 minutes. Please shut down the load in time

Battery End of Discharge Inverters turned off due to battery EOD. Check the mains failure and try to recover it

Mains Volt. Abnormal

The mains voltage is outside specifications and results in rectifier shutdown. Check the rectifier input phase voltage

Mains Undervoltage Mains voltage is under limit with derated load. Check the rectifier input line voltage

Mains Freq. Abnormal

The mains frequency is outside specifications and results in rectifier shutdown. Check the rectifier input voltage and frequency

Batt. Charger Fail The voltage of the battery charger is too high

Control Power 1 Fail The UPS is operating but the control power is abnormal or not available

Mains Phase Reversed The AC input phase rotation is reversed

Rectifier Fault Internal fault of a power module is detected and results in rectifier shutdown and battery discharging

Rectifier Overtemp

The temperature of the heatsink is too high to keep the rectifier running. The UPS can recover from this fault automatically. Check the environment and ventilation

Soft Start Fail

The rectifier can not start owing to low DC bus voltage. Seek assistance from the local customer service center of Emerson

Bypass Unable to Trace

This alarm is triggered by an inverter software routine when the amplitude or frequency of bypass voltage is outside specifications. The amplitude threshold is fixed for ±10% rating. This alarm automatically resets once the bypass voltage goes normal.

1. First verify that the bypass voltage and frequency displayed on the LCD are within the selected ranges. Note that here the rated voltage and frequency are specified by Output voltage level and Output frequency level respectively.

2. If the displayed voltage is believed to be abnormal, then verify the bypass voltage and frequency presented to the UPS. Check the external supply if it is found faulty

Bypass Abnormal

This alarm is triggered by an inverter software routine when the amplitude or frequency of bypass voltage exceeds the limit. The amplitude threshold is fixed for ±10% rating. This alarm automatically resets once the bypass voltage returns to normal.

1. First check if there are some relevant alarms such as Bypass phase reverse and Mains neutral lost. If they appear, solve them first.

2. Then verify that the bypass voltage and frequency displayed on the LCD are within the bypass limits. Note that here the rated voltage and frequency are specified by Output voltage level and Output frequency level respectively.

3. If the displayed voltage is believed to be abnormal, then measure the bypass voltage and frequency presented to the UPS. If the bypass voltage and frequency are abnormal, check the external bypass supply.

4. If the mains is likely to trigger this alarm frequently, the bypass limits can be changed to a wider

Chapter 5 Operator Control And Display Panel 39

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Alarm Explanation

tolerance through the service configuration software

Inverter Asynchronous

This alarm is triggered by an inverter software routine when the inverter and bypass waveforms are misaligned by more than six degrees in phase. The amplitude threshold is fixed for ±10% rating. This alarm resets automatically once the condition is no longer true.

1. First check if the alarm Bypass unable to trace or Bypass abnormal occurs. If so, solve it first.

2. Verify the waveform of the bypass voltage

Inverter fault

Inverter output voltage outside specifications. Load transfers to bypass. The faulty power module will shut down and open output relay, and the remaining power

modules will remain online

Fan fault At least one of the cooling fans failed

Bypass STS Fail At least one of the STSs at the bypass side is open or shorted. This fault is locked until power-off

Output Fuse Fail

At least one of the inverter output fuses is blown. The inverter shuts down, and the load transfers to bypass if the remaining power modules are insufficient to support the load

Control power 1 fail The UPS is operating but the redundant control power is abnormal or not available

Unit Over load

This alarm appears when the load arises above 105% of the nominal rating. The alarm automatically resets once the overload condition is removed.

1. Find out if this alarm is true by checking which phase has overload through the load (%) displayed on the LCD.

2. If this alarm is true, measure the actual output current to confirm if the displayed value is correct.

3. If yes, disconnect the non-critical load. In a parallel system, this alarm will be triggered if the load is severely unbalanced

System Over load

This alarm appears when the total load rises above 105% of the nominal rating of the parallel system.The alarm automatically resets once the overload condition is removed.

1. Find out if this alarm is true by checking which phase of which unit has overload through the load (%) displayed on the LCD.

2. If this alarm is true, measure the actual output current to confirm if the displayed value is correct.

3. If yes, disconnect the non-critical load. This alarm will be triggered if the load is severely unbalanced

Unit Over load Timeout

The UPS overload status continues and the overload times out. Note that:

1. T

he highest loaded phase will indicate overload time-out first.

2. When the timer is active, then the alarm Unit Over load should also be active as the load is above the nominal rating.

3. When the time has expired, the load transfers to static bypass. The inverter shuts down and will restart after 10 seconds.

