Liebert 7400 User Manual

Manual Reference: 6310018A - 2 (02/98) LCA 10/01

7400 Series UPS

Single Module

and

1+1 Configuration

User Manual

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7400 Series UPS
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IMPORTANT

This manual contains information concerning the installation, operation and maintenance of the

Liebert Series 7400 Uninterruptible Power System (UPS) for the Single Module and One plus

One Systems.

All relevant parts of the manual should be read prior to commencing installation.

The UPS must be commissioned by an engineer approved by the manufacturer (or his

agent) before being put into to service. Failure to observe this condition will invalidate any

implied warranty.

The Series 7400 UPS has been designed for Commercial/Industrial use only.

The Series 7400 UPS has not been designed for direct use in any life support applications.

If you encounter any problems with the procedures contained in this manual you should seek

immediate assistance from the Liebert Sales Office from whom the equipment was purchased.

Alternatively contact the manufacturer's Customer Support department at the address shown

below:

Customer Service and Support Department,

Customer Support Systems,

Liebert Europe

Globe Park, Marlow, SL7 1YG, U.K.

Telephone [phone]

Fax [phone]

Outside the UK prefix the number with - (44 - 1628)

The manufacturer reserves the right to change the equipment design without notice.

©Copyright 1998 by Liebert Europe.

Unauthorised reproduction prohibited

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All rights reserved.

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ELECTRO MAGNETIC COMPATIBILITY

WARNING

This is a UPS for restricted sales distribution to informed partners with the appropriate

EMC technical competence. Installation restrictions or additional measures may be needed

to prevent disturbances (EMC Standard 50091-2).

To convert to a class `A' UPS, the following factory installed

optional e.m.c. kits must be fitted:

80 kVA Module - Option kit part number 4641018 S
120 kVA Module - Option kit part number 4641014 O
200 kVA Module - Option kit part number 4641029 D
300 kVA Module - Option kit part number -
400 kVA Module - Option kit part number -

When fitted with the above optional e.m.c. kits the following warning applies:

This is a class `A' UPS product. In a domestic environment this product

may cause radio interference in which case the user may be

required to take additional measures.

This equipment complies with the requirements of the EMC Directive 89/336/EEC

and the published technical standards.

Continued compliance requires installation in accordance with these instructions

and the use of manufacturer approved accessories only.

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This manual describes the following equipment:

EQUIPMENT PART NUMBER

80 kVA UPS Module 5410270 I
120 kVA UPS Module 5410272 K
200 kVA UPS Module 5410276 O
300 kVA UPS Module 5410250 O
400 kVA UPS Module 5410252 Q
300 kVA UPS 12 pulse Module 5410251 P
400 kVA UPS 12 pulse Module 5410253 R

80 kVA 12 Pulse option 5332001 Z
120 kVA 12 Pulse option 5332002 A
200 kVA 12 Pulse option 5332004 C

80 kVA EMC compatibility kit 4641018 S
120 kVA EMC compatibility kit 4641014 O
200 kVA EMC compatibility kit 4641029 D
300 kVA EMC compatibility kit
400 kVA EMC compatibility kit

860 mm Battery Cabinet (250 Amp) 5320024 I
Battery Circuit Breaker Box for UPS 80 kVA (250 A) 4641007 H
Battery Circuit Breaker Box for UPS 120 kVA (400 A) 4641008 I
Battery Circuit Breaker Box for UPS 200 kVA (630 A) 4641009 J
Battery Circuit Breaker Box for UPS 300 kVA (800 A) 4641011 L
Battery Circuit Breaker Box for UPS 400 kVA (1000 A) 4641012 M

5th Harmonic Input filter 80 kVA 5331016 C
5th Harmonic Input filter 120 kVA 5331018 E
5th Harmonic Input filter 200 kVA 5331020 G
5th Harmonic Input filter 300 kVA (internal to UPS) 4641010 K
5th Harmonic Input filter 400 kVA (internal to UPS) 4641013 N
AS400 alarm interface board 4590041 B
AS400 ( X4 ) alarm interface board 4590045 F
External interface board 4590044 E
Remote Alarm Monitor (RAM) 4305001 Z
Remote alarm and control Panel 4305002 A
RS-232 Communications Interface (SGC) 4550002 C
Top cable entry kit for 80 kVA - 120 kVA 2174011 V
Top cable entry kit for 200 kVA 2174033 R

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Safety Precautions

WARNING

THIS UPS DOES NOT INCORPORATE AUTOMATIC BACKFEED PROTECTION. A

WARNING LABEL MUST BE FITTED TO ALL EXTERNAL PRIMARY POWER

ISOLATORS STATING:

ISOLATE THE UNINTERRUPTIBLE POWER SYSTEM BEFORE WORKING ON THIS

CIRCUIT.

General

In common with other types of high power equipment, da ngerous voltages are present within the UPS

and battery enclosure. The risk of contact with these voltages is minimised as the live component parts

are housed behind a hinged, lockable door. Further internal safety screens make the equipment

protected to IP20 standards. No risk exists to any personnel when operating the equipment in the

normal manner, following the recommended operating procedures.

All equipment maintenance and servicing procedures involve internal access and should be carried out

only by trained personnel.

Batteries

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.

Test Equipment

When the battery is under charge it is earth-referenced about its mid-point e.g. if the battery

is being charged at 446 V the battery extremities will be at +223V and -223V with respect to

neutral (earth). When using mains-powered test equipment such as oscilloscopes in the UPS

high voltage area, always use a differential mode of operation to avoid the need to

disconnect the oscilloscope frame earth.

Personnel

When working inside the UPS (trained personnel only) it is recommended that protection be

worn to prevent eye damage, should an electrical arc be struck by mishandling or severe

electrical fault.

Some of the power components are very heavy. If their removal is necessary ensure that

sufficient manpower is available, otherwise use adequate mechanical handling

equipment.When working in the general area of the UPS where high voltages are present, a

second person should be standing-by to assist and summon help in case of accident.

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Table of Contents

1. Chapter 1 - General Description.............................................................................................................................1-1

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

1.2 Design Concept ....................................................................................................................................................1-1

1.2.1 Module Design..............................................................................................................................................1-1

1.2.2 Bypass supplies .............................................................................................................................................1-5

1.2.3 UPS Power Switch Configuration ..............................................................................................................1-5

1.2.4 Battery circuit breaker...................................................................................................................................1-6

1.2.5 Battery Cabinet..............................................................................................................................................1-6

1.2.6 Battery circuit breaker box............................................................................................................................1-6

1.3 One Plus One System...........................................................................................................................................1-8

1.3.1 Redundant vs Non-Redundant configuration................................................................................................1-8

1.3.2 One-Plus-One Parallel Control............................................................................................ ..........................1-8

1.3.3 Common battery..........................................................................................................................................1-10

1.4 Operator Control Panel.......................................................................................................................................1-12

1.4.1 Mimic indications........................................................................................................................................1-12

1.4.2 Control switches..........................................................................................................................................1-13

1.4.3 LCD Display................................................................................................................................................1-15

2. Chapter 2 - Operating Instructions..........................................................................................................................2-1

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

2.1.1 General notes.................................................................................................................................................2-1

2.2 One plus One........................................................................................................................................................2-1

2.2.1 Redundant module system.............................................................................................................................2-1

2.2.2 Non-Redundant module system.....................................................................................................................2-3

3. Chapter 3 - Installation Procedure..........................................................................................................................3-1

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

3.1.1 Equipment positioning and environmental considerations ...........................................................................3-2

3.1.2 Raised floor installation.................................................................................................................................3-3

3.1.3 Battery Location............................................................................................................................................3-3

3.2 Preliminary Checks.............................................................................................................................................3-13

3.3 Reassembling the 300 kVA and 400 kVA cabinets............................................................................................3-14

3.4 Connecting the UPS power cables......................................................................................................................3-16

3.4.1 Cable entry...................................................................................................................................................3-16

3.4.2 Cable rating .................................................................................................................................................3-16

3.4.3 Cable connections........................................................................................................................................3-17

3.4.4 Safety earth..................................................................................................................................................3-17

3.4.5 Cabling procedure .......................................................................................................................................3-18

3.5 Battery Installation.............................................................................................................................................3-24

3.5.1 860 mm cabinet (250 Amp circuit breaker).................................................................................................3-25

3.5.2 Battery circuit breaker boxes.......................................................................................................................3-28

3.5.3 Battery Display Initialisation.......................................................................................................................3-31

4. Chapter 4 - Optional equipment .............................................................................................................................4-1

4.1 AS400 Interface Board (4590041B).....................................................................................................................4-2

4.1.1 AS400 Interface Board outputs.....................................................................................................................4-2

4.1.2 Remote control inputs....................................................................................................................................4-2

4.1.3 Calibration.....................................................................................................................................................4-2

4.2 4-Way AS400 Interface Board (4590045F) .........................................................................................................4-4

4.2.1 Remote control inputs....................................................................................................................................4-4

4.2.2 Calibration.....................................................................................................................................................4-4

4.3 Output Interface (Remote Alarms) Boards (4590044E).......................................................................................4-6

4.3.1 Alarm outputs................................................................................................................................................4-6

4.3.2 Remote control inputs....................................................................................................................................4-6

4.4 Remote Alarm Monitor (RAM) (P/N 4305001Z).................................................................................................4-8

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4.4.1 Connections...................................................................................................................................................4-8

4.5 Remote Alarm and Control Panel (Part No. 4305002 A)...................................................................................4-10

4.5.1 Introduction.................................................................................................................................................4-10

4.5.2 Connections.................................................................................................................................................4-11

4.6 RS 232 Communications Management Board (SGC) (4550002C)....................................................................4-15

4.6.1 Introduction.................................................................................................................................................4-15

4.6.2 General Information ....................................................................................................................................4-16

4.7 5th Harmonic Input Filter...................................................................................................................................4-18

4.7.1 Introduction.................................................................................................................................................4-18

4.7.2 Specification................................................................................................................................................4-18

4.7.3 Notes on connection....................................................................................................................................4-18

4.8 Cable top entry kit..............................................................................................................................................4-24

4.8.1 Introduction.................................................................................................................................................4-24

4.9 Pulse Option.......................................................................................................................................................4-25

4.9.1 Introduction.................................................................................................................................................4-25

4.9.2 Electrical connection...................................................................................................................................4-25

4.10 Option Board Kit (Part no. 77000005).............................................................................................................4-29

4.10.1 Introduction...............................................................................................................................................4-29

4.10.2 Installation.................................................................................................................................................4-29

5. Chapter 5 - Maintenance.........................................................................................................................................5-1

5.1 Introduction.......................................................................................................................................................... 5-1

5.2 Safety Precautions................................................................................................................................................5-1

5.3 Scheduled Maintenance........................................................................................................................................5-1

5.3.1 Daily checks..................................................................................................................................................5-1

5.3.2 Weekly checks...............................................................................................................................................5-3

5.3.3 Annual Service ..............................................................................................................................................5-3

5.3.4 Extended service............................................................................................................................................5-4

5.3.5 Battery maintenance ......................................................................................................................................5-4

6. Chapter 6 - Troubleshooting...................................................................................................................................6-1

6.1 Troubleshooting UPS Systems .............................................................................................................................6-1

6.1.1 Operating parameters and limitations............................................................................................................6-1

6.1.2 General Troubleshooting Procedure............................................................................................................. 6-1

6.2 Display panel message interpretation...................................................................................................................6-5

7. Chapter 7 - SPECIFICATION................................................................................................................................7-1

7400 Series UPS User Manual Chapter 1 - General Description
Single Module and One plus One Systems Introduction

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1. Chapter 1 - General Description

1.1 Introduction

The 7400 Series uninterruptible power supply (UPS) system is connected
between a critical load, such as a computer, and its three phase mains
power supply. Being designed to furnish a well regulated 3 phase output
power supply under all rated load and input supply conditions, the
system offers the user the following advantages:-

Increased power quality:

The UPS has its own internal voltage and frequency regulator circuits
which ensure that its output is maintained within close tolerances
independent of voltage and frequency variations on the mains power
lines.

