Gtec MUST400 User Manual

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Preliminary Version

Modular UPS MUST400

USER Manual

Preliminary Version

Safety Precautions

This manual is about installation and operation of MUST400 modular UPS (Hereinafter referred as UPS).

Please carefully read this manual prior to installation. The UPS must be debugged and maintained by an engineer commissioned by the manufacturer or the agent. Otherwise, human safety may be endangered and the damage of UPS shall not belong to the warranty scope.

APPLICABLE STANDARDS

This product complies with 2006/95/EC- CE 73/23 & 93/68 (low voltage safety) and 89/336 – 2004/108/EC (EMC) , and 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 C3 *IEC62040-3 Performance requirements and test methods

WARNING- High earth leakage current

Earth connection is critical before connecting the input supply (include both utility supply and battery). This equipment must be earthed in accordance with local electrical authority codes of practice. Earth leakage current exceeds 3.5 mA and is less than 1000 mA. Transient and steady-state earth leakage currents, which may occur when starting the equipment, should be taken into account when selecting instantaneous RCCB or RCD devices. Residual Current Circuit Breakers ( RCCBs) must be selected insensitive to DC unidirectional pulses ( class A ) and transient current pulses ( RCCBs). Note it that the earth leakage currents of the load will also flow across RCCB or RCD.

Components that can be maintained by user

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 user. This UPS full complies with “IEC62040-1-1-General and safety requirements for use in operator access area. UPS dangerous voltages are present within the battery box. However, the risk of contact with these high voltages is minimized for non-service personnel. Since the component with dangerous voltage can only be touched by opening the protective cover with a tool, the possibility of touching high voltage component is minimized. No risk exists to any personnel when operating the equipment in the normal manner, following the recommended operating procedures in this manual.

Battery Voltage Higher Than 400Vdc

All the battery maintenance and servicing procedures involving internal access need special tools or keys and should be carried out only by trained personnel. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING WITH THE BATTERIES ASSOCIATED WITH THIS EQUIPMENT. WHEN CONNECTED TOGETHER, THE BATTERY TERMINAL VOLTAGE WILL EXCEED 400Vdc AND IS POTENTIALLY LETHAL. Battery manufacturers supply details of the necessary precautions to be observed when 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.............................................................................................................................. 4

1.1 Introduction ................................................................................................................................. 4

1.2 Initial Checking............................................................................................................................ 4

1.3 Positioning .................................................................................................................................. 5

1.3.1 Distribution Room ............................................................................................................ 5

1.3.2 Battery Room................................................................................................................... 5

1.3.3 Storing ............................................................................................................................. 5

1.4 Disassembly, Initial Checking and Positioning ............................................................................ 5

1.4.1 System Packaging: .......................................................................................................... 5

1.4.2 Module Packaging: .......................................................................................................... 7

1.4.3 UPS Composition ............................................................................................................ 9

1.4.4 Operation Space............................................................................................................ 10

1.4.5 Front and Back Access.................................................................................................. 10

1.4.6 Final Positioning ............................................................................................................ 10

1.4.7 Power Module Installation.............................................................................................. 10

1.4.8 Cable Entry .................................................................................................................... 11

1.5 Protective Devices .................................................................................................................... 12

1.5.1 Rectifier and Bypass Input Supply of the UPS............................................................... 12

1.5.2 Battery ........................................................................................................................... 12

1.5.3 UPS Output.................................................................................................................... 13

1.6 Power Cables............................................................................................................................ 13

1.6.1 Maximum stable state current and configuration of cable system.................................. 13

1.6.2 Cable Connection .......................................................................................................... 13

1.7 Control and Communication Cabling......................................................................................... 14

1.7.1 Dry Contact Interface of Battery and Environmental Temperature Detection ................ 15

1.7.2 Remote EPO Input Port ................................................................................................. 15

1.7.3 Generator Input Dry Contact.......................................................................................... 16

1.7.4 BCB Input Port............................................................................................................... 16

1.7.5 Battery Warning Output Dry Contact Interface............................................................... 17

1.7.6 Integrated Warning Output Dry Contact Interface.......................................................... 17

1.7.7 Mains Failure Warning Output Dry Contact Interface .................................................... 18

1.7.8 RS232 Port and SNMP Card Port.................................................................................. 18

1.7.9 LBS (Load Bus Synchronizer) Port ................................................................................ 19

1.8 Installation Drawing................................................................................................................... 19

Chapter 2 Operations............................................................................................................................ 23

2.1 Introduction ............................................................................................................................... 23

2.1.1 Principle......................................................................................................................... 23

2.1.2 Bypass Module .............................................................................................................. 24

2.2 Operation Mode ........................................................................................................................ 24

2.2.1 Normal Mode ................................................................................................................. 25

2.2.2 Battery Mode ................................................................................................................. 25

2.2.3 Auto-Restart Mode......................................................................................................... 25

2.2.4 Bypass Mode ................................................................................................................. 25

2.2.5 Maintenance Mode ........................................................................................................ 25

2.2.6 ECO Mode..................................................................................................................... 26

2.2.7 Frequency Converters Mode ......................................................................................... 26

2.3 Battery Management................................................................................................................. 26

2.3.1 Normal Function ............................................................................................................ 26

2.3.2 Advanced Functions (Battery Self-checking and Maintenance)..................................... 26

2.4 Battery Protection...................................................................................................................... 27

Chapter 3 Operating Steps ................................................................................................................... 28

3.1 Power Switches ........................................................................................................................ 28

3.2 UPS Start-up............................................................................................................................. 28

3.2.1 Normal Module Start...................................................................................................... 29

3.3 Procedure for Switching between Operation Modes ................................................................. 32

3.3.1 Procedure for Switching the UPS into Battery mode from Normal Mode....................... 32

3.3.2 Procedure for Switching the UPS into Bypass mode from Normal Mode ...................... 32

3.3.3 Procedure for Switching the UPS into Normal from Bypass Mode ................................ 32

3.3.4 Procedure for Switching the UPS into a Maintenance Bypass from Normal Mode ........ 32

3.3.5 Procedure for Switching the UPS into Normal from a Maintenance Bypass Mode ........ 32

3.4 Procedure for Completely Powering down a UPS..................................................................... 33

3.5 EPO Procedure......................................................................................................................... 33

3.6 Language Selection .................................................................................................................. 33

3.7 Control Password...................................................................................................................... 33

Chapter 4 Operator Control and Display Panel .................................................................................. 34

4.1 Introduction ............................................................................................................................... 34

4.1.1 LED Indicator ................................................................................................................. 35

4.1.2 Audible Alarm (buzzer) .................................................................................................. 35

4.1.3 Functional Keys ............................................................................................................. 36

4.2 LCD Display Type ..................................................................................................................... 36

4.3 Detailed Description of Menu Items .......................................................................................... 39

4.4 Alarm List .................................................................................................................................. 41

Chapter 5 Installation of Parallel Operation System .......................................................................... 43

Chapter 6 Maintenance ......................................................................................................................... 45

6.1 Instruction to Power, Bypass, and Output Power Distribution Module ...................................... 45

6.1.1 Precautions.................................................................................................................... 45

6.1.2 Instruction to Power Module .......................................................................................... 45

6.1.3 Instruction to Bypass Module......................................................................................... 45

6.2 Replacing Dust Screen (optional).............................................................................................. 46

Chapter 7 Product Specification .......................................................................................................... 47

7.1 Applicable Standards ................................................................................................................ 47

7.2 Environmental Characteristics .................................................................................................. 47

7.3 Mechanical Characteristics ....................................................................................................... 47

7.4 Electrical Characteristics (Input Rectifier) ................................................................................. 48

7.5 Electrical Characteristics (Intermediate DC Link)...................................................................... 48

7.6 Electrical Characteristics (Inverter Output)................................................................................ 49

7.7 Electrical Characteristics(Bypass Mains Input) ......................................................................... 50

7.8 Efficiency................................................................................................................................... 50

Appendix A Guidebook to Ordering and Selection of PM System .Errore. Il segnalibro non è definito.