4. If the load decreases to lower than 95%, after five minutes, the system will transfer back to the inverter.Check the load (%) displayed on the LCD to confirm if this alarm is true. If the LCD tells that overload happens, then check the actual load and confirm if the UPS has overload before the alarm happens

Byp. Abnormal Shutdown Both the bypass and inverter voltages are abnormal, and the output is off

Inverter Over Current The inverter has overcurrent fault

Bypass Phase Reversed

The phase rotation of the bypass voltage is reverwed. Normally, phase B lags 120 degrees behind phase A, and phase C lags 120 degrees behind phase B. Check that the phase rotation of the UPS bypass supply is correct

Load Impact Transfer

A transfer to bypass occurred due to a large step load. The UPS can recover automatically. Turn on the load equipment in stages to reduce the load impact on the inverter

Transfer Time-out

The load remains on bypass power owing to excessive number of transfers that occurred within the last hour. The UPS can recover automatically and will transfer the load back to inverter power within an hour

Load Sharing Fault The UPSs in a parallel system are not sharing the load current correctly

DC Bus Abnormal The DC bus voltage is abnormal and results in inverter shutdown. The load transfers to bypass

System Transfer

All UPSs in the parallel system transfer to bypass at the same time when one of them needs to transfer to bypass. This message appears on the LCD of the UPS with passive transfer to bypass

DC Bus Over Voltage

The rectifier, inverter and battery converter shut down because the DC bus voltage is too high.. Check if the rectifier has any fault. If no, check if an overload has occurred. Restart the inverter after the fault is cleared

Bypass Over Current The bypass current is above 135% of the rated current. The UPS alarms but has no action

LBS Active The LBS setting is active. The UPS is acting as an LBS master or slave in a dual bus configuration

Mains Neutral Lost The neutral line of the AC input mains is not detected

Battery ground fault

The battery ground fault option has detected a battery ground fault. Contact the local customer service center of Emerson to inspect the battery installation

40 Chapter 5 Operator Control And Display Panel

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Alarm Explanation

Manual Turn On INVERTER ON button activated on the operator control and display panel to turn on the inverter

Manual Turn Off INVERTER OFF button activated on the operator control and display panel to turn off the inverter

EPO The local or remote EPO has been activated

Interrupted Transfer Confirm

A prompt for the user to decide whether to press the Enter key to acknowledge an interrupted load transfer to bypass

Transfer Cancel

A prompt for the user to decide whether to press the ESC key to avoid an interrupted load transfer to bypass

Unit Risk Off Confirm

A prompt for the user to decide whether to press the Enter key to shut down a UPS in the parallel system

Parallel System Risk Off Confirm

A prompt for the user to decide whether to press the Enter key to shut down the parallel system

Fault Reset FAULT CLEAR button pressed

Alarm Silence SILENCE ON/OFF button pressed

Turn On Fail

The inverter failed to turn on when the INVERTER ON button is pressed. This may be the result of an invalid operation (maintenance bypass on) or DC bus or rectifiers not ready

Audible Alarm Reset FAULT CLEAR or SILENCE ON/OFF button pressed

Bypass Mode The UPS is in bypass mode

Normal Mode The UPS is in normal mode

Battery Mode The UPS is in battery mode

Source share mode The inverter is supplied by the battery and rectifier at the same time

UPS Shutdown UPS shutdown with no output power

BCB Open BCB status (open)

BCB Close BCB status (closed)

Batt. Float Charging Battery status (float charge mode)

Batt. Boost Charging Battery status (boost charge mode)

Battery Discharging Battery status (discharge mode)

Battery Period Testing The battery is under automatic periodic battery maintenance test (20% capacity discharge)

Batt. Capacity Testing The user initiated a battery capacity test (100% capacity discharge)

Battery Maintenance Testing

The user initiated a maintenance test (20% capacity discharge)

Inverter in Setting The inverter starts up and is in synchronization

Rectifier in Setting The rectifier starts up and is in synchronization

Battery room alarm The temperature in the battery room is high and needs to be attended

BCB open BCB status (open)

BCB closed BCB status (closed)

Battery Reverse Reconnect battery and check battery wiring

Auto start After UPS shutdown at EOD, the inverter automatically starts upon mains restoration

Rec Flash Update Rectifier software being updated

Inv Flash Update Inverter software being updated

Monitor Flash Update Monitoring software being updated

Bypass Flash Update Bypass software being updated

LBS abnormal LBS abnormal

Chapter 6 Operating Instructions 41

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 6 Operating Instructions

This chapter provides detailed operating procedures of the UPS.