Increased noise rejection:

By rectifying the input a.c. power to d.c. power, and then converting it
back to a.c., any electrical noise present on the input mains supply line is
effectively isolated from the UPS output, therefore the critical load sees
only clean power.

Power blackout protection:

If the mains power fails, the UPS continues to power the critical load
from its battery source, leaving the load immune from power
disturbances.

1.2

Design Concept

This section describes an individual module’s operating principles for
both 6 and 12 pulse systems - the effects of the additional parallel control
facilities required on the one plus one system on the standard module are
described later.

6 pulse Rectifier

The UPS basically operates as an AC-DC-AC converter (see figure 1-1).
The first conversion stage (from a.c. to d.c.) uses a 3 phase, fully­controlled SCR bridge rectifier to convert the incoming mains supply
into a regulated 446 V d.c. busbar for a 400 V a.c. input (or 432 V d.c.
for a 380 V a.c. input or 459 Vd.c. for a 415V a.c. input).

1.2.1 Module Design

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Design Concept Single Module and One plus One Systems

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Figure 1-1. Series 7400 UPS Single Module block diagram

Mains
Supply

RECTIFIER

STATIC
SWITCH

BATTERY

INVERTER

UPS

Output

Supply

Bypass
Supply

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12 Pulse Rectifier

The UPS basically operates as an a.c.-d.c.-a.c. converter (see figure 1-1).
The first conversion stage (from a.c. to d.c.) uses a 3 phase 12 pulse (2 x
6 pulse), fully-controlled SCR bridge rectifier system to convert the
incoming mains supply into a regulated d.c. busbar (432V d.c. for a
380V a.c. input; 446V d.c. for a 400V a.c. input or 459V d.c. for a 415V
a.c. input).
The input a.c. supply is applied (a) directly into a six pulse rectifier and
(b) via a 30° phase shift transformer into a second six pulse rectifier (see
figure 1-2). This phase shifting results in less distortion of the alternating

input supply (i.e. the lower order harmonics are cancelled).

Inverter

The d.c. busbar produced by the rectifier provides both battery charging
power and power to the inverter section-which uses the latest IGBT
switched pulse width modulation (PWM) design and provides the second
conversion phase; i.e. reconverting the d.c. busbar voltage back into an
a.c. voltage waveform.
During normal operation both the rectifier and inverter sections are
active and provide regulated load power whilst simultaneously float
charging the battery. In the event of a mains power failure, the rectifier
becomes inoperative and the inverter is powered solely from the battery.
Critical load power is maintained under these conditions until the battery
is fully discharged, whereupon the UPS shuts down. The end of battery
discharge is assumed when the battery voltage falls to 320 Vd.c. for a
system with a 380V a.c. input supply, 330V d.c. with a 400V a.c. input
supply and 340V d.c. with a 415V a.c. input supply.
The period for which the load can be maintained following a mains
power failure is known as the system’s ‘Autonomy Time’ and is
dependent upon both the battery A/Hr capacity and the applied
percentage load. It is usual in larger installations to provide an
alternative UPS input power source from a standby generator when the

L1

L2

AT1

Mains
Supply

12 Pulse
(2 x 6 pulse)
Recti fi er syste m

To DC

Busbar

DC

Inductor

Phase

displacement

transformer

Inductor

Rectifier

bridges

Rectifier

bridges

Figure 1-2 . 12 Pulse rectifier block diagram

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mains supply fails. Once such a genera tor has been b rought on-line , and
the UPS input power has been re-established, the batteries

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immediately begin to recharge. Modern generators can be started and
brought on-line very quickly and where such a facility is incorpor ated
into the UPS installation it results in short battery discharge periods and
correspondingly rapid recharge times.

The circuit block annotated ‘Static Switch’ in figure 1-3 contains an
electronically controlled switching circuit which enables the critical load
to be connected either to the inverter output or to a bypass power source
via the ‘static bypass line’. Normally, the load is connected to the
inverter; but in the event of a UPS overload, or inverter failure, it is
automatically transferred to the static bypass line due to the static switch
action.
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 synchronised during normal operating conditions. This is achieved
through the inverter control electronics which make the inverter
frequency track that of the static bypass supply-provided that the bypass
remains within an acceptable frequency window. The synchronising
window is pre-selected to 2% of nominal frequency, giving an acceptable
frequency window of ±1Hz.
An [

INVERTER UNSYNCHRONIZED] warning message is displayed on the

operator control panel when the inverter and bypass supplies are not
synchronized.
A second, manually controlled, ‘maintenance bypass’ supply is also
incorporated into the UPS design. Its purpose is to enable the critical
load to be powered from the mains (bypass) supply while the UPS is shut
down for maintenance or troubleshooting.
Note:- The load is unprotected against mains power supply aberrations or
failure when it is connected to either the static bypass or maintenance

bypass supply.

The power switch locations in the various 7400 models are shown in

Figure 1-4.Figure 1-3 illustrates the 7400 series UPS module power

switches in what is known as a “Split Bypass” configuration. This is the

standard configuration for all models in the 7400 range.
In the “Split Bypass” configuration the static bypass line is switched by a
separate isolator to a dedicated ‘bypass’ power source which also feeds
the maintenance bypass line.
With the exception of the maintenance bypass isolator, all the isolators
shown must be closed during normal UPS operation.
Although it cannot be classified as a ‘power switch’, the reset switch may
be used as part of the UPS operating procedure. Fitted to the UPS Logic
Board, the reset switch is used by the operator to re-transfer the load to
the inverter following a detected overload or over temperature fault.

1.2.2 Bypass supplies

1.2.3 UPS Power Switch

Configuration

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Figure 1-1 . Series 7400 UPS isolator configuration

The battery is connected to the d.c. Busbar through a circuit breaker
fitted inside the battery cabinet or located adjacent to the batteries where
a battery cabinet is not used. This circuit breaker is closed manually, but
it contains an undervoltage release coil which enables it to be tripped
from the UPS control electronics following certain detected faults. It also
has a magnetic trip facility for overload protection.

In the case of the 80kVA and 120kVA UPS models, the batteries
associated with the UPS are generally housed in a purpose-built cabinet
located along-side the main UPS equipment.
It is possible to install batteries of various types and capacity in the
cabinet to obtain the required autonomy characteristics.
The battery cabinet can be purchased in one of the following forms:

1. Complete installation comprising the battery cabinet, batteries and

circuit breaker.

2. Battery cabinet and circuit breaker only  with no batteries.

3. Battery cabinet only  with no batteries or circuit breaker.

For the larger units and as an alternative to the battery cabinets, a
battery circuit breaker can be provided in a custom built box. This
Battery Circuit Breaker Box is designed to be wall or rack mounted and
is connected between the UPS and Battery.

Mains
Supply

RECTIFIER

STATIC
SWITCH

BATTERY

INVERTER

UPS
Output
Supply

Bypass
Supply

Battery
Circuit
Breaker

Input

Isolator

Output

Isolator

Bypass Isolator

Maintenanc

e

Bypass Isolator

1.2.4 Battery circuit breaker

1.2.5 Battery Cabinet

1.2.6 Battery circuit breaker

box

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200 kVA

120 kVA

300-400 kVA

80 kVA

I4 I3 I2 I1

I4 I1

I3

I2

I1 = Input Isolator
I2 = Static Bypass Isolator
I3 = Maintenance Bypass Isolator (with padlock)
I4 = Output Isolato r

I4 I3 I2 I1

I4 I3 I2 I1

Figure 1-1 . Power isolator identification

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1.3 One Plus One System

The one-plus-one system comprises two standard 7400 series UPS
modules which are modified to allow their outputs to be connected in
parallel. These can then be used in a "redundant" or "non-redundant"
configuration as explained below.

In a non-redundant module configuration, the system is sized such that
both UPS modules are required to feed the potential load, and if one of
the two modules develops a fault, or is for some reason shut down, the

other module automatically shuts down also.
Note: In such an event the load is transferred to an unprocessed bypass
supply -as described later.
In a redundant module configuration the system is sized such that the
potential load can be provided by just one of the two modules. Under
normal circumstances both modules are operational and share the load
current equally; but if one module develops a fault, or is shut down, the
second module is able to take over the full load demand and continue to
provide it with processed, backed-up power. The advantages of a
redundant system over a non-redundant system in terms of overall system
reliability are self evident.
Changing a one-plus-one system’s configuration between redundant and
non-redundant is quite straightforward, being carried out by
configuration links on the circuit board which governs the modules’
parallel control operation.

When two of the standard 7400 modules just described are connected

together to form a one-plus-one system, each module is fitted with an

additional circuit board which allows the two modules to communicate

with each other. Communication takes place via a single ribbon cable

connected between the modules as illustrated in figure 1-5.
The inter-module parallel control responsibilities are complex but can be
summarised as follows:

Synchronisation:

As the outputs from both UPS modules are connected together to provide
a single load supply, it is imperative that the inverters are fully
synchronised both in frequency and phase. This is achieved by digitally
locking the two inverter control oscillators. Similarly, as has already
been mentioned, it is necessary for the inverters to be synchronised to the
bypass supply to enable a "no-break" transfer to be achieved when the
static switch transfers the load to the bypass supply. The inverter control
oscillators are therefore not only locked together but are also made to
track the bypass frequency.

Current sharing:

The parallel control circuit compares the module’s output current with
that of its partner and is thereby able to effect current sharing between
the modules by making fine adjustments of an individual module’s
output voltage .

1.3.1 Redundant vs

Non-Redundant
configuration

1.3.2 One-Plus-One Parallel

Control

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Redundancy configuration:

A link in the parallel control logic determines whether the one-plus-one
system operates in a "redundant" or "non-redundant" configuration.
If a non-redundant mode is selected the two static switch sections are
effectively locked together in that both static switches are turned off or
on by a single control signal. Thus if one module develops a fault, when
running, its static switch control logic will transfer its output from the
inverter to the static bypass line and simultaneously send a signal to the
static switch control logic in the second module to do likewise.
This does not happen if the system is configured as a redundant system,
in which case the second module is allowed to continue supplying the
load from its inverter when the first module trips its inverter off line.

Reverse current:

A reverse current monitor circuit detects current flowing into, rather than
out of, the module’s output terminals. Such a condition can arise if a
module develops an internal power fault or if for some reason the two
modules become unbalanced, and is liable to further damage the module
and also degrade the load supply. If a reverse current is detected the
inverter on the affected module is immediately shut down and
(depending on the system redundancy configuration) the load is
transferred to the bypass supply "Non-Redundant system", or remains on
the good inverter "Redundant system".

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The illustration in figure 1-5 shows a dedicated battery installation for each

module; however, it is possible to fit an option kit which allows the two
modules in a one-plus-one system to share a common battery. Such an
installation is shown in figure 1-6 overleaf.
Note: the "Common battery" configuration is possible with 6 pulse
rectifiers only, not with 12 pulse rectifiers.