Chapter 1 Installation

This chapter introduces the installation of RM series UPS (hereby referred to as UPS), including

initial checking, sitting, positioning, cabling and installation drawings.

1.1 Introduction

This chapter introduces the relevant requirements for positioning and cabling of the UPS.

As each site has its requirements, this chapter provides step-by-step installation instructions, which acts as a guide to the general procedures and practices that should be observed by the installing engineer.

Warning-Installation can only be done by authorized engineers

1. Do not apply electrical power to the UPS equipment before the approval of commissioning engineer.

2. The UPS should be installed by a qualified engineer in accordance with the information contained in this chapter.

Note: 3-Phase 4-Wire Input Power is required

The standard UPS can be connected to TN, TT and IT AC distribution system (IEC60364-3) of 3-phase 5-wire

WARNING: battery hazards

SPECIAL CARE SHOULD BE TAKEN WHEN WORKING WITH THE BATTERIES ASSOCIATED WITH THIS EQUIPMENT. When connecting the battery, the battery terminal voltage will exceed 400Vdc and is potentially lethal.

 Eye protection should be worn to prevent injury from accidental electrical arcs.  Remove rings, watches and all metal objects.  Only use tools with insulated handles.  Wear rubber gloves.  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.  If electrolyte comes into contact with the skin, the affected area should be washed immediately with water.

1.2 Initial Checking

Perform the following checking operations prior to the UPS installation.

1. Visually examine if there is any damage inside and outside the UPS rack and battery equipment

due to the transportation. Report any such damage to the shipper immediately.

2. Verify the product label and confirm the correctness of the equipment. The equipment label is

attached on the back of front door. The UPS model, capacity and main parameters are marked on

the label.

Chapter 1 Installation

1.3 Positioning

1.3.1 Distribution Room

The UPS is designed for indoor installation, which shall be located in a clean environment with adequate ventilation to keep the environmental temperature within the required specification. The UPS uses forced convection cooling by internal fans. Cooling air enters the module through ventilation grills located at the front part of the cabinet and exhausted through grills located in the rear part of the cabinet. Please do not block the ventilation holes.

If necessary, a system of extractor fans should be installed to aid cooling-air flow. An air filter should be used when the UPS is to operate in a dirty environment and should be regularly cleaned to maintain airflow.

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

1.3.2 Battery Room

The battery will generate some amount of hydrogen and oxygen at the end of charging, so the fresh air volume of the battery installation environment must meet 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 battery is 20°C. Operating above this temperature will reduce the battery life, and operation below this temperature will reduce the battery capacity. If the average operating temperature of battery is increased from 20ºC to 30ºC, then the service life of the battery will be reduced by 50%. If the operating temperature of the battery is above 40ºC, then 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 or air outlets.

If external batteries are to be used, a battery protection device (a DC circuit breaker) must be

mounted as close as possible to the batteries, and the connecting cables should be as short as possible.

1.3.3 Storing

If the equipment is not installed immediately, it must be stored in a room so as to protect it against excessive humidity and heat sources. The battery needs to be stored in dry and cool place with good ventilation. The most suitable storage temperature is 20 ºC to 25ºC.

1.4 Disassembly, Initial Checking and Positioning

Check the packaging first upon the arrival of product to see if there is any damage; open the packaging to check the equipment; report any such damage to the shipper immediately.

1.4.1 System Packaging:

Open the wooden case first, the open method is shown in fig 1-1:

Chapter 1 Installation

Fig 1-1 Open method

Firstly, open the top plate of the steel-edged wooden case with slotted awl and plier, followed by

sideboards. Be careful not to scratch the product. See fig 1-2.

Fig 1-2 Disassemble the case

Take out the foam after disassembling the sideboards of the case as shown in fig 1-3.

Chapter 1 Installation

Fig 1-3 Complete the disassembly

Tip: Dismantle the bolt that connects the cabinet and wooden pallet after disassembly, then lift the

cabinet to installation position. The dismantlement should be careful so as not to scratch the body.

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

1.4.2 Module Packaging:

The open method is shown in fig 1-4:

The packing case should be placed horizontal and stable;

Fig 1-4 Open method

Cut the plastic packing belt and scotch tape to open the carton, see fig 1-5:

Chapter 1 Installation

Fig 1-5 Open the carton

Open the foamed cover, the equipment with plastic package can be see as shown in fig 1-6:

Fig 1-6 Open the foamed cover

At last, take out the equipment with plastic package, and dismantle the packaging materials.

Warm Tips: Please dispose the wasted materials in accordance with environmental protection requirements after disassembly.

To prolong the service life, the place chosen for the UPS must guarantee:

 Easy wiring

 Sufficient space for operation

Carton

Foamed package

Carton

Equipment

Top cover of foamed package

Foamed package

Chapter 1 Installation

 Air sufficient enough to dispel heat produced by UPS

 Against ambient corrosive gases

 Against excessive humidity and heat sources

 Against dust

 With the current fire prevention requirements

 The operating environment temperature is within 20°C～25°C. The batteries are at maximum

efficiency in this temperature range (for information about the battery storage and transportation as well as the environment, please refer to table 6-2).

1.4.3 UPS Composition

UPS composition shall refer to fig 1-7; UPS configuration shall refer to table 1-1.

功率模块

旁路模块

开关单元

配电单元

2m cabinet (front view) 2m cabinet (back view)

Bypass module

Power module

Distribution unit

Switch unit

Chapter 1 Installation

开关单元

旁路模块

功率模块

配电单元

1.6m cabinet (front view) 1.6m cabinet (back view)

Fig 1-7 UPS Composition Diagram Table 1-1 UPS Configuration Table

Involved part name Quantity (Piece)

Note

Switch PDU 1 Standard configuration

Cabinet

Monitoring + bypass

module

1 Standard configuration

Power module

1～6 or 1～10

Field installation is

required

1.4.4 Operation Space

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

To enable routine tightening of power terminations within the cabinet, it is recommended that clearance around the front and back of the equipment should be sufficient to enable free passage of personnel with the doors fully opened.

1.4.5 Front and Back Access

The component layout of the UPS supports front and back access for servicing, diagnosing and

repairing the UPS, thus reducing the space requirement for side access.

1.4.6 Final Positioning

When the equipment has been finally positioned, ensure the adjustable feet are set so that the UPS

will remain stationary and stable.

1.4.7 Power Module Installation

The installation position of power module and output distribution module are shown in fig 1-8. the installation principle of these modules is to installed from bottom to top to prevent inclination of the cabinet due to high center of gravity .

As is shown in fig 1-8, the installation procedure of power module is as follows:

Switch unit

Bypass module

Power module

Distribution unit

Chapter 1 Installation

1. Each module shall be installed from bottom to top, the default setting of the system is module No. 1,

2, 3, 4, 5, 6, 7, 8, 9, and 10.

2. Insert the module into installation position, and push in the cabinet. The wiring terminals in between

shall be tight, and excessive force shall be prevented against the damage to inserted pins of the terminals.

3. Fix the module to the cabinet though the mounting holes on two sides of the front plate of the

module.

固定孔

A处放大

Fig 1-8 Power Module Installation Diagram

1.4.8 Cable Entry

Cables can enter the UPS from top and below as shown in fig 1-9. Both the top and bottom of the UPS have cable entrance.

The recommended installation practice is to install power cables in the entrance channel

at both sides of the cabinet back door, so as not to affect the ventilation.

进线通道

Fig 1-9 Cable Entry Diagram

Power module

Fixing hole

Amplification of A

Cable entrance Cable entrance

Chapter 1 Installation

1.5 Protective Devices

For safety concerns, it is recommended to install external circuit breakers or other protective devices for the input AC supply of the UPS system. This section provides generic practical information for qualified installation engineers. The installation engineers should have the knowledge of the regulatory wiring standards, and of the equipment to be installed.

1.5.1 Rectifier and Bypass Input Supply of the UPS

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

Note

For IT power network system, 4-pole protective device must be installed on the external input distribution of the UPS.