The audible alarm may annunciate at various points in these procedures. Pressing the SILENCE ON/OFF button can cancel the audible alarm at any time.

Warning: hazardous mains and/or battery voltage present behind protective cover

The components that can only be accessed by opening the protective cover with tools cannot be operated by user. Only qualified service personnel are authorised to remove such covers.

6.1 Power Switches

The UPS provides a maintenance switch only (silkscreen: MAINTAIN CB), as shown in Figure 6-1 to Figure 6-3. The user needs to provide the other switches.

Maintenance switch

Figure 6-1 Location of maintenance switch of 30kVA (NXr 30K-B) UPS

42 Chapter 6 Operating Instructions

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Maintenance switch

Figure 6-2 Location of maintenance switch of 30kVA (NXr 30K) ~ 160kVA UPS

Maintenance switch

Figure 6-3 Location of maintenance switch of 200kVA UPS

6.2 UPS Startup Procedures

It is assumed that the installation is complete, the system has been commissioned by authorized personnel, and the external power isolators are closed.

Chapter 6 Operating Instructions 43

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

6.2.1 Procedures For Startup Into Normal Mode

Warning

1. These procedures result in mains voltage being applied to the UPS output terminals.

2. If any load equipment is connected to the UPS output terminals, check with the user that it is safe to apply power. If the load is not ready to receive power, ensure that it is safely isolated from the UPS output terminals.

3. Do not start the UPS until the installation is completed and the system has been commissioned by authorized personnel.

Use the following procedures to turn on the UPS from a fully powered down condition. In a parallel system, perform each step of the procedures in every UPS module before proceeding to the next step.

1. Close the external input switch to the UPS to feed the mains power to the UPS, and close the external BCB. In split bypass configuration, it is required to close both input switches.

At this point, the LCD starts up. The rectifier indicator flashes in green color during rectifier startup. About 30s after the rectifier enters normal operation, the rectifier indicator goes solid green. After system initialization, the bypass STS is closed. The UPS indicator states are as listed in Table 6-1.

Table 6-1 UPS indicator state

Indicator State

Rectifier indicator Green

Battery indicator Off

Bypass indicator Green

Inverter indicator Off

Output indicator Green

Status indicator Amber

2. Press and hold the INVERTER ON button for 2s.

The inverter starts up, and the inverter indicator flashes in green color. After the inverter is ready, the UPS transfers from bypass to inverter, the bypass indicator turns off, the inverter indicator and output indicator turn on.

The UPS is in normal mode, and the UPS indicator states are as listed in Table 6-2.

Table 6-2 UPS indicator state

Indicator State

Rectifier indicator Green

Battery indicator Off

Bypass indicator Off

Inverter indicator Green

Output indicator Green

Status indicator Green

6.2.2 Procedures For Startup In Battery Mode (Startup Without A.C. Input Supply)

1. Verify that the battery is properly connected.

2. Press the battery start button (see Figure 6-4) on the front panel of any power module.

At this point, the LCD starts up, and the battery indicator starts flashing in green color. After the rectifier has operated normally for 30s, the battery indicator stops flashing and becomes solid green.

电池启动按钮

Battery start button

Figure 6-4 Location of battery start button

Note

44 Chapter 6 Operating Instructions

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

After step 2, if any of the following conditions occurs, open the BCB or confirm that the BCB has tripped automatically and is open. The system can be started up one minute later.



EPO action



Fault in system commissioning

3. Press and hold the INVERTER ON button on the operator control and display panel for 2s, and the UPS begins to operate in battery mode.

6.3 Procedures For Transfer Between Operation Modes

6.3.1 Transfer From Normal Mode To Battery Mode

Open the external power switch to isolate the mains power and initiate the UPS on battery mode. To transfer the UPS back to normal mode, wait for several seconds, then close the external power switch to re-connect the mains power to the UPS. 10s later, the rectifier restarts automatically to feed power to the inverter.

6.3.2 Transfer From Normal Mode To Bypass Mode

When the UPS is in normal mode, press the INVERTER OFF button on the operator control and display panel transfers the UPS from normal mode to bypass mode.

Note

In bypass mode, the load is directly fed by the mains power instead of the pure AC power from the inverter.

6.3.3 Transfer From Bypass Mode To Normal Mode

When the UPS is in bypass mode, press the INVERTER ON button on the operator control and display panel. After the inverter enters normal operation, the UPS is transferred from bypass mode to normal mode.

6.3.4 Transfer From Normal Mode To Maintenance Mode

These procedures transfer the load from the UPS inverter output to the maintenance bypass supply, but the precondition is that the UPS is in normal mode.