1+1 Parallel Control

Mains
Supply

Mains
Supply

RECTIFIER

STATIC

SWITCH

BATTERY

INVERTER

UPS
Output
Supply

1+1 Parallel Control

RECTIFIER

STATIC

SWITCH

BATTERY

INVERTER

Figure 1-1 . Parallel control in a one-plus-one system

1.3.3 Common battery

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The "Common Battery" option kit contains a DCCT (d.c. Current
Transformer) in series with the battery, which replaces the equivalent
DCCT’s inside the UPS’s (these are inhibited).
To ensure balance of the rectifiers output currents a link on the Parallel
control p.c.b. interconnects the control circuits of the two rectifiers.
The components used by the "Common Battery Option" are contained in
a separate cabinet known as the Common Battery Panel.

BATTERY

1+1 Parallel Control

RECTIFIER

INVERTER

STATIC

SWITCH

Control

Logic

Main
Supply

Main
Supply

UPS
Output
Supply

RECTIFIER INVERTER

STATIC

SWITCH

1+1 Parallel Control

Figure 1-1 . “Common battery” configuration

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Operator Control Panel Single Module and One plus One Systems

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1.4 Operator Control Panel

The operator control panel is divided into three functional areas; ‘mimic
indications’, ‘control switches’, and ‘LCD display panel’.

Six leds are mounted on a single line diagram to represent the various

UPS power paths. These leds, which
are annotated in figure 1-8, show the current UPS operational status and
should be interpreted as detailed below.

LS1 - Input supply OK / Rectifier operative:

This led illuminates when the
input isolator (I1) is closed, the
input supply is within 20% of
nominal voltage, and the
rectifier is operative.
LS2 - Battery volts OK: This
led illuminates when the
battery circuit breaker is closed
and the battery voltage is
within the UPS operating range
(320V - 490V nominal).
LS3 - bypass supply OK: This
led illuminates when the static
bypass supply is within ±10%
of its nominal voltage.

LS4 - Inverter output OK:

This led illuminates when the
inverter is operating and its output is within a preset (±10%) acceptable
voltage window.

LS5 - Load on bypass

This led illuminates when the output isolator is closed and the load is
connected to the bypass supply via the static switch.
LS6 - Load on inverter:
This led illuminates when the output isolator is closed and the load is
connected to the inverter via the static switch.

Figure 1-1 . Operator control panel

1.4.1 Mimic indications

LS3

LS5

LS1 LS2 LS4 LS6

Figure 1-1 . Mimic panel

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Seven tactile switches are located on the Operator Panel, together with
an emergency stop pushbutton which is fitted with a safety cover to
prevent inadvertent operation.

Switch S1 (Vo) - Output volts:

When this switch is pressed, the lower line of the LCD Display shows
the output line-to-line voltages on all three phases.

Switch S2 (Fo) - Output frequency:

When this switch is pressed, the lower line of the LCD Display shows
the output frequency.

Switch S3 (Io) - Output current:

When this switch is pressed, the lower line of the LCD Display shows
the output line ( and neutral) currents.

Switch S4 (B) - Battery:

When this switch is pressed, the lower line of the LCD Display shows
the battery voltage, current and % charge or autonomy time remaining in
minutes. Note that a discharging current is symbolised by a preceding
minus [] sign.

Switch S5 - ((.)) - Alarm reset:

Pressing this switch cancels the audible alarm. The alarm led and
messages will remain active if a detected fault condition is still present.

Switch S6 - Inverter OFF:

Pressing this switch turns OFF the inverter and causes the load to be
transferred to the static bypass supply.

Switch S7 - Inverter ON:

Pressing this switch activates the inverter and causes the load to be
transferred to the inverter side of the static switch after the inverter
voltage has had time to stabilise.

Switch S8 - Emergency stop:

When the emergency stop switch is pressed it disables the static switch
block entirely (so removing load power). It also disables the rectifier and
inverter, and trips the battery circuit breaker. Under normal
circumstances it does not remove UPS input power since this is applied
through a manually contro lled isol ator ; however , if the U PS inp ut supp ly
is connected via a circuit breaker having an electrical trip facility the
emergency stop signal can be used to drive the external circuit breaker’s
trip circuit.
There are two leds contained within the switch panel area:

LS7 - Alarm:

This led accompanies the audible alarm warning when any alarm
condition is initiated. The audible warning can be cancelled by the reset
switch (S5) but LS7 will only extinguish after the alarmed condition has
reverted to normal.

1.4.2 Control switches

S1

S2 S3 S4 LS7 S5 S6 S7 LS8

S8

Figure 1-1 . Control panel switches

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LS8 - Inverter status:

This green led situated near the inverter ON switch illuminates when the
inverter is selected ON.

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An LCD display, capable of
showing two rows of 40
characters, is used to indicate
the UPS operating
parameters, warnings and
alarms.
A DIP switch fitted to the
display microprocessor board
enables the disp layed language
to be easily selected to English,
French, Italian, Spanish or
German.
The lower row of characters
are used to display metered
parameters; which include
output (or bypass) voltage,
frequency, or current together
with battery current, voltage
and % charge or time
remaining on battery.
Warning and alarm messages
are displayed on the upper row
of characters. The ALAR M led
and audible warning
accompany all alarm messages
but are not activated by
warning messages. In all cases,
the message automatically
resets when the alarmed (or
warning) condition reverts to
normal.

When two (or more) alarm or
warning conditions are active
simultaneously, the
appropriate messages are
displayed in a cyclic fashion,
with each message appearing on the display for approximately 10 seconds.

Battery condition display

You can display the relative condition/state of the battery as a % of the
nominal capacity with the input a.c. power supply present by pressing
switch 4 (‘B’) . The time remaining on battery is automatically displayed
in minutes during a input ac power supply failure.
On first installation or on the installation of a new battery the nominal
capacity of the battery must be entered into the system software (see
chapter 3).

1.4.3 LCD Display

*** ALARM ***

*** ALARM ***

*** ALARM ***

*** ALARM ***

*** ALARM ***

*** ALARM ***

*** ALARM ***

*** ALARM ***

EMERGENCY STOP

INVERTER OFF OR FAILED

OVER TEMPERATURE

OVERLOAD

BA TT ER Y C B OPE N

OUTPUT CB OPEN

INPUT CB OPEN

RECTIFIER OFF OR FAILED

** WARNING *

** WARNING *

** WARNING *

** WARNING *

** WARNING *

UPS ON MAINTENANCE
BYPASS

INVERTER UNSYNCHRONIZED

BA TTERY ON LOAD

MAINS FAILURE

LOAD ON BYPASS

Fig

ure 1-1 .Display messages

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2. Chapter 2 - Operating Instructions

2.1 Introduction

The UPS can be considered to be in one of three operating conditions:

• Shutdown - All power isolators and circuit breakers open - no

load power.

• On Maintenance Bypass - UPS shut down but the load connected

to the unprotected mains via the Maintenance Bypass Supply line.

• Normal operation - All relevant power isolators and circuit

breakers closed, the load is powered by the UPS.
This chapter contains detailed instructions to enable you to switch
between these three conditions.

Note 1: All the user controls and indicators mentioned in these
procedures are identified in chapter 1 (figures 1-3, 1-4, 1-7, 1-8 and 1-9).
Note 2: The audible alarm may annunciate at various points in these
procedures. It can be cancelled at any time by pressing the `Alarm Reset'
pushbutton.
Note 3: The 7400 series UPS incorporates an optional automatic boost
charge facility which can be used in systems containing non-sealed lead­acid batteries. If this type of battery is used in your installation you may
notice that the battery charger voltage will be greater than its normal
value when the mains supply returns from a prolonged outage. The
revised voltage will be 460V d.c. for a 380V a.c. system, 475V d.c. for a
400V a.c. system and 490V d.c. for a 415V a.c system. This is the
normal response of the boost charge facility: the charger voltage should
return to normal after a few hours.

2.2

One plus One

Starting and stopping the one-plus-one system is the same as a single
module, however the modules' response depends on whether it is
configured as a Redundant or Non-Redundant system. The operating
procedures are the same irrespective of the selected redundancy mode; in
simple terms you start (stop) one module and then repeat the operation
on the second module.

The difference in the system response concerns the point at which the
load is transferred between the bypass and uninterruptible (i.e. inverter)
supplies and is summarised below:

Starting:

When starting a redundant module system the load is transferred from

the bypass to the inverter of the first module as soon as the first module

is started and i ts inverter is brought o n line. When t he second mod ule is

started its static bypass line is totally inhibited due to the first module

being on line, and the second module will not be connected to the load

until its inverter is operational and fully synchronised with the first

module.

Stopping:

2.1.1 General notes

2.2.1 Redundant module

system

When the first module is stopped its static bypass is inhibited because the
load will be fully maintained by the inverter of the second module.

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When shutting down the second module, the static bypass lines of both
modules will be turned on as soon as its inverter is stopped. That is, both
modules will provide load power through their paralleled bypass lines.

Starting:

In a Non-Redundant module system both modules must be running
before the load is transferred to their paralleled inverters. Therefore,
when the first module is started, the load will remain connected to its
static bypass line while waiting for the second module to synchronise.

Stopping:

The load will be transferred to the static bypass lines in both modules
simultaneously as soon as the inverter stops in the first module to be shut
down.

How to turn on the system from a shutdown condition

This procedure should be followed when turning on the UPS from a fully powered down condition - i.e. where the load is not
being initially supplied through the internal Maintenance Bypass supply.
Note: For a one plus one system, complete these actions on one module at a time.

Step Action Response

1. Close the module's Output Isolator and check that the UPS
input mains supply (and bypass supply if separate) is
turned on externally.

2. Close the Input Isolator and Static Bypass Isolator .

Mimic panel leds

LS1 LS3 and LS5 should illuminate immediately, to
indicate that the load is being supplied through the static
bypass line. (NB: In a one plus one Redundant Module

system LS5 will not illuminate on the second module to
be started as its static bypass line is inhibited).

The inverter should start automatically once the d.c.
Busbar reaches its working voltage (after about 30
seconds), and when this occurs LS4 (inverter OK) will
illuminate followed by LS6 (load on inverter). (NB: In a

one plus one Non-Redundant module system LS6 will not
illuminate on the first module to be started until you
reach this point in starting the second module.)

Note that LS5 will extinguish when LS6 illuminates.

3. Wait 20 seconds then close the battery circuit breaker: This
is located inside the battery cabinet (if used) or is
otherwise located adjacent t o the battery racks

Mimic panel leds

LS2 should illuminate on the mimic panel and LS7
(alarm) should extinguish.

4. Press the battery metering selector switch [B]: The display should indicate a positive (+) battery

charging current.

2.2.2 Non-Redundant

module system

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How to turn on the system from a maintenance power-down condition

This procedure should be followed to start the UPS from a MAINTENANCE power-down condition - i.e. where the load is
being initially powered through the internal maintenance bypass supply.

Note: For a one plus one system, complete these actions on one module at a time.

Step Action Response

1. Check that the UPS input mains supply (and bypass supply
if separate) is turned on externally.

2. Close the Input Isolator and Static Bypass Isolator.

Mimic panel leds

LS1 and LS3 should illuminate immediately, to indicate
that the input and bypass supplies are healthy.

The inverter should start automatically once the d.c.
Busbar reaches its working voltage (after about 30
seconds), and when this occurs LS4 (inverter OK) will
illuminate

3. Wait 20 seconds then close the battery circuit breaker: This
is located inside the battery cabinet (if used) or otherwise
adjacent to the batt ery racks.

Mimic panel leds

LS2 should illuminate.

4. Press the battery metering selector switch [B]: The display should indicate a positive (+) battery

charging current.

