Liebert UPS System User Manual
Liebert iTRUST UPS System
User Manual
E1-20020516-C-1.0
Liebert Corporation
Contents
Chapter 1 Introduction .....................................................................................................................1
1.1 Basics.................................................................................................................................1
1.2 Configuration ......................................................................................................................1
1.3 Operation Theory................................................................................................................2
1.4 Structure and Layout ..........................................................................................................3
1.5 Operation Modes................................................................................................................4
1.6 Basic Functions ..................................................................................................................8
1.7 Specifications .....................................................................................................................8
Chapter 2 Cabinet Installation .......................................................................................................13
2.1 Environmental Conditions.................................................................................................13
2.2 Unpacking.........................................................................................................................13
2.3 Dimensions.......................................................................................................................13
2.4 Transportation ..................................................................................................................16
2.5 Positioning of UPS............................................................................................................16
2.6 Cable Access....................................................................................................................18
2.7 Ventilation.........................................................................................................................19
2.8 Layout of Cabinet .............................................................................................................20
Chapter 3 Electrical Assembly.......................................................................................................23
3.1 Selection of cables ...........................................................................................................23
3.1.1 Current carrying capacity of cables ........................................................................23
3.1.2 Selection of power cables.......................................................................................23
3.1.3 Selection of signal cables.......................................................................................24
3.2 Cable connections............................................................................................................24
3.2.1 Power cables..........................................................................................................24
3.2.2 Signal cable............................................................................................................28
3.3 Connection of Single UPS System ...................................................................................35
Chapter 4 Commissioning of UPS.................................................................................................37
4.1 Startup Procedure ............................................................................................................37
4.1.1 Explanation of Circuit Breakers ..............................................................................37
4.1.2 Startup....................................................................................................................37
4.2 Setting the functions.........................................................................................................38
4.3 Functional checks.............................................................................................................40
4.3.1 Check the function of the display panel..................................................................41
4.3.2 Switching between operation mode........................................................................41
Chapter 5 Operation of Display Panel ...........................................................................................43
5.1 Display panel....................................................................................................................43
5.1.1 Layout of Display Panel..........................................................................................43
5.1.2 LED Indication........................................................................................................44
5.1.3 Functional Keys......................................................................................................45
5.1.4 Alarm Buzzer..........................................................................................................46
5.1.5 LCD and Menu Keys .............................................................................................. 46
5.2 The displayed information ................................................................................................ 48
5.2.1 Opening display ......................................................................................................48
5.2.2 Main Menu Display.................................................................................................48
5.2.3 UPS Basic Information...........................................................................................48
5.2.4 Menu Keys Display Window...................................................................................49
5.2.5 Information of main menu.......................................................................................50
5.3 Function Setup .................................................................................................................54
5.3.1 Language setup .....................................................................................................54
5.3.2 Address setup ........................................................................................................55
5.3.3 Time setup .............................................................................................................55
5.3.4 Manual battery self-test..........................................................................................58
5.3.5 Contrast adjustment ...............................................................................................59
5.3.6 History log ..............................................................................................................59
5.3.7 background communication setup.......................................................................... 60
5.3.8 Call-back number setup ..........................................................................................61
5.4 Prompt window.................................................................................................................63
5.5 Events and State Information: .......................................................................................... 66
Chapter 6 Maintenance ................................................................................................................. 69
6.1 Setup procedures.............................................................................................................69
6.1.1 Start up...................................................................................................................69
6.1.2 Shutdown ............................................................................................................... 70
6.1.3 Transferring between operation modes..................................................................71
6.1.4 Emergency shutdown and recovery.......................................................................71
6.1.5 Mute .......................................................................................................................72
6.1.6 Fault clear ..............................................................................................................72
6.1.7 Monitoring system..................................................................................................73
6.1.8 Input and output contacts........................................................................................75
6.1.9 Temperature measuring.........................................................................................76
6.2 Maintenance.....................................................................................................................76
6.2.1 Daily maintenance..................................................................................................76
6.2.2 Battery maintenance .............................................................................................. 78
6.2.3 Shutdown maintenance..........................................................................................80
Chapter 7 Troubleshooting............................................................................................................81
7.1 UPS system troubleshooting............................................................................................81
7.1.1 Basics.....................................................................................................................81
7.1.2 Procedures............................................................................................................. 81
7.2 LED indicator....................................................................................................................81
7.2.1 LED display............................................................................................................81
7.2.2 LED indicator of lightning protection device ...........................................................82
7.3 Buzzer alarm ....................................................................................................................82
7.4 LCD indication for fault information .................................................................................. 83
Chapter 8 Parallel System.............................................................................................................87
8.1 System Introduction..........................................................................................................87
8.1.1 Basics.....................................................................................................................87
8.1.2 Theory of Operation...............................................................................................88
8.1.3 Operation modes....................................................................................................90
8.2 Installation ........................................................................................................................91
8.2.1 Cabinet installation .................................................................................................91
8.2.2 Electrical installation...............................................................................................92
8.3 External Power Distribution ..............................................................................................93
8.4 Start up of Parallel Operation System ..............................................................................93
8.5 Using the Parallel Operation System ................................................................................94
8.5.1 Switch on the Parallel System................................................................................94
8.5.2 Shutdown the Parallel Operation System...............................................................95
8.5.3 Transferring between Operation Modes .................................................................96
8.5.4 Repairing the failed UPS unit in parallel operation system .....................................97
8.5.5 Emergency shutdown.............................................................................................98
8.5.6 Fault and Fault Process Methods...........................................................................99
Chapter 9 Optional Parts .............................................................................................................101
9.1 Battery ............................................................................................................................101
9.1.1 Capacity selection ................................................................................................101
9.2 Battery cabinet................................................................................................................102
9.2.1 External Dimensions.............................................................................................102
9.2.2 Installation of battery cabinet................................................................................103
9.2.3 Wiring of the batteries...........................................................................................103
9.3 SNMP Card and the Software ........................................................................................106
9.3.1 Product structure and ports ..................................................................................106
9.3.2 Technical features ................................................................................................106
9.4 Network Software ...........................................................................................................107
9.5 MODEM..........................................................................................................................107
9.6 Temperature sensor TMP12Z.........................................................................................108
9.7 Level C Lightning Protection System SPD24Z...............................................................108
9.7.1 Introduction of SPD24Z ........................................................................................109
9.7.2 Installation procedures of SPD24Z.......................................................................109
9.7.3 Using and Maintenance.........................................................................................111
9.8 Bypass Isolation Transformer.........................................................................................111
Chapter 10 Service after Sales....................................................................................................112
10.1 Abnormal Fault Handling..............................................................................................112
10.2 Technical support ............................................................. Error! Bookmark not defined.
10.3 Warranty.......................................................................................................................115
1.1 Basics
The Liebert iTrust UPS System is connected between the utility source and the
critical load to provide uninterruptible power to the load. The power from the UPS
being free of voltage and frequency variation and disturbances from utility. The UPS
has an output isolation transformer to provide galvanic isolation between the load
and utility. The UPS also uses the latest in high frequency double conversion
PWM technology and a fully digital control.
It also has advanced network management functions.
1.2 Configuration
The UPS consists of the following modules : rectifier, inverter, static bypass,
maintenance bypass, output isolation transformer, inverter static switch, battery and
input and output circuit breakers.
Chapter 1 Introduction
Chapter 1 Introduction
As shown in Figure 1-1, the AC utility source is input at Q1 and the rectifier
converts the AC Utility into DC source. The Inverter will convert the DC source or
the DC source from the batteries into AC source that is output from the isolation
transformer. The battery will power the load through the inverter in case of a power
failure. The utility source can also power the load through the static bypass.
Besides this, if maintenance or repair of the UPS is necessary, the UPS can
support the load through the maintenance bypass without interrupting the load.
Figure 1-1 Theory of UPS
1
1.3 Operation Theory
The UPS circuit diagram is shown in Figure 1-2.
A1
B1
C1
A2
B1
C1
N2
BP
BN
U
V
W
N
Q1
Q2
Q3BP
Q5
FU1
FU2
FU3
Chapter 1 Introduction
KM1
KA1
Res1
Res2
KM2
FU4
FU5
FU6
AC2
TR1
L1
DC1
+
Res3
AC4
AC3
TR2
DZN6
Figure 1-2 Main circuit of UPS
The utility source is input at Q1 and flows through the fuse, the transformer,
inductor and into the high frequency rectifier which will convert the AC power into
DC power. The rectifier has PFC and charger function and make use of soft start
and DSP digital technology to improve the system immunity against surge, improve
the stability of the DC bus voltage, reduce the charging current ripple and prolongs
the battery life.
The battery is connected to the UPS through contactor. If the DC bus voltage drop
through certain threshold, then the contactor will activate to connect the battery to
the DC bus. The battery will supply the DC power to the inverter through a filtering
circuit.
The inverter uses digital vector control technology based on DSP to modulate six
IGBTs through SVPWM and invert DC power to AC three phase power.
The output is isolated from the load by Delta/Zig-Zag transformer, static switch,
fuse and circuit breakers.
The bypass source is input at Q2 and output through the bypass static switch.
2
The double DSP and MCU form the full digital control system to realize the powerful
function of the UPS. The switching between the operation modes is realized by
controlling the bypass static switch and the inverter static switch. Advanced battery
management prolongs battery life.
Multi-communication ports and management software make it possible for the
customer to monitor the UPS performance locally or remotely. The Liebert UPS
uses full digital, discrete and on-line parallel operation technology. In parallel
operation, several UPS units input parallel logic signals and cross current detection
signals through parallel operation boards to enable a maximum of four UPS units to
operate in parallel. (N+X) redundancy parallel operation, capacity expansion and
hot-standby configuration can be realized. If an additional UPS is required to be
added to the system, no auxiliary equipment is required and power to the load
need not be interrupted.
1.4 Structure and Layout
The structure and layout of the system is shown on Figures 1-3 and 1-4. The
system consists of the rectifier, inverter, auxiliary power supply, input and output
power distribution, monitoring system, parallel control system, lightning protection
unit, EMI filter, fan and input and output isolation filters.
Chapter 1 Introduction
1:Fan 2:rectifier 3:two auxiliary power supply boards ULW2L61M5
4:contactor 5:battery input terminals 6:circuit breaker Q3BP for maintenance
7:Inverter 8:Power distribution board ULK2L61R1
9:D level lightning protection device SPD12Z
10: Output circuit breaker Q5 11:rectifier input circuit breaker Q1
12:bypass input circuit breaker Q2 13:operation keypad board ULW2L61K1
14:LCD 15:parallel board ULW2L61M3
16:monitoring board ULW2L61U2 17:4 leveling feet (M20)
Figure 1-3 Components of 20/30kVA UPS
3
Chapter 1 Introduction
Front view
1:Fan 2:rectifier 3: softstart relays 4:contactor
5: two auxiliary power supply boards ULW2L61M5
6: D level lightning protection device SPD12Z 7: Hall current sensor
8:battery input terminals 9:circuit breaker Q3BP for maintenance
10:rectifier input circuit breaker Q1 11:bypass input circuit breaker Q2
12:Inverter 13: fast fuse
14: parallel board ULW2L61M3 15: EMI board ULW2L61M4
16: magnetic core 17: output circuit breaker
18:operation keypad board 19: LCD
20: monitoring board ULW2L61U2 21: Battery EMI board
22: Fuse NT100 23: 4 leveling feet (M20)
1.5 Operation Modes
1. Normal mode
When the utility is normal, the UPS powers the load through the rectifier and
inverter and charges the batteries at the same time, as shown in Figure 1-5. This is
called the Normal Mode.
Figure 1-4 Components of 40/60kVA UPS
4
Chapter 1 Introduction
-
~
-
output
Bypass
Mains output
2. Battery Mode
When the utility fails, the UPS system will switch to battery mode without
interruption and the battery will power the load through the inverter.
The UPS can return to normal mode automatically when the utility returns to normal,
as shown in Figure 1-6.
Bypass
Mains
~
Figure 1-5 Normal mode
~
-~
Figure 1-6 battery mode
3. Bypass Mode
In the event of an inverter overload which last longer than the typical time, an
output short circuit or a fault on the inverter, the UPS will transfer the load to bypass.
There are two kinds of bypass modes. In the first kind, the UPS can be set to
return to normal mode automatically when the fault is cleared. In the second kind,
the UPS is set to return to normal mode only with a manual transfer.
When the main UPS circuit fails, the battery is depleted or a severe fault occurs,
the inverter will be shut down and the system will remain in the bypass mode. The
system can return to normal mode only with a manual reset after the fault is cleared,
as shown in Figure 1-7.
Bypass
Mains
~-
output
~-
Figure 1-7 bypass mode
5
Chapter 1 Introduction
4. ECO Mode
If the load has no requirement for power quality but has a high requirement for
efficiency, then the UPS can be set in ECO mode. In this mode, the system will
power the load through the static bypass switch and the rectifier will charge the
batteries. When the bypass source fails or out of normal range, the UPS will revert
back to normal mode and powers the load through the batteries. The total transfer
time will be less than 15 msecs. When the bypass source recovers back to normal,
the system will return to ECO mode automatically and the system efficiency is
greatly improved, as shown in Figure 1-8. Note that the ECO mode function can
only be set by qualified personnel and applies to single UPS modules only.
-
-~
outputMains
~
Bypass
Figure 1-8 ECO mode
5. Maintenance Mode
When the UPS has to be repaired or has to undergo routine maintenance, the UPS
can be set to maintenance mode by switching on the maintenance bypass circuit
breaker. The load will be powered from the maintenance bypass supply without
interruption.
During maintenance, the circuit breakers Q1, Q2, QF1 and Q5 should be switched
off to ensure the safety of maintenance personnel. See Figure 1-9.
Q3BP
-
-~
QF1
~
Q5
OutputMains
Bypass
Q1
Q2
6
Figure 1-9
Chapter 1 Introduction
6. United Power Mode
When the utility is not available and the capacity of the generator set is inadequate
to support the load, the battery will power the load together with the generator
automatically. The operating time under this mode should not exceed the autonomy
time of the batteries, as shown in Figure 1-10
Note :
This mode can only be set by qualified personnel only.
-
-
outputMains
~
Bypass
~
Figure 1-10
7. Parallel Operation mode
When several UPS units (maximum four units) are in parallel operation mode, they
will share the load automatically amongst themselves. If one unit fails, this unit will
be shut down automatically and the remaining units will share the load equally. If
overload occurs, the UPS will transfer to bypass operation mode. Parallel operation
mode also has normal mode, battery mode, bypass mode, maintenance mode and
united power mode.
8. Dual Input Mode
The main circuit and the bypass can use the same or different sources. The input
methods are shown in Figure 1-11 and Figure 1-12.
7
-
Fig 1-11
~
Mains output
~
Bypass
Mains
Chapter 1 Introduction
~
-~
-
output
1.6 Basic Functions
Battery Management Function - The UPS has advanced battery management
functions including battery fault detection and backup time forecast.
Soft Start Function - Complete delay soft start function can reduce the surge to the
UPS unit and utility source.
Alarm and Protection Function - The UPS can generator audible and visual alarm
through LCD, input/output contacts and network transmission. It can help
maintenance personnel to locate and clear the faults that are sent out in time,
accurately and in detail.
Dark Start Function - When the utility is unavailable, the UPS can start from battery
that is connected to the DC Bus.
Automatic Re-start when Utility returns - This function only applies to the UPS that
has batteries. The UPS shuts down due to low battery, and restart automatically
when the utility returns. At this time , its operation mode is the one before the utility
fails.
Fig 1-12
Monitoring Functions - The UPS monitoring system has an advanced monitoring
function and parallel control functions. It supports flexible network monitoring to
satisfy different customer requirements.