Caution

Before making this operation, read the information on the LCD to make sure that the bypass supply is normal and that the inverter is synchronous with the bypass sypply, so as not to risk a short interruption in power to the load.

1. Press and hold the INVERTER OFF button on the operator control and display panel for 2s.

At this point, the inverter indicator turns off, the bypass indicator turns on, and the status indicator changes to amber, accompanied by an audible alarm. The load transfers to the bypass, and the inverter shuts down.

Note

Pressing the SILENCE ON/OFF button cancels the audible alarm but leaves the alarm message displayed until the alarm condition is rectified.

2. For a single UPS, open the UPS door and rotate the maintenance switch from the OFF position to the ON position; for a 1+N parallel system, close the external maintenance switch.

At this point, the load power supply is provided by the manual maintenance bypass.

Warning

1. If you need to maintain a faulty module, wait for 10min to let the internal DC bus capacitor fully discharge before removing the faulty module for maintenance.

2. When the UPS in operating in maintenance mode, the neutral line is still energized. Therefore, only qualified personnel shall

Chapter 6 Operating Instructions 45

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

maintain the UPS.

Caution

When the UPS is in maintenance mode, the load is not protected against abnormal mains supply.

6.4 Procedures For Completely Powering Down The UPS

Caution

The following procedures will switch off all power to the load.

Warning: hazardous battery voltage

The UPS battery and connecting terminals remain energized at hazardous voltage levels at all times.

The following procedures are used to completely power down the UPS and load. All power switches, isolators and circuit breakers will be opened and the power will be removed from the load. In a parallel system, perform each step of the procedures in every UPS module before proceeding to the next step.

1. Press the EPO switch on the UPS front panel. This disables the rectifier, inverter, static transfer switch and battery operation, and the load is de-energised. Note: Unless in an emergency situation, do not press the remote EPO switch.

2. Open the external a.c. input switch and BCB. In split bypass configuration, it is required to open both a,c. input switches.

In a parallel system, at this point, other UPSs report Parallel Comm. Fail, which is normal. Other UPSs continue to power the load through the inverter.

All of the indicators and the LCD on the front panel will extinguish as the mains-driven internal power supplies decay.

3. Open the external a.c. output switch of the UPS.

6.5 Procedures For Completely Powering Down The UPS While Maintaining he

Power Supply To The Load

Caution

Ensure that the UPS has been installed with an external maintenance bypass cabinet before carring out these procedures.

The following procedures are applicable for completely powering down the UPS and still keeping the power supply to the load. In a parallel system, perform each step of the procedures in every UPS module before proceeding to the next step.

1. Use the procedures in 6.3.4 Transfer From Normal Mode To Maintenance Mode to transfer the UPS to

maintenance mode.

2. Close the maintenance switch of the external maintenance bypass cabinet.

3. Open the external a.c. input switch of the UPS. In split bypass configuration, it is required to open both external a.c. input switches.

4. Open the output switch of the UPS.

6.6 Isolation Procedures (Of One UPS In A Parallel System)

Caution

The following procedures will switch off all power to the load.

46 Chapter 6 Operating Instructions

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Warning: hazardous battery voltage

The UPS battery and connecting terminals remain energized at hazardous voltage levels at all times.

The following procedures are used to isolate one UPS from a parallel system.

1. Press the EPO switch of the UPS to be isolated.

2. Open the external a.c .input switch and BCB of the UPS. In split bypass configuration, it is required to open both external a.c input switches.

At this point, other UPSs report Parallel Comm. Fail, which is normal. Other UPSs continue to power the load through the inverter.

3. Open the external a.c output switch of the UPS.

4. Wait for 10 minutes before carrying out UPS maintenance or repair.

6.7 Insertion Procedures (Of One UPS In A Parallel System)

The procedures are used to re-integrate a UPS that has been previously isolated from a parallel system. It is assumed that the installation is completed and the system has been commissioned by authorized personnel.

1. Close the external a.c output switch of the UPS to be re-integrated.

2. Close the external a.c input switch and BCB of the UPS. In split bypass configuration, it is required to close both external a.c input switches.

3. Press and hold the INVERTER ON button of the UPS for 2s.

The inverter starts up, and the inverter indicator starts flashing in green color. When the inverter is ready, the UPS transfers to parallel operation with other UPSs, and the inverter indicator goes to a continuous on state.

The UPS is in normal mode, and the UPS indicator states are as listed in Table 6-3.