5. Press the Inverter OFF pushbutton (S6).
( On both modules for a 1 + 1 system ).

Mimic panel leds

LS4 should extinguish.

6. Close the Output Isolator.
( On both modules for a 1 + 1 system ).

Mimic panel leds

LS5 should illuminate to indicate that the load is
connected to the st atic bypass lin e. (On both modules for
a 1 + 1 system).

7.

Open the Maintenance Bypass Isol at or (on both modules
in a one plus one system) then Press the Inverter ON
switch (S7) (on both modules in the one plus one system).
(NB: The inverters of both modules are inhibited if either
modules' Maintenance Bypass Isolator is closed.)

Mimic panel leds

LS4 (Inverter OK) and LS6 (Load on inverter) should
illuminate after approximately 30 seconds. (NB: In a one

plus one Non-Redundant module system LS6 will not
illuminate on the first module to be started until you
reach this point in starting the second module.).

LS5 should extinguish at the same time as LS6
illuminates.
LS7 (alarm) should extinguish.

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How to turn off the system but continue to provide load power through the

maintenance bypass

This procedure should be followed if the UPS is to be powered-down while continuing to supply the load through the
maintenance bypass line. Note that during this procedure the load will be unprotected against mains supply disturbances once
the inverter(s) has been switched off.

Step Action Response

1. Ensure that LS3 is illuminated on the mimic panels
(indicating that the static bypass supply is healthy).

2.

Press the Inverter OFF switch (S6) (on both modules

in the one plus one system)

Mimic panel leds
LS4 and LS6 should e xtingui sh ( o n bo th mod ules i n
the one plus one system) and LS5 should illuminate
to show that the load has been transferred to the
static bypass line.

Note: On a one plus one redundant system both
Inverter OFF switches (S6) must be operated before
LS5 illuminates but in a non-redundant system the
Inverter OFF switch must be pressed on one
module only before LS5 illuminates. However, as
the load is transferred to the static bypass, the
second module should be turned OFF also.

3.

Close the Maintenance Bypass Isolator (on both

modules in the one plus one system).

Mimic panel leds
No change.

4.

Open the Output Isolator (on both modules in the

one plus one system).

Mimic panel leds
LS5 should extinguish (o n both modules in the one
plus one system).

5.

(On each module in the one plus one system) 
Open the battery circuit breaker followed by the
Input Isolator and Static Bypass Isolator.
On 80 - 120 - 200 kVA: open auxiliary fuses F1... F6
WAIT AT LEAST 5 MINUT ES

All the operator panel led indications and messages
should extinguish as the mains driven internal
power supplies decay. .

WARNING

Wait at least 2 minutes for the d.c. capacitors to discharge.

The following points will be live within the UPS:

- Bypass supply input terminals -

- Maintenance Bypass Isolator switch -

- Static Bypass Isolator Switch (if fitted) -

- UPS output terminals -

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How to totally power-down the system

This procedure should be followed only if the UPS AND LOAD are to be completely powered down.

Step Action Response

1.

Press the Inverte r OFF switch (S6) (on both modules
in the one plus one system):

Mimic panel leds

LS4 and LS6 should extinguish, and LS5 should
illuminate to show that the load has been transferred
to the static bypass line. (NB: in a Non-Redundant

Module system LS5 and LS6 will also change-over
on the second module).

2.

Open the battery circuit breaker:

Mimic panel leds

LS2 should extinguish.

3.

Open the Input Isolator and Static Bypass Isolator.
On 80 - 120 - 200 kVA open auxiliary fuses F1 ... F6

All the operator panel led indications and messages
should extinguish as the mains driven internal
power supplies decay.

IMPORTANT

The Maintenance Bypass Isolator may be operated at any time
when the UPS is powered down to connect/disconnect the load

to the raw maintenance bypass supply if required.

Emergency stop

The emergency stop pushbutton is located behind a hinged safety shield to prevent

inadvertent operation. When this switch is pressed modules are electronically shut down and

battery circuit breakers are tripped. Power is removed from the critical load,

but pressing the emergency stop pushbutton will not remove the modules' input mains

supply unless an external contactor, controlled via the emergency stop pushbutton auxiliaries,

is fitted in the mains supply line..

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3. Chapter 3 - Installation Pr ocedure

3.1 Introduction

WARNING

Do not apply electrical power to the UPS equipment before the arrival of the

commissioning engineer.

WARNING

The UPS equipment should be installed by a qualified engineer in accordance with the

information contained in this chapter and the drawing package shipped inside the

UPS cabinet.

WARNING

Battery hazards

Special care should be taken when working with the batteries associated with this

equipment. When connected together, the battery terminal voltage will exceed 400

Vd.c. and is potentially lethal.

Eye protection should be worn to prevent injury from acci dental electrical a rcs.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 should be placed in a container resistant to sulphuric acid and

disposed of in accordance with local regulations.

If electrolyte comes into contact with the skin the affected area

should be washed immediately.

This chapter contains information regarding the positioning and cabling
of the UPS equipment and batteries.
Because every site has its peculiarities, it is not the aim of this chapter to
provide step-by-step installation instructions, but to act as a guide as to
the general procedures and practices that should be observed by the
installing engineer.

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The UPS cabinets can be moved by fork lift or crane. Fork lift apertures
are provided in the sides of the base plate and are accessible after
removing blanking covers fitted to the side panel ventilation grills. Roof­mounted eye-bolts are fitted to enable the cabinet to be crane-handled.
These can be removed once the equipment has been finally positioned.
Note: In a 1 + 1 system the models should be positioned adjacent to each

other.

WARNING

Ensure that the UPS weight is within the designated S.W.L. of any handling equipment.

See the UPS specification for weight details.

Do not move the battery cabinet with the batteries fitted..

The 300kVA and 400 kVA UPS modules are split into two cabinets, a
Main Inverter cabinet and a Rectifier/Static Bypass cabinet, to allow
easier transportation and positioning. Once finally positioned, the two
cabinets have to be bolted together and the interlinking power and
control cable connections made. It is therefore necessary to observe
cabinet A & B positioning (see figures 3-5 and 3-6 ).
The UPS module should be located in a cool, dry, clean-air environment
with adequate ventilation to keep the ambient temperature within the
specified operating range. If necessary, a system of extractor fans should
be installed to aid cooling-air flow, and a suitable air filtration system
used where the UPS is to operate in a dirty environment.

Cables

All control cables whether screened or not, should be run, separate from
the power cables, in metal conduits or metal ducts which are electrically
bonded to the metalwork of the cabinets to which they are connected.

Cooling air flow

All the models in the 7400 range are force-cooled with the aid of internal
fans. Cooling air enters the module through ventilatio n grills located at
various parts of the cabinet a nd exhausted through grills located in the
equipment roof. When the equipment is located on a raised floor, and
bottom cable entry is used, additional cooling air also enters the UPS via
the floor void.

Clearances

To allow adequate cooling air flow, you should position the equipment
with the following space around the back and sides.

80kVA-120 kVA Models  100mm minimum required in all cases.
200/300/400 kVA Models  300mm minimum required in all c ases.

The UPS modules do not require back-access for maintenance servicing;
but, where space permits, a clearance of approximately 4 feet (1.2
metres) will ease access to some component parts. Clearance around the
front of the equipment should be sufficient to enable free passage of
personnel with the doors fully opened.

3.1.1 Equipment positioning

and environmental
considerations

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If the equipment is to be located on a raised floor it should be mounted
on a pedestal suitably designed to accept the equipment point loading.
The installation diagrams in the back of this manual identify the location
of the holes in the ba se pl ate thr ough which the equi pment c an b e b olt ed

to the floor.

Note: Temperature is a major factor in determining the battery life and
capacity. Battery manufacturers quote figures for an operating
temperature of 20°C. Operating above this temperature will reduce the
battery life, operation below this temperature will reduce the battery
capacity. On a normal installation the battery temperature is maintained
between 15°C and 25°C.
In 80kVA and 120 kVA module installations the batteries associated
with the UPS equipment are usually contained in a purpose-built battery
cabinet which sits alongside the main UPS equipment. Sealed,
maintenance-free batteries are normally used in this type of installation.
Due to their increased capacity, the batteries associated with larger UPS
installations are usually too big to be mounted in a single cabinet and are
either rack mounted or fitted in multiple, or bespoke, battery cabinets.
Such installations may utilise non-sealed lead acid cells, requiring
regular attention and impose their own environmental requirements.
Pedestals are required for the battery cabinets when they are located on
raised floors, in the same way as for the UPS cabinets.
The batter i es are connecte d to the UPS t hrough a circuit breaker which is
manually closed and electronically tripped via the UPS control circuitry.
If the batteries are cabinet-mounted this circuit breaker is fitted within
the cabinet; however, if the batteries are rack-mounted or otherwise
located remote to the main UPS cabinet then the battery circuit breaker
must be mounted as near as possible to the batteries themselves, and the
power and control cables connected to the UPS using the most direct
route possible. Liebert offer a purpose-designed remote battery circuit
breaker box, containing the circuit breaker and its necessary control
board, as a standard option kit.

3.1.2 Raised floor

installation

3.1.3 Battery Location

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Figure 3-1 . Installation Diagram for 80 kVA Module

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Figure 3-2 . Installation Diagram for 120 kVA Module

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Figure 3-3 . Installation Diagram for 200 kVA Module

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Figure 3-4 . Installation Diagram for 300/400 kVA Module 6 & 12

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Figure 3-5 . Inst. Diagram for 80 kVA Modules 12 Pulse

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Figure 3-6 . Installation Diagram for 120 kVA Module 12 Pulse

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Figure 3-7 . Installation Diagram for 200 kVA Module 12 Pulse

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3.2 Preliminary Checks

Before you install the UPS hardware you should carry out the following
preliminary checks:

1. Verify that the UPS room satisfies the environmental conditions

stipulated in the equipment specification, paying particular attention
to the ambient temperature and air exchange system.

2. Remove any packaging debris then visually examine the UPS and

battery equipment for transit damage, both internally and externally.
Report any such damage to the shipper immediately.

3. Verify that the shipment is complete  e.g. that the battery contains

the correct number of cells etc. Report any discrepancy immediately.

4. When you are satisfied that the equipment is complete and in good

condition move it to its proposed final position.

Note: If ‘side’ cable entry is to be used (see below) ensure that the

blanking plates are removed before finally fixing the cabinets in
position.

5. All models have a stabilising bar fitted to the output transformer T1

during shipment, this should be removed when the UPS has been
placed in its final position.

Caution

Ensure the stabilising bar fitted to the output transformer T1 is removed before

proceeding with the installation.

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3.3 Reassembling the 300 kVA and 400 kVA cabinets

Place the cabinets in their final position as shown in figure 3-6 ensuring
any protective packaging is removed (Inverter Cabinet on the right and
Rectifier/Static Switch Cabinet on the left), and connect them together
following the procedure below:

Caution

Ensure loose cables are not trapped between the two cabinet frames.

1. Align the Rectifier/Static switch and Inverter Cabinets and bolt them

together through the holes provided.

2. Open the doors to the Inverter cabinet and remove the lower

protective cover to gain access to the a.c. busbars R, S, T & N from
the output transformer T1.

3. Locate the four a.c. busbars from the Output Isolator numbered 7(R),

8(S), 9(T) and 10(N) in the Rectifier/Static Switch cabinet and the
linking straps connected to them. Take the free end of the linking
straps and connect them to the Inverter cabinet a.c. busbars ensuring
correct phase connection as illustrated in figure 3-6.

4. Ensure the transformer transportation stabilising bar is removed.

Refit the lower protective cover to the Inverter cabinet.

5. Open the upper inner left hand protective door of the inverter cabinet

to gain access to the d.c. busbars.

6. Open the doors to the Rectifier/Static Switch cabinet and open the

inner upper right hand door to gain access to the d.c. busbars.

7. Using the two angled copper busbar links provided, connect the

Rectifier/Static Switch cabinet d.c. busbar to the Inverter Cabinet d.c.
busbar as illustrated in figure 3-6.

8. Locate the flat cable assembly FC17 from CN8 on the Inverter Logic

board in the Inverter cabinet and secure to the end panel, in the
position illustrated in figure 3-6.

9. Locate the flat cable assembly FC17 from CN2 on the UPS Logic

board in the Rectifier/Static Switch cabinet and connect to cable
assembly FC17 secured above.

10. Locate wires 27, 28, 29, 30, 31, 32, 33, 98 & 99 terminated in

connector CN4 and wires 7, 8, 9 & 10 terminated in connector CN5
in the Inverter cabinet and secure the connectors into cabinet end
panel in the positions illustrated in figure 3-6.

11. Locate the Rectifier/Static Switch cabinet cable assemblies from the

Interface board which terminate in connectors CN4 and CN5 and
connect to CN4 and CN5 secured above.

12. Close the inner protective doors and outer doors to both cabinets.

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Figure 3-1 . 300/400 kVA model inter-connection cables

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3.4 Connecting the UPS power cables

WARNING

Before cabling-up the UPS, ensure that you are aware of the location and operation of

the external isolators that connect the UPS input/bypass supply to the mains

distribution panel.

Check that these supplies are electrically isolated, and post any necessary warning signs

to prevent their inadvertent operation.

Cables can enter the smaller UPS modules and battery cabinet either
from below or through either side. Side entry is made possible by
removing blanking pieces fitted in the side ventilation grills to reveal the
cable entry holes. This cable entry method allows the equipment to be
positioned on a solid floor without the need for cable trenching and also
allows cables to pass from one module to the other when positioned side-

by-side.

On units up to 200kVA normal cable entry is from the bottom, however,
if top entry is necessary, the optional top entry kit Pt.No. 2174011 Vfor
80 and 120kVA or Pt. No. 2174033 R for 200kVA is required. On the
300/400kVA unit cable entry is from the bottom or top of the unit.

The maximum current ratings for the power cables are given in table 3-1.
The neutral cable (bypass and output) should be sized at up to 1.5 times
the phase current to take into account the possible presence of 3rd
armonic currents due to single phase "computer loads".

In a one-plus-one Non-Redund ant system, the lenght o f the ca ble s on the
Bypass line of the two UPS’s should be equal (+/- 20%) to ensure the
balance of the currents, when the load is supplied by the mains.

UPS

RATING

NOMINAL CURRENT (Amps) CABLE CONNECTION

MAXIMUM SIZE

(kVA)

Input Mains

(with full battery recharge)

380V

Bypass/output

380V

Battery

(at low battery

disconnect)

Input/output

Cable

Terminations

Battery

Termin-

ations

6 Pulse 12 Pulse U - V - W - N +ve & -ve

80 167 158 121 216 Secure with M8 Bolt M8 Bolt
120 251 237 182 322 Secure with M10 Bolt M10 Bolt
200 412 390 304 534 Secure with M10 Bolt M10 Bolt
300 609 579 442 791 Secure with M12 Bolt M12 Bolt
400 808 769 608 1053 Secure with M12 Bolt M12 Bolt

Table 3-1 - Nominal current for power cables

When sizing battery cables, a maximum volt drop of 3V d.c. is
permissible at the urrent ratings given in t able 3-1.

3.4.1 Cable entry

3.4.2 Cable rating

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Power cables are connected either directly to their respective circuit

breakers, or to busbars which are themselves connected to the circuit
breakers  see figures 3-8 to 3-12.
Note: If the installation includes the use of optional Input Filter Cabinets
refer immediately to the Options Chapter, Where these cabinets are fully
described. The inclusion of these cabinets in the system affects the
method of connecting the UPS power cables given below.

The safety earth busbars are located near the input and output power

supply connections as shown in the
following diagrams. The safety cable must be connected to the earth
busbar bonded to each module cabinet.
All cabinets and cable trunking should be earthed in accordance with
local regulations.

WARNING

FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES CAN RESULT IN
ELECTRIC SHOCK HAZARD TO PERSONNEL, OR THE RISK OF FIRE, SHOULD

AN EARTH FAULT OCCUR.

3.4.3 Cable connections

3.4.4 Safety earth

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Power Cables

Once the equipment has been finally positioned and secured, connect the
power cables as described in the following procedure.
Study the connection diagrams in figures 3-8 to 3-11 and positively
identify the diagram relevant to your equipment before commencing
cabling.

1. Verify that the UPS equipment is totally isolated from its external

power source and all the UPS isolators are open.

2. On each module, connect the input supply cables between the mains

distribution panel and the UPS input mains terminals. Check that
links are fitted between input mains bus bars and bypass supply bus
bars (U1 - U3; V1 - V3; W1 - W3).

 ENSURE CORRECT PHASE ROT ATION.

3. If a "split-bypass" configuration is used, connect the UPS bypass

supply cables between the bypass distribution panel and the UPS
bypass supply terminals on each module. Ensure any links fitted
between input and bypass bus bars are removed.

 ENSURE CORRECT PHASE ROT ATION.

4. On a Single module connect the UPS output cables between the UPS

and the load distribution panel.

5. On modules in a one plus one system connect the output terminals of

both modules together (in parallel).

 ENSURE CORRECT PHASE-PHASE CONNECTION (U2-U2, V2-

V2, W2-W2, N2-N2).

Then connect the UPS output cables between the paralleled UPS output

terminals and load distribution panel.

Note: If the UPS is to be commissioned before the load equipment is

ready to receive power then SAFELY isolate the load cables.

6. On each module, connect the battery cables between the UPS battery

terminals and its associated battery circuit breaker  see figures 3-13
to 3-17. As a safety precaution remove the battery fuse in the module
until the arrival of the commissioning engineer.
 OBSERVE THE BATTERY CABLE POLARITY.

WARNING

Do not close the battery circuit breaker before the equipment has been commissioned

7. Connect the safety earth and any necessary bonding earth cables to

the copper earth busbar located on the floor of the equipment below
the power connections.
Note:- The earthing and neutral bonding arrangement must be in
accordance with local and national codes of practice.

Control Cables

8. Connect the battery circuit breaker control cables between the UPS

auxiliary terminal block and battery circuit breaker controller board
as shown in figures 3-13 to 3-17.

3.4.5 Cabling procedure

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9. If an external emergency stop facility is to be used then remove the

link between terminals 4 and 5 of the auxiliary terminal block and
connect the ‘normally closed’ remote stop circuit between these two
terminals.
Note: Terminals 8 and 9 on the auxiliary terminal block are
connected to a pair of ‘normally closed’ contacts on the UPS
emergency stop button and will go open circuit when the emergency
stop push-button is pressed. These terminals can be used to control
an external circuit breaker connected in the UPS input mains supply
line to isolate the UPS input power when the emergency stop button
is pressed.

One plus one only

10. On the one-plus-one system only connect the parallel control ribbon

cables between the Parallel Interface Boards (Part no. 4590049 J) of

both modules. Connect one ribbon cable between sockets CN1 on
one board and CN2 on the other, and connect the second ribbon cable
between the remaining CN1 and CN2 sockets.

Caution

To maintain EMC compliance all external control and communications cables must be

screened.

CN3

CN2

CN1

CN3

CN2

CN1

CN3

CN2

CN1

CN3 CN3

CN2

CN2

CN1

CN1

Module 1 Module 2

Module 1 Module 2

Common Battery
Pa n e l

Figure 3-1 . Connecting the parallel interface cables

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Figure 3-2 . Cable connections for standard 80kVA

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Figure 3-3 . Cable connections for standard 120kVA

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Figure 3-4 . Cable connections for standard 200kVA

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Figure 3-5 . Cable connections for 6 & 12 Pulse 300/400 kVA modules

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3.5 Battery Installation

WARNING

Only qualified personnel should install or service batteries.

A battery can present a risk of electric shock or burn from high short circuit currents.

Eye protection should be worn to prevent injury from acci dental electrical a rcs.

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 should be placed in a

container resistant to sulphuric acid and disposed of in accordance with local regulations.

If electrolyte comes into contact with the skin the affected area should be washed

immediately.

Batteries must be disposed of according to local environmental laws.

Due to the inverter design the d.c. bus bar voltage level is dependent on the
system output a.c. voltage. Therefore, the number of battery blocks required
will differ according to the system requirements, as shown below:

380V a.c. system requires 432V d.c. bus bar = 32 battery blocks / 12 V (192
cells).
400V a.c. system requires 446V d.c. bus bar = 33 battery blocks / 12 V (198
cells).
415V a.c. system requires 459V d.c. bus bar = 34 battery blocks / 12 V (204
cells).

The batteries associated with the 80 kVA and 120 kVA UPS can be
contained in a purpose-built battery cabinet ( part number 5320024I
{860mm wide, 250 A circuit breaker}) which sits along side the main UPS
equipment. Sealed, maintenance-free batteries are normally used in this type
of installation.
Where battery racks are used, they should be sited and assembled in
accordance with the battery manufacturer’s recommendations. In general,
batteries require a well ventilated, clean and dry environment at reasonable
temperatures to obtain efficient battery operation.
Battery manufacturers’ literature provides detailed safety measures to be
observed when employing large battery banks and these should be studied
and the proposed battery installation checked to verify compliance with the
appropriate recommendations.
In general a minimum space of 10 mm must be left on all vertical sides of
the battery block. A minimum clearance of 20 mm should be allowed
between the cell surface and any walls. A clearance of 150 mm should be
allowed between the top of the cells and the underside of the shelf above
(this is necessary to for monitoring and servicing the cells). All metal racks
and cabinets must be earthed. All live cell connections must be shrouded.
The batter ies are connected to the U PS through a circuit b reaker which is
manually closed and electronically tripped via the UPS control circuitry. If
the batteries are cabinet-mounted this circuit breaker is fitted within the
cabinet; however, if the batteries are rack-mounted or otherwise located
remote to the main UPS cabinet then the battery circuit breaker must be
mounted as near as possible to the batteries themselves, and the power and
control cables connected to the UPS using the most direct route possible.
Liebert offer a purpose designed remote battery circuit breaker box,
containing the circuit breaker and its necessary control board, as a standard
option kit. The battery cabinet or circuit breaker box must be bonded to the
UPS cabinet.

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The 860 mm cabinet with a 250 Amp circuit breaker and extension

cabinets are designed for use with the Series 7400 80-120 kVA UPS.

