JADAC Power Support 3300 UPS Manual
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1
INSTRUCTION MANUAL
TOWER 3300 ON LINE UPS SYSTEM
Tel. (031) 4643110 – Cell 0824516856
PO Box 39514 – Queensburgh 4070
e-mail –
jadac@intekom.co.za
JADAC Power Support 3300 UPS Manual
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CONTENTS
1.0 INTRODUCTION
1.1 General description 3
1.2 UPS building blocks 3
1.2.1 Boost converter 3
1.2.2 Inverter 3
1.2.3 Static transfer switch 3
1.2.4 Battery charger 3
2.0 INSTALLATION
2.1 Installation precautions 4
2.2 General 4
2.3 Cable and circuit breaker ratings 4
2.4 Wiring layout and connections 5
2.5 The internal battery 6
2.5.1 Battery safety 6
2.5.2 Battery tray connection 6
2.5.3 Installing the battery trays 7
2.5.4 The battery fuse arrangement 7
3.0 OPERATING PROCEDURES
3.1 Circuit breaker layout 8
3.2 Initial startup 8
3.3 Transferring load to static bypass 9
3.4 Manual bypass (detour) 9
4.0 TOUCH PANEL
4.1 Display Views 10
4.1.1 Line diagram 10
4.1.1.1 Boost block 11
4.1.1.2 Inverter block 12
4.1.1.3 Static switch block 12
4.1.1.4 Bypass breaker 12
4.1.1.5 Battery Block 12
4.1.1.6 Battery level indicator 13
4.1.1.7 Lines 13
4.1.2 AC values 13
4.1.3 DC values 14
4.1.4 Loading 14
4.1.5 Inverter alarms 15
4.1.6 Battery alarms 15
4.1.7 Unit alarms 16
4.2 Menu navigation 16
4.3 Confirmation 17
4.4 Alarm acceptance 17
4.5 Event history 17
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5.0 REMOTE SIGNALING
5.1 Voltage free relay board 19
5.2 RS232 serial connection 19
5.3 Ethernet connection 19
6.0 APPENDIX A
Specifications 20
7.0 APPENDIX B
Alarm explanation 21
8.0 APPENDIX C
Menu tree 22
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1.0 INTRODUCTION
1.1 General description
The Tower 3300 series of three phase double conversion Uninterruptible Power
Supplies (UPS) provide quiet, reliable and continuous power to an external load.
The load is protected against input transients and the output frequency is
controlled to within specified parameters. In the event of a power failure the UPS
will continue to maintain the load demands for a period dependant on the size of
the installed battery and the degree of loading.
In the unlikely event of UPS failure, the load will be automatically transferred
without any interruption directly onto the reserve mains supply. The unit can then
be connected into Manual Bypass mode for repairs to the unit (if required) without
disturbance to the load.
1.2 UPS building blocks
The Tower 3300 series has the following major building blocks:
1.2.1 Boost converter
The boost converter is able to utilize any of two sources to create a regulated,
filtered DC link which supplies the inverter.
State of the art power electronics is used to provide a near unity input power
factor while boosting its primary rectifier mains source.
If the incoming supply is lost, the boost converter boosts the battery.
When the primary source becomes available again, a linear soft start circuit
ensures that there is no inrush current drawn by the UPS.
1.2.2 Inverter
The inverter’s input is connected directly to the DC link with which it generates
three phase power to support the load.
The inverter uses Digital Signal Processors (DSP) to closely control and
monitor its output precisely – ensuring that the waveform remains perfectly
sinusoidal under all load conditions.
The frequency of the inverter is maintained in a phase locked condition with the
reserve supply frequency as long as it remains within the selectable tolerance
band. The inverter will run at its own oscillator derived frequency if the reserve
supply should fail.
1.2.3 Static transfer switch
The static switch is totally independent along with its own two independent
power supplies. The static switch will normally connect the load to the inverter
output. If the inverter becomes unavailable or goes out of tolerance, the static
switch (analog detection) will transfer the load to the reserve source without
interruption. The static switch also enables no break transfer/retransfers during
the maintenance bypass procedure.