Table 6-3 UPS indicator state

Indicator State

Rectifier indicator Green

Battery indicator Off

Bypass indicator Off

Inverter indicator Green

Output indicator Green

Status indicator Green

6.8 Emergency Power Off (EPO) Procedures

The EPO switch is designed to switch off the UPS in emergency conditions (that is, fire, flood, and so on). The system will turn off the rectifier, inverter and stop powering the load immediately (including the inverter and bypass), and the battery stops charging or discharging.

If the input mains is present, the UPS’s control circuit will remain active; however, the output will be turned off. To remove all power from the UPS, the external feeder breaker should be opened.

Note

In a parallel system, the EPO only isolates the UPS whose EPO has been activated.

6.9 Automatic Restart

In the case of a mains failure, the UPS draws power from the battery system to supply the load until the batteries are depleted. When the UPS reaches its end of EOD threshold, it shut will down.

The UPS will automatically restart and enable output power:

Chapter 6 Operating Instructions 47

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

 after the mains power is restored

 if Auto Recovery after EOD Enabling is enabled

 after the Auto Recovery after EOD Delay Time expires (the default delay is 10min). during the automatic

recovery delay, the UPS will charge its batteries to provide a safety margin for equipment shutdown if input power fails again

If the Auto Recovery after EOD Enabling feature is disabled, the user may restart the UPS manually by pressing the FAULT CLEAR button.

6.10 UPS Reset Procedures

After an EPO action or UPS shutdown due to inverter over temperature, overload, battery over-voltage or too many transfer times, once all appropriate measures have been taken to correct the problem indicated by the alarm message on the LCD, carry out the following procedures to restore the UPS to normal operation.

1. Press the FAULT CLEAR button to let the system exit the shutdown state.

2. When the rectifier begins to operate normally (rectifier indicator in solid green), press and hold the INVERTER ON button for 2s.

Note

1. The rectifier will start and the bypass will begin to power the load. The rectifier indicator flashes while the rectifier is starting up. When the rectifier enters normal operation (about 30s later), the rectifier indicator turns green.

2. The rectifier will be turned on automatically when the overtemprature fault disappears 5 minutes after the disappearance of overtemprature signals.

After the EPO switch is pressed, if the mains input is cut off, the UPS will shut down completely. When the mains input returns, the UPS will start up on bypass. There will be power at the output terminals of the UPS.

Warning

1. If the maintenance switch is in the ON position and the mains input is present, there will be power at the otuput terminals of the UPS.

2. If you need to maintain a faulty module, wait for 10min to let the internal DC bus capacitor fully discharge before removing the faulty module for maintenance.

48 Chapter 7 Service

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 7 Service

This chapter introduces the UPS service, including the service procedures of the power module and bypass modules, and the replacement procedures of the air filters.

Warning: hazardous mains and/or battery voltage present behind protective cover

1. The components that can only be accessed by opening the protective cover with tools cannot be operated by user. Only qualified service personnel are authorised to remove such covers.

2. In UPS maintenance, note that the neutral line is energized.

7.1 Service Procedures Of Power Module And Bypass Module

7.1.1 Notes

1. Only the customer service engineers shall service the power modules and bypass module.

2. Remove the power modules and bypass module from top to bottom, so as to prevent cabinet toppling due to high gravity center.

3. To ensure safety, before servicing the power modules and bypass module, be sure to use a multimeter to verify that the DC bus capacitor voltage is lower than 60Vdc, and that the voltages between the earth and the components you are going to work on are under dangerous voltage values, that is, lower than 60Vdc or 42.4Vac peak value.

4. The bypass module is not swappable. Only when the UPS is transferred to internal or external maintenance bypass or completely powered off can the bypass module be removed.

5. The power modules and bypass module should be serviced 10 minutes after they are removed.

7.1.2 Service Procedures Of Power Module

Provided that the UPS is in normal mode, and that the bypass is normal:

1. If the available UPS power modules have redundancy, proceed to step 2; if not, press and hold the INVERTER OFF button on the operator control and display panel for two seconds to manually turn off the inverters, and the UPS transfers to bypass mode.

2. Place the ready switch on the front panel of the power module to the up position (that is, in unready state).

3. Two minutes later, remove the fixing screws on both sides of the front panel of the module, and pull the module out of the cabinet.

Note

The module will be blocked by a spring piece on the left side of the module when the module is pulled out of the cabinet halfway. At this point, you must press the spring piece before you continue to pull the module out.

4. After servicing the module, check that the address of this module is different from those of other modules and that the address is in the range from one to five (one to six for 200kVA UPS). Check that the ready switch is in unready state.