1.7 Specifications
1. Functional Parameters
8
Chapter 1 Introduction
Parameters of Liebert iTrust UPS are given in Table1-1
Capacity 20kVA 30kVA 40kVA 60kVA
Model UL33-0200L UL33-0300L UL33-0400L UL33-0600L
Input Voltage 380/400/415V(line-to-line voltage)
AC Power Input Three-phase three-wire
Power Factor >0.99
Harmonic Current <4%(Voltage distortion lower than 2% at rated load)
Rectifier
input
Bypass input
Voltage Range
Input current limiting
frequency range
Input Voltage 380/400/415V(line-to-line voltage)
Input Voltage Range
AC Power Input Three-phase four-wire
Frequency range
Voltage regulation
(balanced load)
Voltage transient response
Transient recovery time <60ms
Voltage distortion(linear load)
+15%~-20%
Lowest operating voltage: -45%
Input Current: <115%In for continuous operation; 115~140%In
for 5 minutes; 140~165%In for 1minute; Current limiting at
current over 165%In(In is the rated output current without
deration)
50Hz ±10%
10%
±
50Hz±10%
380/400/415V±1%
(±5% adjustable)
5%(0~100%linear load)
±
THD<2%(line-to-neutral voltage)(battery float charge state,
rated balance load)
Output
Voltage distortion(nonlinear
load)
Power Factor 0.8(lagged)
Frequency Syn. Range
Frequency regulation(Battery
mode)
Phase Displacement (ThreePhase)
Voltage unbalance rate at
100% unbalance load
Frequency slew rate <1Hz/s
THD<5%(line-to-neutral voltage)(battery float charge state,
rated balance load)
50Hz±2Hz
0.1%
±
120± 1°(balanced load or unbalanced load)
2%(battery float charge state)
±
9
Chapter 1 Introduction
Capacity 20kVA 30kVA 40kVA 60kVA
Model UL33-0200L UL33-0300L UL33-0400L UL33-0600L
105% < load 125% , transfer to bypass mode after 10±0.1min;
Output
System
Overload capability(inverter)
125% < load 150% , transfer to bypass mode after 1 minute;
When load > 150%, transfer to bypass mode after 200ms
135% Rated Current continuously
135%~170% for 1 minute
Overload capability(bypass)
>170%, shutdown in 2s
1000% rated current for 20ms(a standard for selecting static
switch)
Ratio of output current peak
value to RMS value
Transfer time(normal mode)
3: 1
0(uninterrupted transfer)，15ms(interrupted transfer)
Transfer time(ECO mode) 15ms
System efficiency(linear load) 87% 87% 88% 89%
Efficiency in battery
mode(linear load)
92% 93% 93% 94%
Display LCD+LED
Conduction EN50091-2
Radiation EN50091-2 CLASS-A
EMC/EMI
Harmonic IEC1000-3-4
EN 61000-4-2.3.4..6.8.9.11 Level III,
Immunity
EN 61000-4-5 Level Ⅳ
MTBF(inverter) 30,000 hours
MTBF(Single UPS) 150,000 hours
MTBF(1+1 parallel operation
system)
400,000 hours
Safety CCEE
Audible noise at 2m <60dB <65dB
Cross current without
load(1+1)
Cross current without
load(3+1)
<3A
<4A
current unbalance rate(1+1) <3%
current unbalance rate(3+1) <4%
10
Chapter 1 Introduction
Capacity 20kVA 30kVA 40kVA 60kVA
Model UL33-0200L UL33-0300L UL33-0400L UL33-0600L
Insulation Resistance >2M(500VDC)
Dielectric Strength
Surge Immunity
System
Protection index IP20
Number of battery cells 30 battery cells(12V)
Installation Cable access mode top/bottom cable access modes optional
(input to earth, output to earth)2820Vdc, leakage current lower
than 3.5mA, 1min without arc
Satisfy the class IV requirements specified by IEC60664-1, the
ability to withstand 1.2/50us+8/20us not lower than 6kV/3kA
2. Electrical Parameters
For designing of utility power source, air-conditioner, input and output power
distribution and cable selection, please refer to Table 1-2
Table 1-2 electrical parameters
Model UL33-0200L UL33-0300L UL33-0400L UL33-0600L
UPS rated power 20kVA 30kVA 40kVA 60kVA
AC input
Rated loss 2.40kW 3.60kW 4.37kW 5.94kW
Air intake(m3/hour) 500 800 1400 2200
Rectifier: 380/400/415V+15%～(3￠3W), Bypass: 380/400/415V±10%(3￠4W)
Rectifier input
current
Bypass input current 37A 56A 74A 112A
UPS output current 37A 56A 74A 112A
Battery input current 56A 84A 112A 168A
44A 66A 88A 132A
11
Chapter 2 Cabinet Installation
Chapter 2 Cabinet Installation
2.1 Environmental Conditions
Operating Temperature : 0~ 40°C
Storage Temperature: -40~ 70°C(with no battery)
-20~ 55°C(with battery)
Relative Humidity:5%
Cooling method : Fan cooling
Elevation:1500m
Maximum Tilt : 5 degrees
Pollution :Class II
The UPS should be installed in a cool place with good ventilation, low humidity and
free of dust. The recommended operating temperature is 20 – 25 degree C, and
the humidity should be controlled at 50% RH.