The 860mm battery battery cabinet autonomy time can be extended by
attaching a 320mm wide extension cabinet part N°5320025J to the main
cabinet.
All cabinets are secured and bonded together using the bolts supplied
and the holes proved in the cabinet side struts.
A typical battery layout for a single cabinet is shown in figure 3-13, this
can be extended by using extension cabinets attached to the basic unit.
Each extension cabinet is supplied without side covers, as the covers
from the basic unit are then used. This side access allows batteries to be
positioned from either the front or side.
As many different battery combinations can be used only the connections
for the basic unit have been shown in figure 3-13, additional battery
strings can be added and would be connected in parallel.
The battery cabinets are designed to hold between 32 and 34 batteries on
4 levels, free standing on adjustable rails. Nine batteries can be fitted to
the 3 upper levels with up to seven batteries on the lower level. The rails
are adjustable giving a maximum battery width of 176mm and a
maximum depth of 270mm, this allows batteries to be positioned as
shown or turned through 90°. The rails can also be removed or re­positioned to accommodate batteries of different sizes.
Figure 3-14 shows an alternative arrangement to that above. In this
example larger capacity batteries are used. As can be seen, the rails have
been adjusted and removed to accommodate the larger battery of which
only sixteen can be fitted within the cabinet. The other sixteen batteries
(needed to maintain a 432 V d.c. bus bar) are arranged within an
extended battery cabinet and connected in series to the main cabinet
batteries. Further pairs of extended battery cabinets can be added in
parallel.
The basic cabinet is supplied with the battery circuit breaker and
interface board. Connection to the UPS is shown in figure 3-13.
Due to the flexibility of the type and size of cells that can be used in this
installation it would be impracticable to provide specific installation
instructions. Ho wever as a general guide:-

Always install the batteries starting from the bottom and work
upwards.
Leave the end links marked (B) see figure 3-13 until the last
connection on each level.
After each connection is made fit the insulation shroud for that
terminal into position.
As an added safety precaution we suggest that link (A) see figure 3­13 is left disconnected until all batteries are fitted. Once all the

batteries are fitted connect link (A).
Please refer to the battery manufacturers instructions and the drawings
supplied with the module for safety and specific installation instructions.

3.5.1 860 mm cabinet

(250 Amp circuit
breaker)

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Figure 3-1 . 860mm Battery cabinet Typical battery layout and connection delail

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Figure 3-2 . Typical example of battery cabinet with extension cabinet

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A battery circuit breaker box houses the battery circuit breaker and its controller
board and is used to connect the battery to the UPS in installations where the
batteries are not contained in the standard battery cabinet.
Several ‘boxes’, of various current ratings, are available and are similar in their
design and content. These are listed below:

• 250 Amp C/B Part No4641007H for use with 80 kVA models.

• 400 Amp C/B Part No4641008I for use with 120 kVA model.

• 630 Amp C/B Part No4641009D for use with 200 kVA model.

• 800 Amp C/B Part No4641011L for use with 300 kVA model.

• 1000 Amp C/B Part No4641012M for use with 400 kVA model.

3.5.2 Battery circuit breaker

boxes

Figure 3-1 . Battery C/B box connections 80-120 kVA UPS

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Usually the ‘box’ is fitted as close as possible to the batteries.
Figures 3-15 to 3-17 show details of the power and control cable connections
between the circuit breaker box and the UPS itself. These are similar to the
connections made to the battery cabinet previously described.

As a safety precaution, remove the battery fuse in the UPS before making the
battery circuit breaker power connections.

-ve

-ve

+ve

+ve

-

-

+

+

ToBarrery

BATTERY

CIRCUIT

BREAKER BOX

Battery C.B

Controller Bd

(4520063 P)

Figure 3-2 . Battery C/B box connections200 kVA UPS

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-ve

-ve

+ve

+ve

-

-

+

+

-ve

+ve

To Battery

BATTERY CIRCUIT BREAKER

Battery C.B

Controller

Bd (4520063P)

Figure 3-3 . Battery C/B box connections for 300kVA and 400 kVA Modules

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On initial installation or on change of the battery, it is necessary to enter the battery
nominal capacity data into the system. This allows the front panel to display the
battery state either as a percentage of charge with the input a.c. power supply present
or as the time remaining on battery with the a.c. power supply absent. The battery
circuit breaker must be closed during this procedure.

To initialise the system and insert the nominal battery capacity, press push buttom
‘B’ then carry out the following procedure:

1. On the PCB 4550001 B move the link on SH7 to position on pins 2-3.

2. On the display pa nel press push butt ons ‘f’, ‘B’ and ((*)).

3. Check the display reads:

‘PHASE CALIBRATION’ FREQUENCY: XX,X

4. Press the ((*)) push-button twice and the display will show:-

BATTERY (AH) = NEW VALUE

5. Using the keys: Vo(forward 1), I (forward 10), f (back 1) and B (back 10),

insert the nominal value for the capacity of the installed battery, when
completed press the ((*)) key again.

6. Repeat step 3 and check that the new value for the battery capacity is displayed.

BATTERY (AH) = (new inserted value)

7. On conclusion of the above procedure reposition the link on SH7 to pins 1-2.

8. On the display panel press the keys ‘f’, ‘B’ and ((*)).

9. The display should revert to the default screen

UPS BIOS VERSION 2.1 1-7-1995

The unit has now been restored to normal.

Note: It is necessary to ensure that the reading on the display panel shows B =
100% both on initial installation and on change of battery. This is to ensure that the
measurement reading and subsequent readings are correct.

3.5.3 Battery Display

Initialisation

13

13

13

13

LED 1

SH7

SH1

SH4

SH9

I1

TM1

TM2

CN3

CN4

CN2

Figure 3-1 . SH7 location on Microprocessor PCB

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4. Chapter 4 - Optional equipment

Several items of optional equipment are available for fitting to the 7400
series UPS for use by the customer as required.
These options are:

• IBM AS400 Interface (part no. 4590041 B).

• IBM AS400 Interface with 4-way output (part no. 4590045F).

• External Interface Board (part no. 4590044E).

• Remote Alarms Monitor (part no. 4305001Z).

• Remote alarms and control panel (part no. 4305002A).

• RS232 communications interface (SGC) (part no. 4550002C).

• 5th Harmonic Input filter Option.

• Cable top entry kit for 80 and 120 kVA (part no. 2174011V).

• Cable top entry kit for 200 kVA (part no. 2174033 R).

• 12 Pulse system option (80,120 and 200 kVA).

• Option Kit (includes Batt. Temp. compensation; Input current

limit; Batt. Current limit) (part no. 77000005).

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4.1 AS400 Interface Board (4590041B)

The AS400 Interface board connects the five most operationally critical
UPS alarms to an IBM AS400 computer, which is designed to monitor
such alarms and respond to their appearance.
The alarms in question are:

• Mains failure

• Load on inverter

• Low battery and/or battery circuit breaker open

• Load on mains (bypass)

• Load on maintenance bypass

These alarm signals are provided by volt-free relay contacts.
The AS400 Interface Board is fitted to the bottom of the UPS cabinet door
and connected to the UPS control electronics by a ribbon cable (FC13 in
the 80/120/200 kVA models and FC19 in the 300 - 400kVA models )
which is fitted to all modules and normally stowed in the cable loom when
this option is not used.

Two female D-type connectors are provided on the Interface Board to
enable the above signals to be connected to the AS400 computer. One
connector, CN1, has 9 pins and the other, CN2, has 15. Figure 4-1
provides pin-out details for these connectors.

Note: Use one connector only -i.e.

don't use both connectors simultaneously.

In addition to the D-type connectors, the AS400 Interface Board also
contains a number of volt-free relays whose contacts provide a duplicate
set of volt-free alarm outputs that are connected to terminal block M1
Äas shown in figure 4-1. These outputs can be used to drive an external
alarms monitoring device. Maximum contact rating on M1 terminals =
50 Vcc @ 1 Amp.

Note: When using the above contacts for remote alarm annunciation, the
power supply for the remote indicators must be provided from an external
power source. Under no circumstances should the UPS internal low voltage

supplies be used for t his purpos e.

The Interface Board has facilities to accept two remote control inputs, as
shown in figure 4-1. One remote input allows the inverter to be shut
down (transferring the load to the bypass supply) and the other enables
the inverter synchronisation feature to be inhibited. The inverter
synchronisation inhibit feature is most often used if the UPS is powered
from a standby generator when the input mains supply fails and the

generator fr equency is unstable.

The external control signals (12V dc or ac) should be connected to
terminal block M2 as shown in figure 4-1. Once again, the voltage
applied to these terminals must be generated by an external power source
and not taken from the UPS internal low voltage supplies.

When fitting the AS400 interface board to the 7400 series, ensure that
link SH-1 is in position 1-2.

4.1.1 AS400 Interface Board

outputs

4.1.2 Remote control inputs

4.1.3 Calibration

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Figure 4-1 . AS400 Interface Board outputs Single and 1+1 Modules

N

otes:

1.All relays operate on Event

2. M1 pin numbering starts physically from
Bottom.. Pin Numbers are correct.

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4.2 4-Way AS400 Interface Board (4590045F)

The 4-way AS400 Interface board connects five critical UPS alarms to
four output terminal blocks M1 - M4 as shown in figure 4-2. These alarm
signals can be connected to a IBM AS400 computer designed to monitor
such alarms, or to a Remote Alarm Monitor panel.
The alarms monitored are:

• Mains failure

• Load on inverter

• Low battery and/or battery circuit breaker open

• Load on mains (bypass)

• Load on maintenance bypass

The signals commonly interfaced with the AS400 are:

• Mains failure

• Load on inverter or UPS ON

• Low battery .

These alarm signals are provided by volt-free relay contacts (maximum
rating 50V @ 1 Amp).
Note: When using the ab ove co ntacts fo r remote alarm a nnunciatio n, the
power supply for the remote indicators must be provided from an
external power source. Under no circumstances should the UPS internal
low voltage supplies be used for this purpose.
The 4-way AS400 Interface Board is also positioned in the UPS cabinet
(below the power isolators), and connected to the UPS control
electronics by a ribbon cable (FC13 in 80-120 and 200 kVA modules
and FC19 in 300-400 kVA modules) connected to CN1.

The Interface Board has facilities to accept two remote control inputs, as
shown in figure 4-2. One remote input allows the inverter to be shut
down (transferring the load to the bypass supply) and the other enables
the inverter synchronisation feature to be inhibited. The inverter
synchronisation inhibit feature is most often used if the UPS is powered
from a standby generator when the input mains supply fails and the

generator fr equency is unstable.

The external control signals (12V dc or ac) should be connected to
terminal block M1 as shown in figure 4-2. Once again, the voltage
applied to these terminals must be generated by an external power source
and not taken from the UPS internal low voltage supplies.

When fitting the AS400 interface board to the 7400 series, ensure that
link SH-1 is in position 1-2.

4.2.1 Remote control inputs

4.2.2 Calibration

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Figure 4-1 . Four output AS400 interface board

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4.3 Output Interface (Remote Alarms) Boards (4590044E)

One remote alarm board, shown in figure 4-3, enables the alarm signals
generated within the UPS to be connected by means of volt-free change­over relay contacts to a remote monitoring device. The board can be
fitted on the bottom of the UPS cabinet door, together with the AS400
Interface Board.

Note: When using the co ntact s for r emote ala rm annunc iati on, the po wer
supply for the remote indicators must be provided from an external
power source. Under no circumstances should the UPS internal low
voltage supplies be used for this purpose.

The board has facilities to accept two remote control inputs, as shown in
figure 4-3. One remote input allows the inverter to be shut down
(transferring the load to the bypass supply) and the other enables the
inverter synchronisation feature to be inhibited. The inverter
synchronisation inhibit feature is most often used if the UPS is powered
from a standby generator when the input mains supply fails and the
generator fr equency is unstable.

The external control signals (12V dc or ac) should be connected to
terminal block M2 as shown. Once again, the voltage applied to these
terminals must be generated by an external power source and not taken
from the UPS internal low voltage supplies.