5. Push the module (at least 10s after another) into the cabinet, and tighten the screws on both sides.

6. Wait for two minutes, place the ready switch of the module to the down position, and the module will connect to the system. If the UPS has been transferred to bypass, press and hold the INVERTER ON button for two seconds to start up all power modules.

7.1.3 Service Procedures Of Bypass Module

Provided that the UPS is in normal mode, and that the bypass is normal:

Chapter 7 Service 49

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

1. Press and hold the INVERTER OFF button on the operator control and display panel for two seconds to manually turn off the inverters, and the UPS transfers to bypass mode.

2. Close the maintenance bypass, and the UPS transfers to maintenance mode.

3. Open the external a.c UPS output switch and input switch. In split bypass configuration, it is required to open external a.c both input switches.

4. Press the EPO switch, ensure that the battery current is 2A. Open the BCB or disconnect the batteries.

5. Remove the fixing screws on both sides of the front panel of the bypass module, and pull the module out of the cabinet. Wait for 10 minutes before servicing the bypass module.

6. After servicing the module, push the module (at least 10s after another) into the cabinet, and tighten the screws on both sides.

7. Close the external a.c UPS output switch and input switch in turn. In split bypass configuration, it is required to close both external a.c input switches.

Two minutes later, the bypass indicator on the operator control and display panel turns on, indicating the UPS is operating in bypass mode.

8. Open the maintenance switch, press and hold the INVERTER ON button on the operator control and display panel for two seconds to manually turn on the inverters, and the UPS transfers to normal mode.

7.2 Replacement Procedures Of Air Filter

As shown in Figure 7-1 and Figure 7-2, the UPS provides air filters on the back of the front door. Each air filter is fixed by a fixing bar on both sides. The air filter replacement procedures are as follows:

1. Open the front door of the UPS to reveal the air filters on the back of the door.

2. Remove the fixing bar on either side of the air filter, and loosen the fixing screws of the fixing bar on the other side, with no need to remove this fixing bar.

3. Remove the air filter, and insert a clean one.

4. Re-install the removed fixing bar in the original place.

5. Tighten the fixing screws of the fixing bar on the other side.

Fixing screw

Fixing bar

Air filter

Figure 7-1 Replacing air filter of 30kVA ~ 160kVA UPS

50 Chapter 7 Service

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Fixing screw

Fixing bar

Air filter

Fixing bar

Figure 7-2 Replacing air filter of 200kVA UPS

Chapter 8 Product Specifications 51

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Chapter 8 Product Specification

The chapter provides the UPS specifications.

8.1 Conformity And Standards

The UPS has been designed to conform to the European and international standards listed in Table 8-1.

Table 8-1 European and international standards

Item Normative reference

General and safety requirements for UPS used in operator access areas

EN62040-1-1/IEC62040-1-1/AS62040-1-1

Electromagnetic compatibility (EMC requirements for UPS EN62040-2/IEC62040-2/AS62040-2 (C2 type)

Method of specifying the performance and test requirements of UPS

EN62040-3/IEC62040-3/AS62040-3 (VFI SS 111)

Note: The product standards in this table incorporate relevant compliance clauses with generic IEC and EN standards for safety (IEC/EN/AS60950), electromagnetic emission and immunity (IEC/EN/AS61000 series) and construction (IEC/EN/AS60146 series and 60529)

8.2 Environmental Characteristics

Table 8-2 Environmental characteristics

Item Unit Rated power (kVA)

30 40, 60 90, 100, 120 150, 160 200 Noise within 1m (in the front) dB 56 58 60 62 66 Altitude m

≤1000, derate power by 1% per 100m between 1000m and 2000m Relative humidity %RH 0 ~ 95, non condensing Operating temperature °C 0 ~ 40; battery life is halved for every 10°C increase above 20°C Storage and transport temperature for UPS °C -20 ~ 70 Recommended battery storage temperature

°C -20 ~ 30 (20°C for optimum battery storage)

Over voltage category IEC 60664-1 level 2

Pollution degree IEC 60664-1 level 2

8.3 Mechanical Characteristics

Table 8-3 Mechanical characteristics

Item Unit Rated power (kVA)

，

90, 100 120 150, 160 200

Dimensions (W × D × H) mm 600 × 843 × 1400 600 × 843 × 1600 Weight (excluding battery) kg 200 234 268 302 336 380 Color Charcoal Grey ZP7021 / RAL 7021 Protection degree, IEC(60529) IP20 (front door open or closed)

52 Chapter 8 Product Specifications

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

8.4 Electrical Characteristics (Input Rectifier)

Table 8-4 Rectifier AC input (mains)