If protection against earth faults (RCD devices) is required for the upstream of the input supply, the installed device should:

 Sensitive to DC unidirectional pulses (class A) in the network

 Insensitive to transient current pulses

 Have an average sensitivity that is adjustable between 0.3A～1A

The RCCB must be sensitive to DC unidirectional pulses (class A) in the network, while insensitive to transient current pulses, as shown in fig 1-10 respectively.

Fig 1-10 RCCB sign

1.5.2 Battery

A battery unit is composed of 40 batteries connected in series, a centreline is drawn from in between (the joint part between the 20th and 21st battery), plus the line drawn from the front and back, there are altogether 3 lines connected with UPS line contact bank. The battery line must push through a DC circuit breaker before connecting to corresponding UPS line contact bank. The detailed wiring please refer to fig 1-11 below:

Fig 1-11 Diagram of batteries connected in series

40 batteries connected in series

Chapter 1 Installation

1.5.3 UPS Output

A main output switch has been installed in UPS, the user shall install the over current protective

device on the bypass of each output of the external distribution cabinet.

1.6 Power Cables

Design the cables according to the descriptions in this section and local regulatory wiring standards,

and the environmental conditions should be taken into consideration. Refer to IEC60950-1 Table 3B.

Warning

Prior to cabling the UPS, confirm the status and positions of the switches of the UPS rectifier input power supply / bypass power supply and mains power distribution board. Ensure that these switches are opened and attached with WARNING label so as to prevent unauthorized operation to these switches.

1.6.1 Maximum stable state current and configuration of cable system

Maximum stable state current and configuration of cable system, please refer to table 1-2.

Table 1-2 Maximum stable state current and configuration of cable system

System Name RM-120/20 RM-200/20

Capacity System capacity 120kVA 200kVA

Module capacity 20kVA 20kVA

Cabinet dimension

600*900*1600(W*D*H mm) 600*900*1600(W*D*H mm)

Main Input Rated current A 180 300

Cable mm2 50 75

Output

Rated current A 180 300

Cable mm2 50 75

Battery Rated current A 212 355

Cable mm2 75 90

PE Cable mm2 75 90

Warning

FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES CAN RESULT IN EMI, ELECTRIC SHOCK HAZARD OR RISK OF FIRE.

1.6.2 Cable Connection

Note

The operations described in this section must be performed by authorized electricians or qualified technical personnel. If you have any difficulties, do not hesitate to contact our Customer Service & Support department .

Chapter 1 Installation

After the equipment has been finally positioned and secured, connect the power cables as

described in the following procedures:

1. Verify that all the external input distribution switches of the UPS are completely opened and the

UPS internal maintenance bypass switch is opened. Attach necessary warning signs to these

switches to prevent unauthorized operation.

2. Open the back door of the cabinet, remove the cover and then the input and output terminal,

battery terminal and earth terminal are visible.

3. Connect the input earth wire to input earth terminal. Please note: the earth wire shall be connected

in accordance with related local or state regulation

4. For common bypass and rectifier inputs, connect the AC input supply cables to the UPS input

terminals (

Main input A-B-C-N

), and connect the output loaded cable to the UPS output terminals

(Output A-B-C-N) and tighten the connections to 13 Nm (M8 Bolt). ENSURE CORRECT PHASE

ROTATION.

5. Connect the battery cables between the UPS battery terminals and battery switch. ENSURE

CORRECT PHASE ROTATION.

Warning-Hazardous battery terminal voltage of 400Vdc

Ensure the correct polarity connection between the battery terminals and the UPS terminals: Positive terminal to positive terminal, negative terminal to negative terminal, and disconnect one or more than one cable between every two layers of batteries. Do not connect the cables and close the battery circuit breakers before getting the approval from the commissioning engineer.

6. Re-install all the protective covers.

1.7 Control and Communication Cabling

As shown in fig 1-12, the front panel of the bypass module will provide dry contact interface

(J2~J10), communication interface (RS232, 485 and SNMP card interface), as well as LBS interface.

干接点接口

SNMP卡接口

RS485接口

RS232接口

LBS接口

Fig 1-12 Dry contact interface and communication interface

The UPS accepts external signal from zero-voltage (dry) contacts connected through external dry contact terminals produced and phoenix terminals that are in bypass module. Through software programming, these signals become active when these contacts connect to +24V to ground).The cables connected to DRY terminal must be separated from power cables. Moreover, these cables should be double insulated with a typical 0.5 to 1.5 mm

cross-section area for a maximum connection length

between 25 and 50 meters.

Dry contact

interface

SNMP card port

LBS port

RS232 port

RS485 port

Chapter 1 Installation

1.7.1 Dry Contact Interface of Battery and Environmental Temperature Detection

The input dry contact J2 and J3 can detect the temperature of batteries and environment respectively, which can be used in environment monitoring and battery temperature compensation 1.

J2 and J3 interfaces diagram are shown in fig 1-13, the description of interface is in table 1-3.

Fig 1-13 Diagram of J2 and J3 dry contact for temperature detecting

Table 1-3 Description of input dry contact interface J2 and J3

Position Name Purpose

J2.1 TEMP_BAT Battery temperature detection

J2.2 GND Power ground

J3.1 TEMP_ENV Environment temperature detection

J3.2 GND Power ground

Note: Specified temperature sensor is required for temperature detection (R25=5Ohm, B25/50=3275), please confirm with the manufacturer, or contact local maintenance engineers when placing an order.

1.7.2 Remote EPO Input Port

The UPS has an Emergency Power OFF (EPO) function. This function can be activated by pressing a button on the control panel of the UPS or through a remote contact provided by the user. The EPO pushbutton is protected by a hinged plastic cover.

J4 is the input port for remote EPO. It requires shorting NC and +24v during normal operation, and the EPO is triggered when opening NC and +24v, or shorting NO and +24v. The port diagram is shown in fig 1-14, and port description is shown in table 1-4.

Fig 1-14 Diagram of input port for remote EPO

Table 1-4 Description of input port for remote EPO

Position Name Purpose

J4.1 EPO_NC EPO is activated when disconnecting fromJ4.2

J4.2

＋

24V

+24V, connect the common terminal of NC and NO

Chapter 1 Installation

J4.3 EPO_NO EPO is activated when shorting with J4.2

The EPO is triggered when shorting pin 2 and 3 or opening pin 2 and 1 of J4.

If an external emergency stop facility is required, it is connected via the reserved terminals of J4. The external emergency stop facility needs to use shielded cables to connect to the normally open/closed remote stop switch between these two pins. If this facility is not used, then pin 3 and pin 4 of J4 must be open, or pin 1 and pin 2 of J4 must be shorted.

Note

1. The emergency stop action within the UPS will shut down the rectifier, inverter and static bypass. However, it does not internally disconnect the mains input power supply. To disconnect ALL power to the UPS, open the upstream input circuit breaker(s) when the EPO is activated.

2. Pin 1 and 2 of J4 have been shorted before the UPS is delivered.

1.7.3 Generator Input Dry Contact

J5 is status interface for generator connection. Connect pin 2 of J5 with + 24V power supply, it indicates that the generator has been connected with the system. The interface diagram is shown in fig 1-15, and interface description is shown in table 1-5.

Fig 1-15 Diagram of status interface and connection of generator

Table 1-5 Description of maintenance bypass switch and output switch status interface

Position Name Purpose

J5.1 +24V +24V power supply

J5.2 GEN Connection status of generator

J5.3 GND Power ground

1.7.4 BCB Input Port

J6 and J7 are the ports of BCB. The port diagram is shown in fig 1-16, and description is shown in

table 1-6.

Generator

츐

Chapter 1 Installation

BCB_DRV

BCB_CONT

BCB_ONL

Fig 1-16 BCB Port

Table 1-6 Description of BCB port

Position Name Description

J6.1 BCB_DRV BCB actuating signal, provide the actuating signal of +18V, 20mA

J6.2 BCB_CONT BCB contact status, connect with the normally open signal of BCB

J7.1 GND Power ground

J7.2 BCB_ONL

BCB on-line–input (normally open) , BCB is on-line when the signal is connecting with GND

1.7.5 Battery Warning Output Dry Contact Interface

J8 is the output dry contact interface, which outputs the battery warnings of low or excessive voltage, when the battery voltage is lower than set value, an auxiliary dry contact signal will be provided via the isolation of a relay. The interface diagram is shown in fig 1-17, and description is shown in table 1-7.

Fig 1-17 Battery warning dry contact interface diagram

Table 1-7 Battery warning dry contact interface description

Position Name Purpose

J8.1 BAT_LOW_NC Battery warning relay (normally closed) will be open during warning

J8.2 BAT_LOW_NO Battery warning relay (normally open) will be closed during warning

J8.3 GND Center of battery warning relay

1.7.6 Integrated Warning Output Dry Contact Interface

J9 is the integrated warning output dry contact interface, when one or more than one present warning is triggered, the system will send an integrated warning information, and provide an auxiliary dry contact signal via the isolation of a relay. The interface diagram is shown in fig 1-18, and description is shown in table 1-8.

츐

Chapter 1 Installation

Fig 1-18 Integrated warning dry contact interface diagram

Table 1-8 Integrated warning dry contact interface description

Position Name Purpose

J9.1 ALARM_NC Integrated warning relay (normally closed) will be open during warning

J9.2 ALARM_NO Integrated warning relay (normally open) will be closed during warning

J9.3 GND Centre of integrated warning relay

1.7.7 Mains Failure Warning Output Dry Contact Interface

J10 is the output dry contact interface for mains failure warning, when the mains fails, the system will send a mains failure warning information, and provide an auxiliary dry contact signal via the isolation of a relay. The interface diagram is shown in fig 1-19, and description is shown in table 1-9.

Fig 1-19 Mains failure warning dry contact interface diagram

Table 1-9 Mains failure warning dry contact interface description

Position Name Purpose

J9.1 UTI_FAIL_NC

Mains failure warning relay(normally closed) will be open during warning

J9.2 UTI_FAIL_NO

Mains failure warning relay (normally open) will be closed during warning

J9.3 GND

Centre

of mains failure warning relay

1.7.8 RS232 Port and SNMP Card Port

RS232 and RS485 Port: provide serial data which can be used for commissioning and maintenance by authorized engineers or maintainers, or can be used for networking or integrated monitoring system in the service room.

SNMP Card Port: used for field installation of the communication option card(SNMP card).

Chapter 1 Installation

1.7.9 LBS (Load Bus Synchronizer) Port

The dual bus system (DBS) consists of two independent UPS rack module systems, as shown in fig 1-20. The dual bus system is configured for high availability and is suitable for powering the load with dual inputs. If the load is single-input load, the static transfer switch and LBS control is recommended to maintain both UPS outputs synchronized for uninterrupted transfers. Please install the system according to the installation descriptions for different system configurations.

The dual bus system is supported by UPS, it requires connecting the LBS signal cables of two UPS when constructing the dual bus system; please refer to relevant chapter for detailed configuration and installation, and the system software shall be configured as required.

Fig 1-20 LBS Connection Diagram

1.8 Installation Drawing

Please refer to fig 1-21, fig 1-22, fig 1-23 and fig 1-24:

UPS 1 monitoring

bypass module

UPS 2 monitoring bypass module

Chapter 1 Installation

Fig 1-21 Installation Diagram

顶视图

2m cabinet front view

1.6 m cabinet (front view)

Fig 1-22 UPS front view (Unit: mm)

Top view

␰Ѫ

Chapter 1 Installation

2m cabinet

1.6m cabinet

Fig 1-23 UPS back view

␰Ѫ

Chapter 1 Installation

A处放大

Fig 1-24 UPS front view

Amplification of A

Chapter 2 Operations 23

Chapter 2 Operations

This chapter introduces the basic knowledge of UPS operations, including working principle,

operation mode, battery management and protection.

Warning: Hazardous mains voltage and/or battery voltage present(s)behind the protective cover

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

2.1 Introduction

UPS provides the critical load (such as communication and data processing equipment) with high

quality uninterruptible AC power. The power from UPS is free from voltage and frequency variations and disturbances (interruption and spike) experienced at the Mains AC input supply.

This is achieved through high frequency double conversion power pulse width modulation (PWM)

associated with full digital signal processing control (DSP), which features high reliability and convenience for use.

2.1.1 Principle

As shown in fig 2-1, the AC input mains source is supplied at UPS input and converted into a DC

source. This DC source feeds the inverter that converts the DC source into a clean and input independent AC source. The battery powers the load through the inverter in case of an AC input mains power failure. The utility source can also power the load through the static bypass.

When the UPS needs maintenance or repair, the load can be transferred to maintenance bypass

without interruption and the power module and bypass module can be removed for maintenance.

24 Chapter 2 Operations

Fig 2-1 System principle framework

2.1.2 Bypass Module

The circuit blocks labeled “bypass module” in fig 2-1 contain electronically controlled switching

circuits that enable the critical load to be connected to either the inverter output or to a bypass power source via 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 failure, the load is automatically transferred to the static bypass line.

To provide a clean (no-break) load transfer between the inverter output and static bypass line, the

inverter output and bypass supply must be fully synchronized during normal operating conditions. This is achieved through the inverter control electronics, which makes the 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 utility (bypass) supply while the UPS is shut down for routine maintenance.

Note

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

2.2 Operation Mode

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

modes:

 Normal mode

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Chapter 2 Operations 25

 Battery mode

 Auto-Restart mode

 Bypass mode

 Maintenance mode (manual bypass)

 ECO mode



Frequency converters mode

2.2.1 Normal Mode

The UPS inverter power modules continuously supply the critical AC load. The rectifier/charger

derives power from the AC mains input source and supplies DC power to the inverter while simultaneously FLOAT or BOOST charging its associated backup battery.

2.2.2 Battery Mode

Upon failure of the AC mains input power; the inverter power modules, which obtains power from the

battery, supplies the critical AC load. There is no interruption in power to the critical load upon failure. After restoration of the AC mains input power, the “Normal Mode” operation will continue automatically without the necessity of user intervention.

Note: UPS can also be started through battery (charged) mode via battery cold start function upon

failure of the AC mains. Therefore, the battery power can be used independently to improve the utilization rate of UPS.

2.2.3 Auto-Restart Mode

The battery may become exhausted following an extended AC mains failure. The inverter shuts

down when the battery reaches the End of Discharge voltage (EOD). The UPS may be programmed to “Auto Recovery after EOD” after a delay time if the AC mains recovers. This mode and any delay time are programmed by the commissioning engineer.

During the process of delay time, the battery will be charged by UPS to prevent any risks to load

equipment from future mains failure.

2.2.4 Bypass Mode

If the inverter overload capacity is exceeded under normal mode, or if the inverter becomes unavailable for any reason, 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 critical AC load.

2.2.5 Maintenance Mode

A manual bypass switch is available to ensure continuity of supply to the critical load when the UPS

becomes unavailable e.g. during a maintenance procedure.

Note: This manual bypass switch is fitted in all UPS modules. Transfer UPS system to bypass mode

for power supply first, then close maintenance bypass switch Q2, followed by Q1 and Q3.

Warning: Hazard may occur after transferring to maintenance bypass

After UPS being transferred to maintenance bypass, power module and bypass module do not work, no display on LCD, and input and output terminals as well as N bus are electrically connected.

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26 Chapter 2 Operations

2.2.6 ECO Mode

If economical (ECO) mode is selected, the double-conversion UPS will stop to work so as to save energy. During the operation of ECO mode, the load power will be supplied by bypass preferentially. When bypass power is within the range of normal frequency and voltage, load power will be supplied by bypass, or the system will transfer to inverter output, followed by load power interruption which extends within 3/4 of the utility period. E.g. when the frequency is 50Hz, the interruption time will be less than 15ms; when the frequency is 60Hz, the time will be less than 12.5ms.

2.2.7 Frequency Converters Mode

If the frequency converter configuration is used by UPS, it will provide 50Hz or 60Hz stable output frequency. The range of output frequency is 40Hz～70Hz. Under this mode, static bypass is unavailable,

but battery can be selected according to the actual requirements of battery mode.

2.3 Battery Management

2.3.1 Normal Function

The following functions should be fitted by commissioning engineers with specified software.

1. Constant current boost charging

Current can be set up.

2. Constant voltage boost charging

Voltage of boost charging can be set as required by the type of battery.

For Valve Regulated Lead Acid (VRLA) batteries, maximum boost charge voltage should not

exceed 2.4V / cell.

3. Float charge

Voltage of float charging can be set as required by the type of battery.

For VRLA, float charge voltage should be between 2.2V to 2.3V.

4. Float charge temperature compensation (optional)

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

5. End of discharge (EOD) protection

If the battery voltage is lower than the EOD, the battery converter will shut down and the battery is isolated to avoid further battery discharge. EOD is adjustable from 1.6V to 1.75V per cell (VRLA) or 0.9 to 1.1 V per cell

6. Battery low warning time

It is adjustable between 3 and 60 minutes. The default is 5 minutes.

2.3.2 Advanced Functions (Battery Self-checking and Maintenance)

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%, auto-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 5 hours, load equal to 20~100% of rated UPS capacity

Trigger—Manually through the command of “Battery Maintenance Test” in LCD panel or automatically

Battery Self-Test Interval—30-360 days (default setting is battery self-test disabled).

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Chapter 2 Operations 27

2.4 Battery Protection

The following functions should be fitted by commissioning engineers with specified software.

1. Battery Low Pre-warning

The battery under voltage pre-warning occurs before the end of discharge. After this pre-warning, the battery should have the capacity for 3 remaining minutes discharging with full load. The time is user configured from 3 to 60 minutes.

2. Battery discharge (EOD)off protection

If the battery voltage is lower than the EOD, the battery converter will be shut down. EOD is adjustable from 1.6V to 1.75V per cell (VRLA) or 0.9 to 1.1 V per cell (NiCd)

3. Battery Circuit Breaker (BCB) Alarm

The alarm occurs when the battery disconnect device disconnects. The external battery connects to the UPS through the external battery circuit breaker. The circuit breaker is manually closed and tripped by the UPS control circuit.

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28 Chapter 3 Operating Instructions

Chapter 3 Operating Steps

This chapter describes UPS operation instructions in detail.

All functional keys and LED display involved in operation instructions please refer to chapter 4. During operation, the buzzer alarm may occur at any time. Select “mute” on LCD to muffle the audible alarm.

Warning-Hazardous mains voltage and/or battery voltage present(s)behind the protective cover

1. The components that can only be accessed by opening the protective cover with tools cannot be operated by user.

2. Only qualified service personnel are authorized to remove such covers.

3.1 Power Switches

As shown in fig 3-1, open the front door of UPS, the power switch is visible, which includes: input switch, output switch and maintenance bypass switch (with anti-misoperation stop plate).

输入开关

输出开关

维修旁路开关

Fig 3-1 Power switch location diagram

3.2 UPS Start-up

The UPS system only has a maintenance bypass isolating switch, and all the other transfers are processed automatically by internal control logics.

Input switch

Output switch

Maintenance bypass switch

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Chapter 3 Operation Instructions 29

3.2.1 Normal Module Start

This procedure must be followed when turning on the UPS from a fully powered down condition.

The operating procedures are as follows:

Warning

This procedure results in mains voltage being applied to the UPS output terminals. If any load equipment is connected to the UPS output terminals please check with the load user that it is safe to apply power. If the load is not ready to receive power then ensure that it is safely to close the output switch of external distribution cabinet.

1. Close UPS output switch and input switch in turns.

The LCD starts up at this time. The Rectifier indicator flashes during the startup of rectifier. The rectifier enters normal operation state, and after about 30s, the rectifier indicator goes steady green. After initialization, the bypass static switch closes. The UPS Mimic LEDs will indicate as shown in table 3-1:

Table 3-1 Indicator status

LED Status

Rectifier indicator Green

Battery indicator Red

Bypass indicator Green

Inverter indicator Off

Load indicator Green

Status indicator Green

Note

The output circuit breaker must be closed first, followed by input circuit breaker, or the rectifier cannot be started, and alarm “rectifier failure”.

The inverter starts up at this time, the inverter indicator flashes. After the rectifier enters normal operation state, UPS power supply will transfer from bypass to inverter, then the bypass indicator turns off, and load indicator lights. The status of indicators is shown in table 3-2.

Table 3-2 Indicator Status

LED Status

Rectifier indicator Green

Battery indicator Red

Bypass indicator Off

Inverter indicator Green

Load indicator Green

Status indicator Green

2. Close external battery switch, battery indicator turns off, a few minutes later, the battery will be

charged by UPS which will enter normal mode operation. The indicator status is shown in table 3-3.

Table 3-3 Indicator status

LED Status

Rectifier indicator Green

Battery indicator Green

Bypass indicator Off

Inverter indicator Green

Load indicator Green

Status indicator Green

3.2.2 Operating steps of Battery cold Start

1. Check if the batteries have been connected, close the external battery switch.

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30 Chapter 3 Operating Instructions

2. Press the red start-up button of battery under the rectifier input circuit breaker for 3 seconds (see fig

3-2).

The LCD starts up at this time. The green battery indicator flashes. The rectifier enters normal operation states and after about 30s, the battery indicator goes steady green.

3. The inverter starts up automatically, the green inverter indicator flashes. The output of inverter

appears after 60s. The UPS works on battery mode.

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Chapter 3 Operation Instructions 31

电池启动按钮

Fig 3-2 Position diagram of battery startup button

Battery startup button

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32 Chapter 3 Operating Instructions

3.3 Procedure for Switching between Operation Modes

3.3.1 Procedure for Switching the UPS into Battery mode from Normal Mode

Open input switch to cut off the mains, UPS enters the battery mode. If UPS should be switched to

normal mode, wait for a few seconds before closing input switch, so as to supply the mains again. 10s later, the rectifier will start up automatically to supply power to the inverter.

3.3.2 Procedure for Switching the UPS into Bypass mode from Normal Mode

Select “Tran Byp” on the LCD, or press “off” buttons of each power module in turn.

Note

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

3.3.3 Procedure for Switching the UPS into Normal from Bypass Mode

Select exit bypass mode on the LCD.

3.3.4 Procedure for Switching the UPS into a Maintenance Bypass from Normal Mode

In normal operation, this operation instruction will switch the load from inverter input to maintenance bypass.

Caution

Before making this operation, read messages on display to be sure that bypass supply is regular and the inverter is synchronous with it, so as not to have a risk of a short interruption in powering the load.

1. Press “Tran Byp” on the LCD, or press “off” on each power module in turns.

If press ”Tran Byp” on the LCD, the inverter indicator will flash green and the buzzer will alarm.

If press “off” on each power module in turns, the inverter indicator will go off and the buzzer will alarm.

The load will be transferred to static bypass, and the inverter is closed.

2. Close maintenance bypass switch Q2, the load power will be supplied by maintenance bypass, and

then open the main input breaker Q1, output switch Q3 and battery switch.

Warning

If you need to maintain the module, wait for 10 minutes to let the DC bus capacitor fully discharge before removing corresponding module.

3.3.5 Procedure for Switching the UPS into Normal from a Maintenance Bypass Mode

This procedure can transfer the load to normal main mode when the UPS is operating under the maintenance bypass mode.

1. Close output switch Q3 and main switch Q1.

The bypass indicator goes green and the load power will be supplied by bypass and maintenance bypass.

2. Open maintenance bypass switch Q2.

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Chapter 3 Operation Instructions 33

The load power is supplied by bypass. In the meantime, the rectifier starts up, rectifier indicator goes green 30s later, at this time, the inverter will start up automatically, and transfer to inverter mode 1 min later automatically.

3. Close external battery switch, the battery indicator goes off. Check if the battery voltage on LCD

display is normal.

3.4 Procedure for Completely Powering down a UPS

If you need to power down the UPS completely, follow the procedures in section 3.3.4 to transfer the UPS from normal mode to maintenance bypass mode.

If you need to isolate the UPS from the AC power supply, you should open the external input switch.

3.5 EPO Procedure

The EPO button on UPS operator control and display panel is designed to switch off the UPS in emergency conditions (e.g., fire, flood, etc.).To achieve this, just press the EPO button, and the system will turn off the rectifier, inverter and stop powering the load immediately (including the inverter and bypass output), and the battery stops charging or discharging.

If the input utility is present, the UPS control circuit will remain active; however, the output will be turned off. To completely isolate the UPS, you need to open the external mains input supply to the UPS rack.

3.6 Language Selection

The LCD is available in two languages: Chinese, English and a kind of optional language. (Korean, Russian, Turkish and Traditional Chinese)

The language can be selected through LCD prompt window.

3.7 Control Password

When the LCD displays “input control password 1”, the initial password is 12345678.

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34 Chapter 4 Operator Control and Display Panel

Chapter 4 Operator Control and

Display Panel

This chapter introduces the functions and operation instructions of the parts on UPS operator control

and display panel in detail, and provides LCD display information, including LCD display types, detailed menu information, prompt window information and UPS alarm list.

4.1 Introduction

The operator control and display panel is located on the front panel of the UPS. Through this LCD panel, the operator can operate and control the UPS, and check all measured parameters, UPS and battery status and event and alarm logs. The operator control panel is divided into three functional areas as shown in fig 4-1: mimic current path, LCD display & Menu keys, and Control and Operation Keys. The detailed description of parts on operator control and display panel is shown in table 4-1.

Fig 4-1 UPS operator control and display panel

Table 4-1 Description of UPS operator control and display panel

Part No. Function Button Function

REC Rectifier indicator EPO EPO switch

BAT Battery indicator TAB switch

BYP Bypass indicator ENTER confirm

INV Inverter indicator ESC exit

OUTPUT Load indicator

STATUS Status indicator

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Chapter 4 Operator Control and Display Panel 35

4.1.1 LED Indicator

The LEDs shown on the mini current path represent the various UPS power paths and show the

current UPS operating status. The status description of indicators is shown in table 4-2.

Table 4-2 Status description of indicator

Indicator State Purpose

Steady green Rectifier normal for all modules

Flashing green Rectifier for at least on module normal, mains normal

Steady red Rectifier fault

Flashing red Mains abnormal for at least one module

Rectifier

indicator

Off Rectifier not operating

Steady green Battery charging

Flashing green Battery discharging

Steady red

Battery abnormal (battery failure, no battery or battery reverse) or battery converter abnormal (failure, over current or over temperature) , EOD

Flashing red Battery low voltage

Battery

indicator

Off Battery and battery converter normal, battery not charging

Steady green Load power supplied by bypass

Steady red

Bypass power abnormal or out of normal range, or static bypass switch fault

Flashing red Bypass voltage abnormal

Bypass

indicator

Off Bypass normal

Steady green Load power supplied by inverter

Flashing green

Inverter On, start, synchronization of standby (ECO mode) for at least one module

Steady red

System power not supplied by inverter, inverter fault for at least one module.

Flashing red

System power supplied by inverter, inverter fault for at least one module.

Inverter

indicator

Off Inverter not operating for all modules

Steady green UPS output ON and normal

Steady red

UPS output overload and overtime, or output short, or output no power supply

Flashing red Overload output of UPS

Load

indicator

Off No output of UPS

Steady green Normal operation Status

indicator

Steady red Failure

4.1.2 Audible Alarm (buzzer)

There are two different types of audible alarm during UPS operation as shown in table 4-3.

Table 4-3 description of audible alarm

Alarm Purpose

Two short alarm with

a long one

when system has general alarm (for example: AC fault), this audible alarm can be heard

Continuous alarm

When system has serious faults (for example: fuse or hardware fault), this audible alarm can be heard

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36 Chapter 4 Operator Control and Display Panel

4.1.3 Functional Keys

There are 4 functional keys on operator control and display panel, which are used together with LCD. The functions description is shown in table 4-4.

Table 4-4 Functions of functional keys

Functional key Functions

EPO switch

To cut off the load power to shut down the rectifier, inverter, static bypass and battery

TAB switch

ENTER confirm

ESC exit

4.2 LCD Display Type

Following the self-check of UPS LCD display, the main LCD display is shown as fig 4-2, which can be divided into three display windows: system information, data command and current record.

Fig 4-2 Main LCD display

The description of LCD icon is shown in table 4-5:

Table 4-5 Description of LCD icons

Icon Description

Bypass parameter

on-line

1# Inverter abnormal

3# Fan fault

UPS bypass frequency abnormal

UPS system

information

window

Data

command

window

Current

record

window

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Chapter 4 Operator Control and Display Panel 37

Icon Description

Main input parameter

History file, system information

Function setting (display calibration, password setting, time setting, date format, communication protocol and language setting), system setting (used by product maintainers)

Battery data, battery parameter setting (used by service staff)

Test (battery self-test, battery maintenance)

Functional keys used by service staff (fault clearing, history file clearing, noise clearing, manual switch of bypass), user’s setting (system mode, machine number, system ID, output voltage adjustment, frequency tracing speed, frequency tracing limit)

Output parameter

Load

Noise clearing, noise clearing cancel

Log view page up/down

Select an icon on LCD, as shown in fig 4-3, to view the UPS parameter represented by this icon, e.g.

select , the LCD will display the data of system main input:

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38 Chapter 4 Operator Control and Display Panel

相电压(V)

功率因数

相电流(A)

频率(Hz)

主路输入

219.5

50.01

18.3

0.99

RM33-120/20 5模块在线 12:00

Fig 4-3 Select data

Or select and confirm a module, as shown in fig 4-4, the LCD will display the operating status of this module:

Fig 4-4 Select a module

Select

in the operating status of a module, to view the main input data of this module.

1# Inverter abnormal

3# Fan fault

UPS bypass frequency abnormal

5 modules on-line

V phase

I phase

Frequency

Power factor

Main input

5 modules on-line

Module 1

␰Ҫ

Chapter 4 Operator Control and Display Panel 39

Select

in the operating status of a module to view the main output data of this module.

Select , in the operating status of a module to view the load data of this module.

Select in the operating status of a module to view the maintenance code and module software code of this module.

Select to return to the previous page.

Select to return to the home page.

Default display

During the operation of system, if there’s no alarm in 2 min, the system will display default. After a short delay, the backlight of LCD display goes off; press any key to reactivate the display.

4.3 Detailed Description of Menu Items

The LCD main display shown in fig 4-2 is described in details below.

UPS information window

UPS information window: display the current time and UPS name. The information of the window is

not necessary for the user to operate. The information of this window is given in table 4-6.

Table 4-6 Description of items in UPS system information window

Display contents Meaning

RM33-120/20 UPS Name

12:00 Current Time (format: 24 hours, hours, minute)

UPS menu and data window

UPS menu window displays the menu name of data window, while the data window displays the related contents of selected menu in menu window. Select UPS menu and data window to browse related parameters of UPS and set related functions. The details are given in table 4-7.

Table 4-7 Item description of UPS menu and data window

Menu name Menu item Meaning

V phase(V) Phase voltage

I phase(A) Phase current

Freq.(Hz) Input frequency

Main input

PF Power factor

V phase(V) Phase voltage

Freq. (Hz) Bypass frequency

I phase(A) Phase current

Bypass input

PF Power factor

V phase(V) Phase voltage

I phase(A) Phase current

Freq. (Hz) Output frequency

AC output

PF Power factor

Sout (kVA) Sout: Apparent Power

Pout (kW) Pout: Active Power

This UPS

module’s

load

Qout (kVAR) Qout: Reactive Power

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40 Chapter 4 Operator Control and Display Panel

Menu name Menu item Meaning

Load (％)

Load (The percentage of the UPS rating load)

Environmental Temp

Battery voltage(V)

Battery bus voltage

Battery current A)

Battery bus current

Battery Temp(℃) Battery Temp ℃

Remaining Time (Min.)

Remaining battery backup time

Battery capacity

(％)

The percentage compared with new battery capacity

battery equalized charging

Battery is equalized charging

battery float charging

Battery is float charging

Battery data

Battery disconnected

Battery is not connected

Current

record

(current alarm)

Display all current alarm. The alarm list displayed on LCD of UPS operator control and display panel please refer to table 4-8

History

record

(history alarm)

Display all history alarm. The alarm list displayed on LCD of UPS operator control and display panel please refer to table 4-9

Language

(language option)

3 languages can be selected

Display calibration

Adjust the accuracy of LCD display

Date format set MM DD YYYY and YYYY MM DD formats can be selected

Date & Time Date/Time set

Language set

User can set the language (Chinese, English and a kind of optional language)

Communication mode

Set communication mode, MODBUS, Power protocol and

company custom protocol modes can be selected. Power protocol mode can be divided into equipment address, baud rate set; MODBUS protocol mode can be divided into

communication, mode (RTU、ASCⅡ), equipment address,

baud rate and check-bit set; Company custom protocol mode is the customed protocol of the company, no option is available.

Settings

Control password set

User can modify control password 1

Battery maintenance test

This test will lead to the battery being partly discharged to activate battery, at the same time; the approximate battery capacity will be obtained. Bypass must be in normal condition, the battery capacity should be above 25%.

Battery self-check test

UPS switches to battery discharge for discharging to test if the battery is normal. Bypass must be in normal condition, the battery capacity should be above 25%.

Test

Command

(Battery Test

Control /

System Test

Control /

Forced equalized charging)

Stop testing Manually Stop the test including maintenance test, capacity test

UPS system

Monitoring Provide monitoring software version

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Chapter 4 Operator Control and Display Panel 41

Menu name Menu item Meaning

software version

Rectified software version

Provide rectified software version

Inverted software version

Provide inverted software version

Serial No. The serial no set when delivery from the factory

Rated information

Network setting of system operating

information

Module type Type of the module

4.4 Alarm List

The follow table 4-8 gives the complete list of all the UPS events displayed by history record window

and current record window.

Table 4-8 Alarm List

Alarm Explanation

UPS power supply The system is in normal inverted power supply status

Bypass power supply The system is in bypass power supply status

No power supply System no output

Battery equalized

charging

Battery is in boost charging

Battery float charging Battery is in float charging

Battery discharging The system is operating in battery discharging status.

Battery connected Battery is connected

Battery disconnected Battery is not connected

Maintenance circuit

breaker close

Maintenance circuit breaker is close

Maintenance circuit

breaker open

Maintenance circuit breaker is open

Emergency

shutdown

System emergency shutdown, EPO

Generator connected External generator is connected

Mains abnormal Input mains abnormal

Bypass phase

conversion

Bypass input phase converse

Bypass voltage

abnormal

Bypass input voltage abnormal

Bypass fault Bypass fault

Bypass overload Bypass output is overload

Up to bypass

overtime of

overload

Bypass is overtime of overload

Bypass frequency

tracing exceeds

Bypass frequency is out of the tracing range

Switch times up to in

this hour

The times of switch between bypass and inverter exceeds 5 times in the latest hour.

Output short System output short

Battery EOD Battery voltage achieves shutdown point

Battery self-check The system enters battery self-check mode

Battery self-check

success

Battery normal during system self-check

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42 Chapter 4 Operator Control and Display Panel

Alarm Explanation

Battery manual

check failure

Battery fault during system self-check

Battery maintenance The system is in battery maintenance status

Battery maintenance

success

Battery maintenance status completes

Battery maintenance

failure

Battery maintenance process is not normal

Stop testing Battery self-check or battery maintenance status stops

Fault clearing Clear the alarmed fault

Delete history record Delete all history record

N° communication

node connected

N° module is connected to UPS system

N° communication

node disconnected

N° module is not connected to UPS system

N° rectifier fault N° module rectifier fault

N° inverter fault N° module inverter fault

N° rectifier overheat N° module rectifier overheat

N° fan fault N° module fan fault

N° output overload N° module output overload

N° overtime of

overload

N° module output overtime of overload

N° inverter overheat N° module inverter overheat

Inverter power supply

ban

Inverter power ban supply

Manual switch of

bypass

Switch the system to bypass output manually

Cancel manual

switch of bypass

Switch the system from bypass to inverter output manually

Battery low voltage Battery low voltage

Battery reversal Battery polarity reversal

N° inverter protection N° module inverter protection

Input N line

disconnected

System input N line is not connected

Bypass fan fault Bypass module fan fault

N° manual shutdown N° module manual power off

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Chapter 5 Maintenance 43

Chapter 5 Installation of Parallel

Operation System

The parallel operation system is installed as required by the installation procedures of the single

system and this chapter.

The single devices are put parallel and connected as shown in fig. 5-1, and the difference between the lengths of the output cables of the single devices is not more than 10m. It is recommended to use an external bypass cabinet to facilitate maintenance and system testing.

Fig. 5-1 Typical 1+N parallel operation system

Note: when the load exceeds is the capacity of the single device, the maintenance bypass switch CB3 must be removed.

The cables for the parallel operation provide double insulation shielding up to 30m long, the control cables for the parallel operation must be connected with all single devices to form a closed loop, as shown in fig.5-2.

Other power supplies

Rectifier

Charger

Inverter

Output power supply

Load connected

Mains power input,

L1, L2, L3, N terminal

Mains power input,

L1, L2, L3, N terminal

Rectifier

Charger

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44 Chapter 5 Maintenance

Fig.5-2 parallel cables

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Chapter 5 Maintenance 45

Chapter 6 Maintenance

This chapter introduces UPS maintenance, including the maintenance instructions of power module, monitoring bypass module and the change method of dust filter.

6.1 Instruction to Power, Bypass, and Output Power Distribution

Module

6.1.1 Precautions

1. Only maintaining engineers can maintain the power module and monitoring bypass module.

2. In principle, the power module and bypass module should be disassembled from top to bottom, so

as to prevent any inclination from high gravity centre of the cabinet.

3. To ensure the safety before maintaining power module and bypass module, be sure to use a

multimeter to measure the DC bus capacitor voltage and ensure the voltage is below 60V before operation, and use a multimeter to measure the voltage between operating parts and the earth to ensure the voltage is lower than hazardous voltage, i.e. DC voltage is lower than 60Vdc, and AC maximum Voltage is lower than 42Vac.

4. Bypass module doesn’t support any hot insertion and extraction, only when UPS is in maintenance

bypass mode or UPS is completely power off, the bypass module can be disassembled.

5. The module can be maintained 10 mins after extracting power module and bypass module which

can be inserted into the cabinet 10 mins later.

6.1.2 Instruction to Power Module

Suppose UPS were in normal mode, and bypass were normal, a module shall be maintained at

first.

1. Press OFF of the module with a pin point or other tiny matter, the module will shut down

automatically and exit the system

Note: ensure if the remaining module will be overload when exiting a module. If there’s any risk of

overload, transfer the whole UPS system to bypass, followed by other operations.

2. Take off the fixing bolt on the two sides of front and back plate of power module 10 mins later;

extract the module from the cabinet.

3. After maintaining the module, push the module into the equipment cabinet (the interval between

two modules shall be more than 10s), fix the screws on the two sides. Then the module will be connected to UPS system automatically.

6.1.3 Instruction to Bypass Module

Suppose UPS were in normal mode, and the bypass were normal:

1. Select LCD touch screen manual switch of bypass, the UPS power will be supplied by bypass.

2. Close maintenance bypass switch, the UPS power will be supplied by maintenance bypass.

3. Open UPS output switch and input switch.

4. Open external battery switch.

庀

46 Chapter 5 Maintenance

5. Take off the fixing bolt at the two sides of front board of bypass module, extract the front cable

assembly of the module and extract the module from the cabinet.

6. After maintaining the module, insert the module into the cabinet, tighten the screw at the two sides,

and connect the front cable assembly of manufacturer’s module.

7. Close UPS output switch and input switch in turn.

2 mins later, bypass indicator on the operator control and display panel lights on, which indicates

the normal power supply of bypass.

8. Open maintenance bypass switch, the inverter starts automatically, 60s later; the UPS will transfer

to normal mode.

6.2 Replacing Dust Screen (optional)

As shown in fig 6-1, there are 3~4 dust filters on the back of UPS’ front door, each screen is held in place by a bracket on either side of each filter. The procedure of replacing each filter is as follows:

1. Open the UPS’ front door and locate the filters on the back side of the front door

2. Remove one bracket.

3. Remove the dust screen to be replaced and insert the clean one.

4. Reinstall the bracket.

防尘网

固定条

Fig 6-1 Dust screen on the back side of UPS front door

Bracket

Dust screen

␰Ҫ

Appendix 2 Toxic or Hazardous Materials or Elements Identification Table 47

Chapter 7 Product Specification

This chapter provides UPS product specification.

7.1 Applicable Standards

The UPS has been designed to conform to the following European and international standards:

Table 7-1 Compliance with European and International Standards

Item Normative reference

General safety requirements for UPS

used in operator access areas

EN50091-1-1/IEC62040-1-1/AS 62040-1-1

Electromagnetic compatibility (EMC)

requirements for UPS

EN50091-2/IEC62040-2/AS 62040-2(C3)

Method of specifying the performance

and test requirements of UPS

EN50091-3/IEC62040-3/AS 62040-3(VFI SS 111)

Note: The above mentioned product standards 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 60950).

7.2 Environmental Characteristics

Table 7-2 Environmental Properties

Items Unit Requirements

Acoustic noise level at 1

meter

dB 55.0

Altitude of Operation M

≤1000m above sea level, derate power by 1% per 100m between 1000m and 2000m

Relative Humidity

％

0 to 95%, non condensing

Operating Temperature

°C

0 to 40 deg , Battery life is halved for every 10°C increase above 20°C

UPS Storage-Transport

Temperature

°C

－

20 +70°C

Recommended Battery

Storage Temperature

°C

－

20 +30 (20°C for optimum battery storage)

7.3 Mechanical Characteristics

Table 7-3 Mechanical Properties

Cabinet Specification Unit 120/20 200/20

Mechanical Dimension,

W×D×H

Mm 600×900×1600 600×900×2000

Weight Kg 151 182

Color N/A Black

Protection Level,

IEC(60529)

N/A IP20

48 Chapter 5 Maintenance

Module type Unit RM20

Mechanical Dimension, W×D×H mm 440×590×134

Weight kg 22

Color N/A Black

7.4 Electrical Characteristics (Input Rectifier)

Table 7-4 Rectifier AC input (mains)

Items Unit Parameter

Rated AC Input

Voltage

Vac

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

Input voltage range Vac

-40%～+25% (-10%+25% full load)

Frequency2 Hz

50/60Hz (range: 40Hz～70Hz)

Power factor kW/kVA, full load 0.99

THD

THDI％

7.5 Electrical Characteristics (Intermediate DC Link)

Table 7-5 Battery

Items Unit Parameters

Battery bus

voltage

Vdc Nominal: ±240V, one-side range: 198V～288V

Quantity of

lead-acid cells

Nominal

40=[1 battery(12V) ] , 240=[1 battery(2V) ]

Float charge

voltage

V/cell(VRLA)

2.25V/cell(selectable from 2.2V/cell～2.35V/cell)

Constant current and constant voltage charge mode

Temperature

compensation

mV/°C/cl

－

3.0(selectable from : 0～－5.0, 25°C or 30°C, or inhibit)

Ripple voltage

％

V float

≤1

Ripple current

％

C10

≤5

Equalized

charge voltage

VRLA

2.4V/cell(selectable from : 2.30V/cell～2.45V/cell)

Constant current and constant voltage charge mode

Final

discharging

voltage

V/cell(VRLA)

1.65V/cell(selectable from : 1.60V/cell～1.750V/cell) @0.6C

discharge current

1.75V/cell (selectable from : 1.65V/cell～1.8V/cell) @0.15C

discharge current (EOD voltage changes linearly within the set range according to discharge current)

Battery Charge

V/cell

2.4V/cell(selectable from : 2.3V/cell～2.45V/cell)

Constant current and constant voltage charge mode

Battery

Charging Power

Max Current

9%* UPS capacity (selectable from : 0～18%* UPS capacity)

庀

Appendix 2 Toxic or Hazardous Materials or Elements Identification Table 49

7.6 Electrical Characteristics (Inverter Output)

Table 7-6 Inverter Output (to important load)

Rated capacity(kVA) Unit

20～～～～200

Rated AC voltage1 Vac

380/400/415(three-phase four-wire and sharing neutral with the bypass)

Freqency2 Hz 50/60Hz

overload

％

105％ load, 1 hour

110％ load, 10min

125％ load, 1min

150％ load, 5sec

＞

150％ load, 200ms

Fault current

％

340％ short current limitation for 200ms

Non linear load

capability 3

％

100％

Neutral current

capability

％

170％

Steady state voltage

stability

％

±1(balanced load)

±1.5(100％ imbalance load)

Transient voltage

response 4

％

±5

THD

％

＜

1.5(linear load) , ＜5(non linear load3)

Synchronization -

Window

Rated frequency ±2Hz(selectable: ±1～±5Hz)

Max change rate of

synch frequency

Hz/s

1: selectable: 0.1～5

Inverter voltage range

％

V(ac)

±5

Note:

1. Factory setting is 400V. Commissioning engineers can set to 380V or 415V.

2. Factory setting is 50Hz. Commissioning engineers can set to 60Hz.

3. EN50091-3(1.4.58) crest ratio is 3: 1.

4. IEC62040-3/EN50091-3 including 0％～100％～0％ load transient, the recovery time is half circle

to within 5% of stable output voltage.

蜐

50 Chapter 5 Maintenance

7.7 Electrical Characteristics(Bypass Mains Input)

Table 7-7 Bypass Mains Input

Rated

capacity(kVA)

Unit

120kVA 200kVA

Rated AC

Voltage1

Vac

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

Rated current A

182@380V 174@400V 166@415V

302@380V 288@400V 276@415V

Overload

％

125％ load, long term

130％ load, 1 hour

150％ load, 6min

1000％ load, 100ms

Superior

protection bypass

line

N/A

Thermal-magnetic breaker, the capacity is 125％ of rated current output.

IEC60947-2 curve C

Current rating of

neutral cable

A 1.7×In

Frequency2 Hz 50/60

Switch time

(between bypass

and inverter)

ms Synchronized switch: ≤1ms

Bypass voltage

tolerance

％

Vac

Upper limit: ＋10,＋15or＋20, default: ＋20

Lower limit: －10, －20, －30 or－40, default:－20

(acceptable stable bypass voltage delay: 10s)

Bypass frequency

tolerance

％

±2.5, ±5, ±10 or ±20, default: ±10

Synchronization-

Window

Rated frequency±2Hz (selectable from ±0.5Hz～±5Hz)

Note:

1. Factory setting is 400V. Commissioning engineers can set to 380V or 415V.

2. Factory setting is 50Hz. Commissioning engineers can set to 60Hz. For example, UPS is set to frequency inverter mode, and then bypass status will be neglected.

7.8 Efficiency

Table 7-8 Efficiency, Loss and Air Exchange

Rated Efficiency (kVA) Unit 20

～～～～

200kVA

Efficiency

Normal mode(dual conversion)

％

ECO mode

％

Battery discharging efficiency (DC/AC) (battery at nominal voltage 480Vdc and full-rated linear load)

battery mode

％

Gtec MUST400 User Manual

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