Note :
The UPS room should not be stored with flammable, corrosive or explosive
materials. It is not advisable to install the UPS in areas with conductive dust.
2.2 Unpacking
Unpack the UPS only at the installation site and check the equipment for
completeness and damage. Keep accessories for later use.
~95
%, no condensation
Unpacking method is illustrated on the carton. For reliable operation of the UPS,
the installation method should be based on the actual environment condition and
site design standard.
2.3 Dimensions
The dimensions of the UPS are listed in Table 2-1
13
Chapter 2 Cabinet Installation
Figure 2-1
4 fixing holes
4 screws for levelling feet
Figure 2-2
External Dimensions of 40/60kVA UPS are shown in Fig. 2-3 and its installation
position is shown in Fig. 2-4.
14
Chapter 2 Cabinet Installation
Figure 2-3 40/60kVA UPS Outline Dimension
4 fixing holes
4 screws for levelling feet
Figure 2-4 40/60kVA UPS Fixing Holes
15
2.4 Transportation
1. Hoisting the UPS
Prepare four cables of length 1.5 m and the weight bearing capacity of each cable
of 1.5 tons. The UPS has four lifting rings and should be installed at the top of the
UPS
2. Transportatio with Forklift
The UPS can be raised by forklift in four directions – front, back, left and right. But
the transportation distance should not exceed 10 m.
2.5 Positioning of UPS
The UPS cabinet exerts its weight on the floor through four castors. If the load
bearing capacity of the floor is inadequate, add auxiliary equipment to distribute
the weight over a larger area, such as a big iron sheet or increasing the number of
supporting castor wheels.
Chapter 2 Cabinet Installation
Note
As the UPS is cooled from the bottom, at least 10 cm space should be left at the
bottom of the UPS for ventilation
There are three kinds of positioning methods:
1. Non-Fixed position
Place the UPS directly on the flat ground . The ground should be made of Industrial
cement. Level the UPS by lowering and adjusting the leveling bolt at the base of
the UPS.
4 M20 screws for
levelling feet
16
Figure 2-5
Chapter 2 Cabinet Installation
2. Fixed position without a base
In earthquake prone areas, place UPS on a conduit as shown in Figure 2-6.
1. At the edge of the conduit, drill holes for fixing expansion bolts
2. Hoist the cabinet at least 250 mm to remove the four leveling bolts. Take off
the plastic cover of the installation holes on the beam.
3. Position the cabinet at the right position and align the holes on the beam and
the holes on the expansion bolts.
4. Insert the expansion bolts into the installation holes. Adjust the tilt of the
cabinet and screw the expansion bolts to fix the cabinet.
Front door
Steel of conduit
floor of machine
room
Expansive
bolts
Cabinet
Cables
Cement
floor
Figure 2-6 Install UPS on a Conduit
Conduit
Cement
floor
3. Fixed cabinet position on a base
If the UPS is place in a ESD proof floor, a support rack should be designed to
support the cabinet. The design of the rack is illustrated in Figure 2-4 and Figure 27 considering the load carrying capacity of the floor. Level the cabinet according to
section 2.5 – 1
17
2.6 Cable Access
Chapter 2 Cabinet Installation
Figure 2-7 Install the UPS on a support rack
1. Finished state 2. Concrete floor
3. Nut 4. Spring washer
5. Flat washer 6. Supporting frame
The UPS has various methods of cable access. One is bottom access where the
cables are routed in conduit from the bottom of the UPS. This is shown in Figure 2-
8.
Another is top access where the cables are routed on cable trays from the top and
into the UPS as shown in Figures 2-9.
Battery
cables
input N
Cabinet
Signal cables
UPS output
output N
Battery
cables
Rectifier
input
Cabinet
Bypass input
input N
Signal cables
UPS output
output N
Fig. 2-8 UPS input/output cables
18
2.7 Ventilation
Chapter 2 Cabinet Installation
Input cable
Battery cable
Output cable
Signal cable
Fig. 2-9 UPS top cable output
The cooling air comes into the UPS from the bottom and the fan circulates the cool
air inside the UPS. The air is expelled out of the UPS from the back.
Table 2-3 shows the relationship between the power consumed and air intake.
The rear clearance required by the UPS is 500 mm. The front clearance required is
1 m for the convenient of door opening and maintenance, shown in Figure 2-10.
Battery cabinet
UPS cabinet
bottom board
Fig. 2-10 Relative position of cabinet
19
2.8 Layout of Cabinet
Besides the UPS cabinet, there are also battery cabinets, input/output distribution
cabinet and cabinet for bypass transformer. All these cabinets should be laid out
correctly. The layout of battery cabinet and UPS cabinet is shown below.
1. One UPS cabinet and one battery cabinet
If the required battery backup time is 15 – 16 minutes, one battery cabinet is
required to hold all the required batteries. There is no strict requirement for the
relative position of the UPS and the battery cabinet. Figure 2-11 shows this kind of
layout.
Capacity expansion must be considered into layout design.
Chapter 2 Cabinet Installation
Battery cabinet
Fig. 2-11 Layout 1
UPS cabinet
2. One UPS cabinet and several battery cabinets
More than one UPS cabinet should be used if the required backup time is more
than 30 minutes. Please refer to Chapter 9 for the relationship between the battery
backup time and the battery capacity.
The battery cabinets should be placed side-by-side and the UPS cabinet can be
placed on the left or right side, in front of or behind the battery cabinets. Be sure to
leave space for maintenance.
20
Chapter 2 Cabinet Installation
Battery cabinet 1
Battery cabinet 2
Fig. 2-12 Layout 2
UPS cabinet
21
Chapter 3 Electrical Assembly
Chapter 3 Electrical Assembly
This chapter introduces the connection methods of the power and signal cables.
3.1 Selection of cables
3.1.1 Current carrying capacity of cables
The current carrying capacity can be selected according to the voltage drop and
permissible temperature increase.
Table 3-1 Current carrying capacity of cables
Cross sectional area(mm
carrying
capacity (A)
1 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240
2
) Current
Rubber
25°C
Rubber
35°C
21 27 35 45 58 85 110 145 180 230 285 345 400 470 540 660
Plastic
19 24 32 42 55 75 105 138 170 215 265 325 / / / /
20 25 33 42 54 80 103 136 168 215 267 323 374 439 505 617
Plastic
18 22 30 39 51 70 96 129 159 201 248 304 / / / /
3.1.2 Selection of power cables
The power cables include input power cables of main circuit and that of the bypass,
the UPS output cables, battery input cables, protective earth cables and the
lightning protection cables.
1. Calculation of current of power cables
The first calculation method is done according to the following formula:
If the power factor is 0.80, the efficiency is 0.9, the minimum input voltage is 176
volts, output line to neutral voltage is 220V, minimum battery voltage is 324 V,
bypass overload capability is 135% and that of the inverter is 125%,
2. Selection of cable cross sectional areas
2
Power cables are selected according to two factors - 3 – 5 A/mm
current density
and the maximum voltage drop be less than 3 W.
The cross-sectional areas of bypass input neutral cable and UPS output neutral
cable should be 1.5 times of the phase cable. The cross sectional area of the
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Chapter 3 Electrical Assemble
protective earth cable and lightning protection earth cable, should be 0.5 times of
phase cable.
The relationship between the current and cross-sectional area is shown in Table 3-
2.
Table3-2 Recommended cross sectional area of cables
20kVA 30kVA 40kVA 60kVA
Name
Battery 56 25 84 25 112 35 168 50
Bypass 37 16 56 16 74 25 112 35
Output 37 16 56 16 74 25 112 35
Input 44 16 66 16 88 25 132 35
Neutral line 25
Earth cable 16
Current
(A)
Cable
(mm
3.1.3 Selection of signal cables
Signal cables should use shielded multi-conductor cables. But if cable with single
conductor is used, the different cables should be bonded together to increase the
mechanical strength. The number of the bonded cables should not exceed 30. The
cross-sectional area of the cable with single conductor should be at least 0.5 sqmm. Serial communication cables should use 3 or 5 shielded conductor cables.
3.2 Cable connections
2
)
Current
(A)
Cable
(mm2)
25
16
Current
(A)
Cable
(mm2)
35
25
Current
(A)
Cable
(mm2)
50
25
3.2.1 Power cables
1. Cabling layout
Cabling layout is shown in Figures 3-1 and 3-2. For single input UPS, the rectifier
input and bypass input are connected together.
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