Item Unit Rated power (kVA)

30 40 60 90, 100 120 150, 60 200

Rated AC input voltage

Vac 380/400/415 (3-phase and sharing neutral with the bypass input)

Input voltage range

Vac 228 ~ 437

Frequency

Hz 50/60 (tolerance: 40Hz ~ 70Hz)

Power factor kW/kVA, full load (half

load)

0.99 (0.98)

Input power kVA rated

(maximum4) 30

(34.5)

(46)

(69)

(103.5)

120

(138)

150

(173)

180

(207)

Input current A rated

(maximum4) 45 (54) 55

(70)

(108)

135

(162)

180

(216)

225

(270)

270

(320) Harmonic current distortion THDI% FL 3 Duration of progressive power walk-in

s 10s to reach full ratd current (selectable 5s through 30s in 5-second

intervals)

Note:

1. Rectifiers operate at any of the rated supply voltages and frequencies without further adjustment.

2. At 305V input mains the UPS maintains the specified output voltage at rated load without discharging a previously charged battery.

3. IEC62040-3: at rated load and input voltage 400V, battery charged.

4. IEC62040-3: at rated load and input voltage 400V, battery charging at maximum rated power

8.5 Electrical Characteristics (Intermediate DC Circuit)

Table 8-5 Battery

Item Unit Rated power (kVA)

30 40 60 90, 100 120 150, 160 200 Battery bus voltage Vdc Nominal: 360 (VRLA float charge is 405V); range: 300 ~ 576 Quantity of lead-acid cells

Maximum 40 x 6-cell 12V blocks

Minimum 30 x 6-cell 12V blocks

Float voltage V/cell (VRLA) 2.25 (selectable from 2.2V/cell to 2.3V/cell)

Constant current and constant voltage charge mode Temperature compensation

mV/°C/cl –3.0 (selectable from 0 to –5.0 around 25°C or 30°C, or inhibit)

Ripple voltage % V float ≤1 Ripple current % C

≤5

Boost voltage V/cell (VRLA) 2.35 (selectable from 2.30V/cell to 2.40V/cell)

Constant current and constant voltage charge mode Boost control

Float-boost current trigger 0.050C10 (selectable from 0.030 to 0.070)

Boost-float current trigger 0.010C

(selectable from 0.005 to 0.025) 24hr safety time timeout (selectable from 8hr to 30hr) Boost mode inhibit also selectable

EOD voltage

V/cell (VRLA)

1.63 (selectable from 1.60V/cell to 1.750V/cell)3 Automatic inverse, EOD voltage × discharge current mode (the EOD voltage increases at low discharge currents)

Battery charge V/cell

2.4 (selectable from 2.30V/cell to 2.40V/cell) Constant current and constant voltage charge mode Programmable automatic trigger or inhibit of boost mode

Battery charging power

and max charging current (adjustable)

kW 4.5 6 9 13.5 18 22.5 27

A 11 14.7 22 33 44 55 66

Chapter 8 Product Specifications 53

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Note:

1. At low input voltage the UPS recharge capability increases with load decrease (up to the maximum capacity indicated).

2. Max currents listed are for EOD voltage of 1.67V/cell for 240 cells

3.Need to satisfy DC bus voltage for inverter operation of 300-576 Vdc.

8.6 Electrical Characteristics (Inverter Output)

Table 8-6 Inverter output (to critical load)

Item Unit

Rated power (kVA)

30 ~ 200

Rated AC voltage1 Vac 380/400/415 (three-phase four-wire, with neutral reference to the bypass neutral)

Frequency2 Hz 50/60

Overload

％

105, long term 110, 60min 125, 10min 150, 1min >150, 200ms

Fault current % 310% current limination for 200ms

Non-linear load capability

100

Neutral current capability % 170

Steady state voltage stability

± 1

Transient voltage response

± 5

Tatal harmonic voltage % <1 (linear load), <4 (non-linear load3)

Synchronisation window Hz

Rated frequency ±5

Slew rate (max change rate of synchronisation frequency)

Hz/s 1; setting range: 0.1 ~ 3 (single unit), 0.2 (parallel system)

Note:

1. Factory set to 380V. 400V or 415V selectable by commissioning engineer.

2. Factory set to 50Hz. 60Hz selectable by commissioning engineer. 3. IEC 62040-3 (1.4.58) crest factor 3:1.

4. IEC 62040-3 also for 0% ~ 100% ~ 0% load transient. Transient recovery time: return to within 5% of steady state output voltage within half a cycle