1.2.4 Battery charger
The battery charger uses DSP control to regulate the temperature
compensated charging of the battery. The charger is equipped with both a
battery impedance test circuit and boost function. All the charger functions can
be controlled via the display.
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2.0 INSTALLATION
2.1 Installation precautions
The following factors should be considered to determine a suitable location for your
unit:
• Protection against excessive temperature and humidity
• Protection against moisture
• Ease of access and adequate lighting for service personnel
• It’s position relative to the critical load for ease of reticulation
• Adequate ventilation clearance (rear end)
• A close proximity of the UPS to the battery cabinet where applicable
• Potential expansion, e.g. additional battery cabinet/unit
2.2 General
The unit requires access from the front, top and from one side so care should be
taken in positioning the unit accordingly.
2.3 Cable and circuit breaker ratings
The recommended input, output cable and circuit breaker sizes are listed in the
table below. The input circuit breaker must have a D curve response and should
be mounted in the existing DB board. The UPS supply must not be connected via
an earth leakage breaker.
kVA
Rating
Input
Current
Circuit
Breaker
Input Cable
Output
Current
Output
Cable
10 32A 40A 10mm2 15A 2.5mm2
15 32A 40A 10mm2 23A 4mm2
20 32A 40A 10mm2 30 6mm2
30 63A 80A 16mm2 45 10mm2
40 63A 80A 25mm2 60 16mm2
All input and output cables should have four cores plus an earth respectively
2.4 Wiring layout and connections
The cable entry for the unit is at the rear behind a removable cover-plate.
Always ensure that all the cables are secure and the length adequate.
The terminal block layout and wiring numbering is shown on the next page.
It can bee seen that the reserve and rectifier terminals are bridged.
If it is required to supply the unit from two different sources, simply remove the
bridging cables. The phase rotation must always be clockwise.
The labeling notation is as follows:
Rectifier input terminals: 1U1, 1V1, 1W1 & 1N1
Reserve input terminals: 2U1, 2V1 & 2W1
Output terminals: U2, V2, W2 & N2
The earth connection is made to the earth stud under the wiring compartment.
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The wiring terminals as seen from rear of the unit
2.5 The internal battery
The Tower 3300 series can house a maximum of four parallel banks of
32x12V7A/h or 32x12V9A/h internal batteries. The nominal battery voltage is
384VDC, which is dangerous and can be potentially lethal.
2.5.1 Battery safety
Extreme care should be exercised when working with batteries.
Do not short out the battery terminals
Do not drop the batteries
Ensure the polarity connections are correct
Ensure that the battery interconnections are connected securely
Ensure that the interconnections are not pinched between trays
Batteries should only be installed by qualified personnel
2.5.2 Battery tray connection
The batteries in the battery tray are wired to a tray connector plug at the front of
each tray. The tray connectors respectively plug into the interconnections that
are fixed to the UPS chassis.
Note: The top four trays house ten batteries each, while the middle and bottom
trays all house eleven batteries each.
The interconnecting cables are supplied with the unit
Detail of battery tray connection to the tray connector plug
Remove these links
for separate feeds
FRONT
CONNECTOR PLUG
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2.5.3 Installing the battery trays
Each of the four internal battery banks consist of three vertically mounted trays.
These four by three form an array of tray compartments, as shown below.
Ensure that the battery fuses are all open before any of the battery trays are
plugged in.
e.g.: Bank 1 (shown in bold) consists of three vertically mounted trays: (ABC)
Array of battery tray compartments
2.5.4 The battery fuse arrangement
Each of the four internal battery banks are individually fused, thereby allowing
the batteries to be changed safely while the unit is running.
The diagram below details the battery fuse arrangement.
Battery fuse arrangements
TO
BANK 1
TO
BANK
2
TO
BANK
3
TO
BANK
4
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3.0 OPERATING PROCEDURES
It is recommended that one carefully considers all actions that involve switching
the circuit breakers as indiscriminate switching can result in loss of load.
3.1 Circuit breaker layout
The circuit breaker layout is shown below.
Circuit breaker layout
3.2 Initial startup
Close Rectifier Input (CB1).
Close Reserve Input (CB2).
After a short time period the display will power up.
Confirm: “Load on Static Bypass” is displayed
Close Load Output Isolator (SW1).
Open Manual Bypass (CB3).
Close Battery Fuses.
On Display Select:
Confirm: “No Active Alarms” is displayed within approx. 20 sec.
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3.3 Transferring load to static bypass
Confirm: “No Active Alarms” is displayed.
On Display Select:
3.4 Manual bypass (detour)
Perform Load on Static Bypass procedure.
Close Manual Bypass (CB3).
Open Load Output Isolator (SW1).
Open Rectifier Input (CB1).
Open Reserve Input (CB2).
Open Battery Fuses.
The unit will be safe to work on once the display has switched off.
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4.0 TOUCH PANEL
The Tower 3300 UPS series is equipped with a graphic display and touch panel as
a user interface. The touch panel can be pressed using your finger.
(Sharp objects may cause damage to the touch panel.)
Various buttons, which can be pressed, are drawn on the display.
Once pressed, the button’s image is inverted accompanied by a brief click sound.
Certain buttons (such as arrows) can be kept in to perform a repeated scrolling
action.
All buttons (except the tabs) have a distinct button border
around them so they can be easily identified as buttons.
It is shown here what happens when the down arrow is
pressed and held down to activate the scrolling function.
Not all buttons will allow scrolling.
4.1 Display Views
Tabs are used to change the display views. To switch views, simply press the
centre of the corresponding tab.
Although only four tabs are shown, there is in fact more than four and they will
automatically scroll left and right until either the first or the last tab is reached.
The first tab is the left-most tab
The last tab is the right-most tab
4.1.1 Line diagram
The line diagram provides a status of all the UPS’s functional blocks at a
glance. The screenshot on the next page has been labeled for easy
identification of the various components, each of which will be described in
detail.
Button not
pressed
Button
pressed
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4.1.1 Line diagram /…cont
A full list of alarm meanings is given in Appendix C
4.1.1.1 Boost block
The boost block can be seen in three forms as follows:
DISABLED: The boost converter is off.
ENABLED: The boost converter is on but is not supporting the
load.
ACTIVE: The boost converter is on and is supporting the
load.
RECTIFIER
LINE
BOOST
BLOCK
INVERTER
BLOCK
SELECTED
TAB
UNSELECTED
TAB
INVERTER
LINE
OUTPUT
LINE
STATIC
SWITCH
RESERVE LINE
BYPASS LINE
BYPASS
BREAKER
BATTERY
BLOCK
BATTERY LEVEL
INDICATOR
RESERVE
VOLTAGE
INVERTER
VOLTAGE
UPS VOLTAGE & CURRENT
ALARM
INDICATOR
LINK
LINE
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4.1.1.2 Inverter block
The inverter block can be seen in three forms as follows:
DISABLED: The inverter is off.
ENABLED: The inverter is on but is not supporting the load.
ACTIVE: The inverter is on and is supporting the load.
4.1.1.3 Static switch block
The static switch can be seen in three forms as follows:
DISABLED: The static switch output is off.
ENABLED: The static switch is providing output but it is not
supporting the load.
ACTIVE: The static switch is supporting the load.
4.1.1.4 Bypass breaker
The bypass breaker can be seen in two forms as follows:
OPEN The UPS is not in maintenance bypass.
CLOSED: The UPS is in maintenance bypass.
4.1.1.5 Battery block
The battery block can be seen in three forms as follows:
DISABLED: The battery is depleted or not in circuit.
ENABLED: The battery voltage is within limits but is not
supporting the load..
ACTIVE: The battery is supporting the load.
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4.1.1.6 Battery level indicator
The battery level can be seen in the form of a fill on the battery picture:
These illustrations show some of the stages
the battery goes through as it discharges
4.1.1.7 Lines
The various lines can be seen in three forms as follows:
DISABLED: The voltage on the line is out of limits or
there is no voltage on the line.
ENABLED: The voltage on the line is within limits but
the load is not powered via the line
ACTIVE: The line is being used to support the load
The tab scrolling concept can also be seen in the next few illustrations.
4.1.2 AC values
The AC values view will display all the RMS AC voltages/currents in a tabular
form. Included on this view is the UPS temperature and output frequency.
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4.1.3 DC values
The DC values view will display all the DC voltages/currents in a tabular form.
Included on this view is the battery temperature and link voltage.
4.1.4 Loading
The loading view will display all the load related measurements in a tabular
form.
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4.1.5 Inverter alarms
The inverter alarm view will display all the inverter/converter related alarm
statuses in an alarm indicator panel type view. System date and time is also
shown The virtual LED’s are seen in two forms as shown below:
A full list of alarm meanings is given in Appendix C
4.1.6 Battery alarms
The battery alarm view will display all the battery/charger related alarm statuses
in an alarm indicator panel type view. System date and time is also shown
The virtual LED’s are seen in two forms as shown below:
A full list of alarm meanings is given in Appendix C
LED OFF (enlarged)
LED ON (enlarged)
LED OFF (enlarged)
LED ON (enlarged)
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4.1.7 Unit alarms
The unit alarm view will display all the static switch/UPS related alarm statuses
in an alarm indicator panel type view. System date and time is also shown
The virtual LED’s are seen in two forms as shown below:
A full list of alarm meanings is given in Appendix C
Note that this is the last tab, as the tab has positioned itself on the right-most edge of the screen.
4.2 Menu navigation
The UPS has several menus as part of the interface to simplify tasks/instructions.
The factory menu is shown below as an example:
The arrow buttons are used to
scroll the focus line up or down.
The menu list may be longer
than what can be displayed on
the menu screen.
In this case, the focus will only
move until it is one position
away from the, after which, the
list will move instead of the
focus.
At the end of the list, the focus
will move the focus will move
into the last position
If the list is too long to be displayed, it will scroll until the focus reaches the bottom position.
A full list of menus and sub menus is given in Appendix D
LED OFF (enlarged)
LED ON (enlarged)
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4.3 Confirmation
If any command given to the UPS is likely to effect the load, the user will be
prompted for confirmation.
Please ensure that the confirmation is not taken lightly as it’s purpose is to prevent
accidental loss of load.
Each command given to the unit will be logged in the events history log – along
with the date, time and source of the command.
4.4 Alarm acceptance
The UPS has a thirty second delay before any audible alarm is issued.
Once an audible alarm sounds it may be silenced by simply pressing a button on
the display.
Any alarm condition should immediately be investigated or reported as it may
effect the system’s operation if it is ignored.
Even if the audible alarm has been silenced, it will re-initiate if new alarm events
occur.
Each time the alarm is silenced, the date, time and accepted alarm conditions will
be logged in the events history log.
4.5 Event history
The Tower 3300 UPS will log a hundred of the latest events in an event history log.
The event history log closely resembles the alarm tabs:
Although there was only
one active alarm on the
inverter tab at the time of
this log being recorded,
the little bell on the
battery tab indicates that
there were active
alarm(s) on that tab too.
indicates alarm acceptance
indicates display reset
A full list of alarm meanings is given in Appendix C
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4.5 Event history /…cont
Instructions or user actions are also logged as follows:
A full list of possible instruction entries is given in Appendix D
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5.0 REMOTE SIGNALING
The Tower 3300 UPS is equipped with the following remote connectivity:
5.1 Voltage free relay board
The voltage free relay board, situated at the rear of the UPS, has six relays, each
with a normally open and a normally closed set of contacts.
Five of the relays can be selected via the relay menu (alarms from Appendix C)
while the sixth relay is a dedicated common alarm relay.
Layout of the voltage free relay board
5.2 Rs232 serial connection
The RS232 Serial connection, situated at the rear of the UPS is intended for the
use of shutdown software and is designed around the Mega Tec protocol for
UPSilon 2000.
Alternatively this port is used by the service technician to download settings and
events from the UPS’s logs.
5.3 Ethernet connection
The Ethernet connection is intended for remote network connection to the UPS.
A TCPIP link can be established for network control and a SNMP connection can
be established for network monitoring.
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6.0 APPENDIX A
SPECIFICATIONS
INPUT
10kVA
15kVA
20kVA
30kVA
40kVA
Voltage
380 -400 -415V
±20%
380 -400 -415V
±20%
380 -400 -415V
±20%
380 -400 -415V
±20%
380 -400 -415V
±20%
Frequency
45 – 65 Hz
50Hz ±4% 50Hz ±4% 50Hz ±4% 50Hz ±4%
Power Factor
0.98 0.98 0.98 0.98 0.98
OUTPUT
Voltage – (Line – Line)
( Line – Neutral)
380-415V
220-240V
380-415V
220-240V
380-415V
220-240V
380-415V
220-240V
380-415V
220-240V
Voltage stability – static
Voltage stability – dynamic 0 -100%
1%
<5%
1%
<5%
1%
<5%
1%
<5%
1%
<5%
Power Factor
0.8 0.8 0.8 0.8 0.8
Frequency
50Hz +-0.1% 50Hz +-0.1% 50Hz +-0.1% 50Hz +-0.1% 50Hz +-0.1%
Waveform
Sine Sine Sine Sine Sine
Harmonic distortion (linear loads)
Harmonic distortion (non linear loads)
< 2%
< 5%
< 2%
< 5%
< 2%
< 5%
< 2%
< 5%
< 2%
< 5%
Inverter overload 150%
Inverter overload 150%
Inverter overload 125%
0.1 seconds
30 seconds
5 minutes
0.1 seconds
30 seconds
5 minutes
0.1 seconds
30 seconds
5 minutes
0.1 seconds
30 seconds
5 minutes
0.1 seconds
30 seconds
5 minutes
Crest Factor
3 : 1 3 : 1 3 : 1 3 : 1 3 : 1
BYPASS - Static switch Voltage
+-15%
380-415V
220-240V
380-415V
220-240V
380-415V
220-240V
380-415V
220-240V
380-415V
220-240V
BYPASS – Static switch overload
10 times for
1000 m Sec
10 times for
1000 m Sec
10 times for
1000 m Sec
10 times for
1000 m Sec
10 times for
1000 m Sec
Efficiency (input-output)
>90% >90% >90% >90% >90%
BATTERY
No of 12V blocks
32 x 8A/H 32 x 8A/H 32 x 8A/H 32 x 8A/H 32 x 8A/H
Max No of banks in cabinet
4 4 4 4 4
Float voltage
432V 432V 432V 432V 432V
Battery discharging
384V 384V 384V 384V 384V
Low DC off
335V 335V 335V 335V 335V
Recharge current
10A 10A 10A 10A 10A
Autonomy 100% @ 0.8 pf (4 banks)
~ 50 min ~ 30 min ~ 20 min ~ 15 min ~ 10 min
GENERAL
Weight of UPS with 4 set of batteries
420kg 420kg 420kg 420kg 420kg
Dimensions of UPS units and
extended battery cabinets
D - 890mm H - 1270mm W - 610mm
Interfacing
Dry Contacts – RS232 for MEGATEC S/W – Ethernet network connection
Ambient temperature
0 - 40°C –90% maximum humidity
Noise level
50 - 55dBA @ 1 meter
PROTECTION (ALL RANGES )
CIRCUIT BREAKERS AC - rectifier - reserve – bypass – output DC FUSES – Internal batteries
STATIC SWITCH – analog detection – independent power supply
ELECTRONIC - peak current limit pulse by pulse – IGBT supervision – overcurrent peak – RMS overload
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7.0 APPENDIX B
ALARM EXPLANATION
ALARM NAME ALARM MEANING
Inverter Off The inverter is off
Inverter Voltage High The RMS inverter voltage is over the allowable limit
Link Soft Starting The DC link voltage is being pre charged
Rectifier Off The boost converter is off
Inverter Output Low The RMS inverter voltage is under the allowable limit
DC Link Voltage Low The DC link voltage is under the allowable limit
Inverter Fuse Blown The inverter fuse has blown
Rectifier Mains Fail The rectifier supply is under the allowable limit
DC Link Voltage High The DC link voltage is over the allowable limit
Rectifier Fuse Blown The boost converter’s fuse has blown
Overload The UPS is being overloaded
Inverter DC Offset High The DC component of inverter output is over allowable limit
Supervision Stop The inverter bridge has been stopped by supervisory circuits
Over Temperature / Fan Failure The UPS temperature is over allowable limit
* FACTORY SETUP MODE * The UPS is in a drive signal checking mode (used at factory)
Rectifier High / Low The rectifier output voltage is over/under allowable limit
Battery Volts High The battery voltage is over allowable limit
Battery Fault Detected The charger has detected a battery impedance fault
Charger Fail The charger is not working
Battery Discharging The battery voltage has dropped below 2V per cell
* Battery TEST MODE * Battery test is in progress
Charger Feedback Fault The charger is reporting a feedback fault
Battery Warning The battery is nearly depleted
Charger Supply Out Limits The charger’s supply is over/under allowable limit
Low Battery Shutdown The battery voltage is under allowable limit
Battery Boost Charge Active The charger is in boost mode (vented cells only)
Charger Comms Error Communications with the charger has been lost
Load on Static Bypass The load is being supplied by the reserve source
Phase Rotation Fault The reserve source’s phase rotation is incorrect
Reserve Voltage High The reserve source’s voltage is over allowable limit
Retransfer Lockout Attempts to retransfer the load failed - resulting in lockout
Loss of Phase Lock The inverter is unable to synchronize to it’s reserve source
Reserve Voltage Low The reserve source’s voltage is under the allowable limit
Maintenance Bypass Closed The maintenance detour switch has been closed
Supply Freq Out Limits The reserve source’s frequency is over/under allowable limit
Output Voltage High The static switch output voltage is over allowable limit
E.P.O. Activated The external EPO has been triggered
Charger Needs Calibrating The charger failed to receive valid calibration constants
Output Voltage Low The static switch output voltage is under allowable limit
PSU Sleep Mode Warning The PSU is about to go into sleep mode
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8.0 APPENDIX C
MENU TREE
Menu
Commands
Erase History
Inverter On/Off
S/S Mode to Auto/Manual
S/S Lock Reset
Setup
Setup Relays
Assign Relays
Enable Relays
Test Relays
Save Relay Settings
Set Date & Time
View Specifications
Battery Discharge Curve
Password
History
Service
Download
Re-Kit
Control Card
Display
Set points
Battery Float
Battery Boost
Battery I Limit
Inverter Output
Thresholds
UPS Battery High
Ch Battery High
Battery Discharging
Battery Warning
Battery Low
Inverter Low
Reserve Low
Output Low
Inverter High
Reserve High
Output High
Frequency High
Frequency Low
Calibration
Ph Error Adjust
Inverter Voltage
Reserve Voltage
Output Voltage
Output Current
DC Link Voltage
Rectifier Mean Voltage
UPS Battery Voltage
Ch. Battery Voltage
Ch. Battery Current
Battery Temperature
UPS Temperature
Log This Service
Save ALL settings to flash
Reset the display
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Factory
Factory Test On/Off
Battery Test On/Off
Battery Boost On/Off
Service Thresholds
UPS Battery High
Ch Battery High
Battery Discharge
Battery Warning
Battery Low
Inverter Low
Reserve Low
Output Low
Inverter High
Reserve High
Output High
Frequency High
Frequency Low
Factory Thresholds
DC Link High
DC Link Low
DC Link Start
Rectifier Mean Low
Phase Lock Voltage Low
Frequency High
Frequency Low
Centre Frequency
Phase Error
Set points
Battery Float
Battery Boost
Battery Current Limit
Inverter Output
DC Link Voltage
Calibration
Ph Error Adjust
Inverter Voltage
Reserve Voltage
Output Voltage
Output Current
DC Link Voltage
Rectifier Mean Voltage
UPS Battery Voltage
Ch. Battery Voltage
Ch. Battery Current
Battery Temperature
UPS Temperature
DC Offsets
Charger Input Voltage
Battery Impedance
UPS Battery Current
View History
View Traps
Erase History
Erase Traps
Flash Commands
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Commissioned By :
Commissioned Date:
Service Date
Serviced By
Next Service
Date
Notes:
S E R V I C E H I S T O R Y
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