4.3.1 Alarm outputs

4.3.2 Remote control inputs

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Figure 4-1 . Output Interface Board Part N°4590044E

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4.4 Remote Alarm Monitor (RAM) (P/N 4305001Z)

When used in conjunction with one of the alarm interface boards
described previously, the Remote Alarm Monitor enables the auxiliary
alarm signals to be displayed at a remote station up to 200 metres from
the main equipment.
The RAM, which can be mounted either horizontally or vertically,
contains a mains-dri ven power supply for alarm LED annunciation and
displays the following warnings:

Panel Indication Colour Normal

state

Interpretation

Inverter ON: green ON Normal operating condition indicating that the load is being

supplied by the inverter. This is not an ‘alarm’indicator.

Utility failure: red OFF When lit, it indicates that the input mains are out of tolerance.

Battery low: red OFF When lit, it indicates that the battery voltage is below

minimum or that the battery circuit breaker is open.

Bypass ON: red OFF When lit, it indicates that the load is being fed from the

bypass supply, possibly due to a UPS failure.

Maintenance: red OFF When lit, it indicates that the UPS has been selected to

operate on the maintenance bypass and the load is
unprotected.

Alarm: red OFF This is a ‘common alarm’and is lit when any of the red leds

described above are lit.

Table 4-1

An audible warning accompanies any of the above alarm conditions.
This is, however, subject to a short time delay when activated in
conjunction with the ‘Utility Failure’and ‘Bypass ON’alarms, to prevent
the warning being activated by transient conditions. Pressing the
‘reset’pushbutton cancels the audible warning but the alarm indications
remain until the condition is rectified.

Power supply

The RAM contains a single phase 220-240 Vac mains-driven power
supply. Power is applied through a standard CEE22 three-pin fused
mains connector located in the RAM top panel (plug provided) - use 3­core 0.5mm cable (min).
The supply is rated at approximately 4 Watts and fused at 1A.

It is advised that this power supply is taken from the output of the UPS,
otherwise in the event of a mains power supply failure the RAM will be
inoperative.

Alarm connections

A 9 pin D-type connector with solder points is provided with the RAM.
This connector fits into the 9 pin socket on the top of the RAM and
should be cabled to the AS400 Interface Board (4590041B or
4590045F), fitted to the UPS, using 9 core, 0.22mm. (minimum) cable as
shown.

4.4.1 Connections

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Figure 4-1 . Remote Alarm Monitor connection details

for both the single way (on the left) and four way (on the right) Interface boards.

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4.5 Remote Alarm and Control Panel (Part No. 4305002 A)

When used in conjunction with the Output Interface Board (4590044E)
described previously, the Remote Alarm and Control Panel enables the
alarm signals to be displayed at a remote station up to 100 metres away
from the main equipment. In addition the panel allows the operator to
switch OFF the UPS inverters.

The Remote Alarm and Control Panel, which can be mounted either
horizontally or vertically, contains a mains driven power supply for
alarm LED annunciation. An audible warning accompanies any of the
alarm indications after a short time delay, this can be silenced by the
operator.
The following list gives an interpretation of the controls and alarm
facilities:

Panel Indication Priority Ident

Fig. 4-5

Colour Normal

State

Interpretation

BATTERY ON LOAD Alarm 8 red OFF T his i s a sta tus a lar m showing a UP S i s running

on the battery, this may be accompanied with a
mains fault alarm and the indication from the
associated UPS (6) changing from green to red.

LOW BATTERY Alarm 9 red OFF This indicates that either the battery voltage is

low or the battery circuit breaker is open and
would normally follow the BATTERY ON
LOAD (8) alarm. The indication from the
associated UPS (6) will change from green to
red.

OVERLOAD Alarm 10 red OFF This indicates that the system has reached

100% load, after a short period of time it will
be accompanied by the LOAD ON MAINS
(15) alarm. The indication from the associated

UPS (6) will change from green to red.
OVER­TEMPERATURE

Alarm 11 red OFF If an over temperature condition arises the unit

involved will shut down after 3 minutes, should

this exceed the module redundancy the system

will switch to the bypass. This may be

accompanied by a UPS FAULT alarm (13) and

the indication from the associated UPS (6)

changing from green to red.
MAINS FAULT Alarm 1 2 red OFF This indicates that the mains power has either

failed or is out of the specified range. This may

be accompanied by a BATTERY ON LOAD

alarm (8) and the indication from the associated

UPS (6) changi ng from green to red .
UPS FAULT Alarm 13 red OFF This is taken from the UPS common alarm

output and would normally be accompanied

with a UPS alarm and the indication from the

associated UPS (6) changing from green to red.
MAINTENANCE
BYPASS

Alarm 14 red OFF This indicates that the UPS system has been

selected to run on the maintenance bypass

supplies and the load is unprotected from

disturbances.
LOAD ON MAINS Alarm 15 red OFF This is a status alarm warning that the load is

being powered thro ugh the sta tic bypass system

and is therefore unprotected.

4.5.1 Introduction

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Panel Indication Priority Ident

Fig. 4-5

Colour Normal

State

Interpretation

UPS Module status status 6 red/

greenONgreen

These are bi-coloured indicators, when lit green

indicate that the UPS is OK, and when lit red

indicate that a fault is present. Indication for

number 1 module is on the left and number 2

module next to it, the other four indicators are

not used for this application.
Mains OK status 21 green ON When lit indicates that the mains supply to the

modules is OK and therefore bypass supplies

are available.
Load on Mains status 19 green OFF When lit indicates that the load has transferred

to the bypass supplies and is therefore

unprotected.
UPS OK status 20 green ON When lit indicates that the UPS inverters are

synchronised and UPS supplies are available.
Load on UPS status 18 green ON When lit this indicates that the load is being

supplied by the UPS inverters - the normal

status.
UPS OFF status 17 red OFF This shows that the UPS OFF switch, on the

remote panel has been operated and the

inverters have been shut down, the load will be

supplied via the bypass if available.
UPS OFF switch 16 OFF This switch selects all the UPS inverters OFF.

It can only be used when enabled by the key

enable switch (4). The UPS OFF indication

(17) accompanies its operation.
Alarm silence switch 7 OFF This switch silences the horn on the Remote

Alarm and Control panel only, it has no effect

on the UPS system or any indications.
UPS OFF enable switch 4 OFF This key operated switch enables the UPS OFF

switch and is security against the UPS OFF

switch being operated accidentally.

Table 4-2

Power Supply

The panel contains a single phase 220-240 Vac mains driven power
supply. Power is app lied through a standard thr ee pin mains connector
located at the top of the panel (plug provided) - use 3 core 0.5mm cable
minimum.

Alarm connections

Alarm connections from the UPS modules are provided by connectors
M1 (5 way terminal block), M2 (15 way terminal block) and M3 (15 way
terminal block) on the Output Interface boards (4590044E), to CN1 (50
pin D-type connector) on the Remote Alarm and Control panel (4305002
A).

Full installation instructions are provided with the option kit.

4.5.2 Connections

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Figure 4-1 . UPS System connection and identification of the control and

indication of the Remote Alarms and Control Panel

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UPS 1

(or Single Module)

Remote Alarm and

Control Panel

UPS 2

(when 1 + 1 system)

Remote Alarm and

Control Panel

Interface board

Pt. No. 4590044 E

Pt. No. 4305002 A Interface board

Pt. No. 4590044 E

Pt. No. 4305002 A

M3 Terminals CN1 Pins M3 Terminals CN1 Pins

15 15 15 10
14, 11, 8, 5, 2 29 14, 11, 8, 5, 2 24
12 33 12 28
917912
631626
31439

M2 Terminals M2 Terminals

15 30 15 25
14, 11, 8, 5, 2 46 14, 11, 8, 5, 2 41
12 13 12 8
916911
632627
349344
250245

M1 Terminals M1 Terminals

547542
448443

Table 4-3

UPS module Interface board terminal connections to Remote alarm and control panel socket pins.

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Figure 4-2 . Interconnections between the UPS modules and the Remote Alarms and Control Panel

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4.6 RS 232 Communications Management Board (SGC) (4550002C)

The optional RS232 Communications Management Board takes existing

information available from the display
assembly, stores it and converts it into a customer usable form for display
either locally or remote to the UPS. It can be interrogated via a telephone­modem system from a remote service centre and it can activate a remote
station in the event of an alarm to down-load the current status.

Figure 4-7 shows a typical system using the RS232 Communications
Management Board, which is referred to as the SGC (Scheda Gestione
Communicazione). One would be fitted to the MSSC for system
information and one to each UPS module for individual module
information. The SGC has two outputs; the first, as shown, is the modem
connection and the second connects directly into a PC for local
monitoring where required.
Remote communications can be via a dedicated telephone line or a non
dedicated line, in the second case a "Data Switch" will be required to
select the modem connected to the UPS when required.
The information stored on this board is maintained in the event of a UP S
shutdown by (alkaline) batteries. These batteries also maintain an on­board clock which times and dates events as they occur.
The SGC board continually stores information on the dynamic power
parameters within the UPS. Fo ur hundred o f these events are stor ed in a
recirculating memory, the most recent displacing the earliest in the
‘Power History’store. A similar ‘Event History’store tracks the changing
operational status of the machine. This memory reflects the alpha­numeric display on the front panel and updates whenever a change takes
place. The message would normally read ‘NORMAL OPERATION’ but
would change when a ‘WARNING’ or ‘ALARM’ condition occurred. If
an ‘ALARM’ occurs the SGC board marks the event in the ‘Power
History’and after a further 199 events, the system locks out any further
updates. This gives a snap-shot of the events on either side of the alarm.
On ‘ALARM’ the SGC board can be configured to automatically dial out
to the remote site or service centre. Two telephone numbers can be
stored within the memory. The primary number will be tried
preferentially but the system will revert to the secondary number should
the primary connection prove unsuccessful.
An LED located on the SGC board flashes at two hertz per second when
communication is taking place.
A software package is pr ovided with the option to be used with the PC.
This software is used to configure the system and to run the diagnostics.
It has a screen driven menu with an on screen help facility. The software
can be operated in several languages which are set up at the terminal.
Each terminal can be set up to monitor 1000 UPS.

The remote terminal, as well as receiving information fr om the UPS, can
interrogate the system. It can do this in two ways:

1. Manual input from the keyboard will allo w the operator to select any

one of the UPS on the system and request the current status.

2. The operator may select any or all the UP S from a list residing in the

computer and call automatically, overnight if necessary.

4.6.1 Introduction

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The system is made up of the following parts or sub-systems:

1. RS 232 Communications Management Board (SGC), for installation

within the UPS.

2. Batteries:
these may be of any non-rechargeable type (alkaline, ‘environment-

friendly', etc.) a s long as they are of th e correct size (AAA).

3. Personal computer for local connection

4. Flat, 25-wire cable ending in two 25 pin connectors, one male and

one female, for UPS-PC connection.

5. Digital telephone modem for connection to the board.

6. Flat, 25-wire cable ending in two 25 pin connectors, one male and

one female, for local UPS- modem connection.

7. Personal computer plus digital telephone modem for remote station.

8. Flat, 25-wire cable ending in two 25 pin connectors, one male and

one female, for remote modem-PC con nection.

The possible types of connection, as shown in figure 4-8 , are as follows:

Direct Connection

This type of connection requires items 1, 2, 3, and 4 from the above list.
It is possible t o obtain data from a distance of upto 15 metres through the
EIA RS232E interface.

Remote Connection (i.e. via telephone modem)

This type of connection requires items 1, 2, 5, 6, 7, 8 and a commuted
telephone line.

Complete Connection

Complete connection require the total resources of the above.
Full installation and operating instructions are supplied with the option.

4.6.2 General Information

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Figure 4-1 . Typical Series 7400 RS232 Communications configuration

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4.7 5th Harmonic Input Filter

An optional input 5th harmonic filter can be added to the 6 pulse 7400
series UPS to improve the UPS input power factor and reduce the
amount of electrical noise reflected into the input three phase supply.

On units upto 200 kVA the filter components are contained in a purpose­built cabinet which is positioned alongside the main UPS equipment and
connected in series with the UPS input supply. In the case of the 300/400
kVA models the input filter is located within the UPS as illustrated in
figure 4-12. The filter components are matched to the UPS capacity,
resulting in different part numbers for each system as follows:

Part No. Weight
80kVA filter cabinet 5331016 C 220kg.
120kVA filter cabinet 5331018 E 240
kg.200 kVA filter cabinet 5331020 G 280
kg.300 kVA filter (internal) 4641010 K N/A
400 kVA filter (internal) 4641013 N N/A

Input voltage 380-400-415, three phase.

Input voltage tolerance ±15%.
Nominal frequency 50Hz.
Input frequency tolerance ±5%.
UPS input current distortion 10% max. at full load.
UPS input power factor >0.9 lag.
Dimensions (80-120 kVA) 600 x 800 x 1800 mm.
Dimensions (200 kVA) 600 x 800 x 1900 mm.

The 80 - 200 kVA module input filters have a manually operated isolator
I2 plus internal fuse protection. The 300 kVA and 400 kVA filter when
fitted is connected permanently in circuit between the UPS input isolator
and inductor L1. The circuit position of both types of filter are shown in
figure 4-8.
The block diagram in figure 4-9 and the models’connections in figures 4­9, 10, and 11 , illustrate the installation with a "split bypass" supply
configuration.
Note: The input Neutral connection must always be connected to the
bypass input ‘N3’on the UPS.
If the UPS is configured to operate with a "common bypass", a three
phase supply with a separate neutral, or a standard four wire input, may
be used. The bypass supplies may be linked via the input connections of
the filter input isolator I1 or at a junction box/external isolator prior to
the supplies entering the filter cabinet. Ensure all internal links between
the UPS input and bypass bus bars are removed so that the filter does not
carry any bypass supplies. T he Neutral must be terminated at the UPS
bypass input terminal ‘N3', as shown in figure 4-11 for the 200 kVA
model.
Note: The Neutral connection ‘N1’on each input filter Isolator I1 is a
convenient point to terminate or link the Neutral cable. It is not
connected internally to the input filter.

4.7.1 Introduction

4.7.2 Specification

4.7.3 Notes on connection

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Bypass Supply

Mains Supply

Bypass Supply

Mains Supply

Isolator 1

Bypass Supply

Bypass Isolator

Input
Isolator

RECTIFIER INVERTER

STATIC
SWITCH

Battery Circuit
Breaker

BATTERY

80 - 120 - 200 kVA UPS

UPS
Output
Supply

Output
Isolator

UPS
Output
Supply

Output
Isolator

Bypass Supply

Bypass Isolator

Input
Isolator

RECTIFIER INVERTER

STATIC
SWITCH

Fitted
internally

Input Isolator

Battery Circuit
Breaker

BATTERY

300-40

0kVAUPS

Figure 4-1 . Block diagram of Input Filter and UPS

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Figure 4-2 . 80 kVA Input Filter cabinet connections

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Figure 4-3 . 120 kVA Input Filter cabinet connections

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Figure 4-4 . 200 kVA Input Filter cabinet connections

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-ve

+ve

CN8

Internal Input Filter

Figure 4-5 . 300-400 kVA Input Filter location

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4.8 Cable top entry kit

This modification kit is for use with 80 kVA 120 kVA and 200 kVA

models only.
As can be seen in figure 4-13 this kit comprises front, rear and top panels
which when assembled using the extension brackets and existing UPS
end panel, allows you to extend the UPS width by approximately
200mm. This then al lo ws cab le ent ry thro ugh t he to p a luminium p ane l. I t
is necessary for the user to size and cut holes in the top panel for the
cables to be used.

4.8.1 Introduction

CABLE TOP
ENTRY EXTENSION

Existing UPS
side panel

Existing UPS
side panel

FRONT VIEW

Extension bracket

SIDE VIEW

Front panel

Rear
panel

Cable
securing

UPS Cabinet

Figure 4-1 . Cable Top Entry Kit

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4.9 Pulse Option

The 12 pulse option fo r the series 7400 UPS is normally factory fitted.
The power and control cable connections for all units are identical to
those given in chapter 3 of this manual. The 300/400 kVA units have the
option fitted into the existing cabinet. However, for 80, 120 and 200
kVA units with part numbers as indicated in the front of this manual, the
option can be fitted on site by a Liebert certified service engineer. The
option is fitted into a purpose designed cabinet that when bo lted to the
side of the UPS cabinet extends the system width by 400mm. As with all
series 7400 bolt-on options, the mechanical connection is achieved by
removing the UPS cabinet side panel; the additional cabinet is then
bolted on to the UPS cabinet at the four corners; the side panel removed
from the UPS cabinet is then fitted to the additional cabinet side wall to
complete the system.

For electrical connection of the 12 pulse option part no. 53320001 Z for
80 kVA unit 5332002 A for the 120 kVA unit and 5332004 C for the
200 kVA refer to figures 4-14 and 4-15 and the following instructions.

The details given in figure 4-15 refer to the 80kVA unit. The 120kVA
and 200 kVA units are identical except for the following identification
numbers:

80kVA 120kVA 200kVA

Connector ident CN3 CN4 CN4
Extractor fan VL8 VL10 VL12

WARNING

BEFORE STARTING INSTALLATION OF THIS OPTION ENSURE ALL EXTERNAL

ELECTRICAL POWER SUPPLIES ARE SWITCHED OFF AND MADE SAFE.

DISPLAY THE RELEVANT NOTICES. ENSURE THE BATTERIES ARE ISOLATED

FROM THE UPS. CARRY OUT VOLTAGE CHECKS ON ALL INPUT, OUTPUT AND

BATTERY CONNECTIONS..

1. Gain access to UPS interior, open upper hinged panel. Remove the

bus bar +ve and -ve connection links from between the rectifier
output and the d.c. bus bar.

2. Connect cable 88 from the option cabinet TC4 to the UPS rectifier

output +ve bus bar.

3. Connect cable 89 from the option cabinet L2 (term A1) to the UPS

rectifier output -ve bus bar.

4. Connect cable 49 from the option cabinet L2 (term B) to the UPS

d.c. bus bar +ve connection.

5. Connect cable 50 from the option cabinet L2 (term A) to the UPS

d.c. bus bar -ve connection.

4.9.1 Introduction

4.9.2 Electrical connection

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6. Connect cables 4, 5 and 6 from the option cabinet AT1 (terminals A,

B and C) to the UPS input inductor L1 (terminals A', B’and C').

7. Connect flat cable FC22 from the option cabinet PCB 4590051L

(connector CN1) to the UPS PCB 4520073Z (connector CN9).

8. Connect flat cables FC19, FC20 and FC21 from the option cabinet

PCB 4612141 B (connectors CN1, CN2 and CN3) to the UPS PCB
4520073Z (connectors CN6, CN7 and CN8).

9. Connect wire No.80 fr om the option cabinet fan CN3 (1) to the UPS

fuse F12.

10. Connect wire No.82 from the option cabinet fan CN3(2) to the UP S

fuse N.

11. For UPS 200 kVA only: move wires No. 46/48 from terminal 4 to

terminal 2 of TA1 - TA2 in the UPS.

This completes the electrical connection of this option.

Figure 4-1 . Electrical schematic of 12 Pulse option cabinet

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Figure 4-2 . 12 Pulse option cabinet

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4.10 Option Board Kit (Part no. 77000005)

This kit is intended for use in to any Series 7400 UPS fitted with the
appropriate Rectifier Logic Board (part no. 4520073Z). T he kit provides
the following facilities:

p Battery temperature compensation:

With this feature fitted and enabled the nominal float voltage
supplied to the battery is adjusted so as to be inversely proportional
to the ambient battery cab inet/room temperature ( as monitored by a
remote temperature sensor ). This prevents the battery being over
charged at high ambient temperatures.
Example: - the d.c. float voltage is reduced by 1.5V d.c. per oC rise
in battery Temperature from 25oC to 35oC.

p Reduced input current limit:

This facility allows the UPS input current limit to be reduced to a
predetermined level. This may be necessary when running the UPS
on a standby generator. The system is activated by the closure of a
normally open contact. The input current limit can be reduced from
115% to 50% of nominal.

p Reduced battery current limit:

This facility allows the UPS battery current limit ( i.e. the magnitude
of the battery charging current) to be reduced to a preset value. This
may advisable if the battery cabinet/room ventilation system failed.
The system is activated by the closure of a normally open contact.
The battery current limit can be reduced from 100% to 10% of its
initial setting.

Unpack the kit carefully and examine the parts for any signs of transit

damage . Check that the following items are included in the kit:

1 77000002 PCA Option board.
1 83696005 Temperature sensor kit.
4 49030060 Screws (M3 x 6).

Fit the supplied equipment as follows:

1. If the module is op erating and on load, transfer the lo ad to bypass

and open the input isolator (I1) following the instructions in chapter
2 of this manual.

2. Locate onto the plastic stand-offs and secure the option board into

position as shown in figure 4-16 using the screws provided.

3. Fit links into position on the option board for the features required.

See table 1 for enabling link positions

4. Connect 10 way ribbon cable between PL1 on the option board and

connection CNx on the Rectifier Logic board following existing
cable routes.

5. The remote temperature sensor required fo r the battery temperature

compensation feature should be located in such a position so as to
monitor the ambient air temperature of the battery bank. It is
recommended that the remote sensor is connected to the option
board using a twisted pair (1-2 mm

2

) of maximum length 25m.

4.10.1 Introduction

4.10.2 Installation

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Figure 4-1 . Option board fixing location

Figure 4-2 . Option board connection and layout

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6. Connect auxiliary wiring required as shown in figure 4-18

Battery charging temperature compensation
temperature sensing element - TB1-1 and TB1-2
Reduced input current limit

normally open contacts - TB1-3 and TB1-4

Reduced battery current limit

normally open contacts - TB1-5 and TB1-6.

7. Calibrate the options using instructions sheet part number 77000008.

SHUNT LINK

POSITION

DESCRIPTION

1 1 -2 Reduced Input current limit Calibration Mode.

2-3 Normal Operation.

2 1 -2 Reduced Battery current limit Calibration Mode.

2-3 Normal Operation.

3 1 -2 Reduced Input current limit: Link fitted - System enabled

Link not fitted - System Disabled.

3-4 Reduced battery current limit: Link fitted - System enabled

Link not fitted - System Disabled.

1-2 & 5-6 Reduced battery current activated when reduced input current limit isactive.

4 1-3 Temperature Compensation Calibration mode selected. (The remote temperature

sensor MUST be removed before operation in this mode.

2-4 Temperature Compensation mode selected.

5 1 -2 LED 4 illuminates at temperatures set by SOT R26 (i.e. Battery Over Temp

Alarm).

2-3 LED 4 illuminates when the Temperature Compensation system becomes active.

6 1-2 Temperature compensation enabled: This applies to a 6 pulse Rectifier logic board

(part no. 4520049B) NOW OBSOLETE.

2-3 Temperature compensation enabled. 12 pulse Rectifier Logic board (part no.

4520073 Z).

No links Temperature compensation disabled.

Table 3 - Option board - Summary of link settings

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