8.7 Electrical Characteristics (Bypass Input)

Table 8-7 Bypass input

Item Unit

Rated power (kVA)

30 (NXr 30K-B) 30 (NXr 30K) ~ 160 200

Rated AC voltage

Vac

380/400/415, three-phase four-wire, sharing neutral with the rectifier input and providing neutral reference to the output

Rated current

380V 400V 415V

A 45 227 303

A 43.5 217 290

A 42 208 278

Overload %

110, long term 125% 150%

Upstream protection, bypass line

N/A

Thermomagnetic circuit breaker, rated up to 125% of nominal output current. IEC 60947-2 curve C

Current rating of neutral cable

A 1.7 × In

Frequency2 Hz 50/60

Transfer time (between bypass and inverter)

Synchronous transfer: ≤1 Asynchronous transfer (default): 15 (50Hz), 13.3 (60Hz); or 40, 60, 80, 100 selectable

54 Chapter 8 Product Specifications

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Item Unit Rated power (kVA)

Bypass voltage tolerance %Vac

Upper limit: +10, +15 or +20, default: +15 Lower limit: -10, -20, -30 or –40, default: -20 (delay time to accept steady bypass voltage: 10s)

Bypass frequency tolerance

% ±10 or ±20, default: ±10

Synchronisation window Hz Rated frequency: ±5

Note:

1. Factory set to 380V. 400V or 415V selectable by commissioning engineer.

2. Factory set to 50Hz. 60Hz selectable by commissioning engineer

8.8 Efficiency, Heat Losses And Air Exchange

Table 8-8 Efficiency, heat losses and air exchange

Item Unit Rated power (kVA)

30 40, 60 90, 100 120 150, 160 200

Overall efficiency

Normal mode (double-conversion) % Up to 96

Inverter efficiency (DC/AC) (battery at nominal voltage 432Vdc and full-rated linear load)

Battery mode % Up to 96

Heat losses & air exchange

Normal mode kW 1.2 2.4 3.6 4.8 6 7.2

No load kW 0.6 1.2 1.8 2.4 3.0 3.6 Maximum forced air cooling (front intake, rear exhaust)

L/sec 144 288 432 576 720 864

Note: 400Vac input and output, battery fully charged, full-rated linear load

Appendix 1 Option 55

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Appendix 1 Option List

Table 1 Option list

Option Model BOM No. Remark

Dry contact card UF-DRY310 02354309 Installed in Intellislot port, advisably in Intellislot 3

SIC card UF-SNMP810 02351817 Installed in Intellislot port , advisably in Intellislot 2

UF-RS485 card UF-RS485 02351786 Installed in Intellislot port , advisably in Intellislot 3

Modbus card UFMOD41Z1 02354066 Installed in Intellislot port , advisably in Intellislot 3

Battery temperature sensor UF-SENSOR 02350174

Air filter 21120752 One air filter

LBS cable (5m, 10m, 15m)

5m cable (04118683) 10m cable (04118684) 15m cable (04118685)

Two cables should be selected to achieve redundancy

Parallel control cable (5m, 10m, 15m)

5m cable (04118683) 10m cable (04118684) 15m cable (04118685)

Two cables should be selected to achieve redundancy

Bypass load sharing inductor UF-NRBYPCK-30 02354315 Applicable to NXr 30K-B UPS

Bypass load sharing inductor UF-NRBYPCK-100 02354040 Applicable to 30kVA (NXr 30K) ~ 100kVA UPS

Bypass load sharing inductor UF-NRBYPCK-160 02354042 Applicable to 120kVA ~ 160kVA UPS

Bypass load sharing inductor UF-NRBYPCK-200 02354314 Applicable to 200kVA UPS

56 Chapter 8 Product Specifications

NXr UPS Module And Parallel System 30kVA ~ 200kVA User Manual

Appendix 2 List Of Abbreviations

Abbreviation Description

UPS Uninterruptible power system

AC Alternating current

DC Direct current

SCR Silicon-controlled rectifier

RCCB Residual current circuit breaker

RCD Residual current detector

RFI Radio frequency interference

EOD End-of-discharge

CSA Cross sectional area

PE Protective Earth

SCR Silicon-controlled rectifier

EPO Emergency power off

MCCB Moulded-case circuit breaker

CT Center tap

BCB Battery circuit breaker

LBS Load bus synchronizer

PWM Pulse width modulation

DSP Full digital control

STS Static transfer switch

VRLA Valve-regulated lead-acid

LCD liquid crystal display

EMC Electromagnetic compatibility

Emerson NXr, Liebert NXr User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual