Mitsubishi 2033D User Manual

MITSUBISHI ELECTRIC AUTOMATION, INC.

UNINTERRUPTIBLE POWER SUPPLY SYSTEM

2033D SERIES

OWNERS / TECHNICAL MANUAL

Revision 1.3: December 18, 2003

MITSUBISHI ELECTRIC 2033D SERIES UPS

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2033D SERIES UPS

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Preface

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2033D SERIES UPS

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TABLE OF CONTENTS

LIST OF TABLES ............................................................................................... iii

LIST OF FIGURES ............................................................................................ iv

HOW TO USE THIS MANUAL ........................................................................... v

1.0 INTRODUCTION ....................................................................................... 1-1

1.1 GENERAL ................................................................................................. 1-3

1.2 DEFINITIONS ............................................................................................ 1-4

1.3 OVERVIEW ............................................................................................... 1-5

1.4 SPECIFICATIONS .................................................................................... 1-11

2.0 OPERATOR CONTROLS AND INDICATORS ......................................... 2-1

2.1 LED DISPLAY ........................................................................................... 2-2

2.2 MBP LAMP....................................................................................................2-2

2.3 EPO BUTTON ........................................................................................... 2-2

2.4 LIQUID CRYSTAL DISPLAY ..................................................................... 2-3

2.5 EXTERNAL SIGNAL TERMINAL BLOCK ................................................. 2-8

2.6 EXTERNAL COMMUNCATION CONNECTOR .......................................... 2-13

3.0 INSTALLATION AND OPERATION ......................................................... 3-1

3.1 TRANSPORTATION AND INSTALLATION .............................................. 3-1

3.2 INSTALLATION PROCEDURE ................................................................. 3-1

3.3 PROCEDURE FOR CABLE CONNECTIONS ........................................... 3-3

3.4 OPERATING PROCEDURES ................................................................... 3-12

3.5 MAINTENANCE BYPASS SET-UP PROCEDURES ....................................3-13

4.0 RESPONSE TO UPS FAILURE ................................................................ 4-1

5.0 PARTS REPLACEMENT .......................................................................... 5-1

6.0 FAULT CODES ......................................................................................... 6-1

7.0 WARRANTY & OUT OF WARRANTY SERVICE ..................................... 7-1

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List of Tables

Table 1.1 Power Specifications ................................................................... 1-11

Table 1.2 UPS Module Information.............................................................. 1-11

Table 1.3 Detail of Specifications ................................................................ 1-12

Table 1.4 Rating of Contactor and Fuses .................................................... 1-13

Table 3.1 How to Transport and Install the System..................................... 3-1

Table 3.2 List of UPS Weights (lb.).............................................................. 3-1

Table 3.3 Type and number of Battery ........................................................ 3-2

Table 3.4 Maximum Permitted Fault Current............................................... 3-3

Table 3.5 Recommended Cable Size and Torque Requirements ............... 3-5

Table 3.6 Crimp Type Compression Lug ..................................................... 3-6

Table 6.1 Fault Code ................................................................................... 6-2

iii

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List of Figures

Figure 1.1 Single Line Diagram-Normal Operation .................................................... 1-5

Figure 1.2 Single Line Diagram-Bypass Operation.................................................... 1-6

Figure 1.3 Single Line Diagram-Battery Operation .................................................... 1-7

Figure 1.4 UPS Parts Location .................................................................................. 1-8

Figure 1.5 UPS Parts Location (Continued)............................................................... 1-9

Figure 1.6 External I/F circuit PCB IOAU-05.............................................................. 1-9

Figure 2.1 Operation/Display Panel ........................................................................... 2-1

Figure 2.2 Main Screen ............................................................................................. 2-3

Figure 2.3 Start/Stop Screen ..................................................................................... 2-4

Figure 2.4 PIN Protection Screen .............................................................................. 2-4

Figure 2.5 Bypass Voltage Abnormal Message Screen............................................. 2-4

Figure 2.6 Measurement Screen ............................................................................... 2-4

Figure 2.7 Setup Screen............................................................................................ 2-5

Figure 2.8 Log Select Screen .................................................................................... 2-5

Figure 2.9 Event Log Screen ..................................................................................... 2-5

Figure 2.10 Battery Log Screen ................................................................................. 2-6

Figure 2.11 Main Screen (Battery Operation) ............................................................ 2-6

Figure 2.12 Measurement Screen (Battery Operation) ................................................ 2-6

Figure 2.13 Main Screen (Fault Indication) ................................................................ 2-7

Figure 2.14 Message Screen ..................................................................................... 2-7

Figure 2.15 External Signal Terminal Block................................................................. 2-8

Figure 2.16 Control Wiring for External Contacts ........................................................ 2-10

Figure 2.17 Remote "Start" Contact Connections........................................................ 2-11

Figure 2.18 External communication connector........................................................... 2-13

Figure 3.1 UPS Terminal Designation ...................................................................... 3-7

Figure 3.2 Diagram of input/output bus bars and terminal blocks ............................ 3-8

Figure 3.3 Diagram of Power Wire Connect (Parallel Connection) .......................... 3-10

Figure 3.4 Diagram of Power Wire & Control Wire Connect (Parallel Connection ) . 3-11

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How to use this Manual

This manual is designed for ease of use, giving the user easy and quick reference to

information.

This manual uses notice icons to draw attention to the user important information regarding the

safe operation and installation of the UPS. The notice icons used in this manual are explained

below, and should be taken into account and adhered to whenever they appear in the text of

this manual.

Warning: A warning notice icon conveys information provided to protect

the user and service personnel against hazards and/or possible equipment

damage.

Caution: A caution notice icon conveys information provided to protect

the user and service personnel against possible equipment damage.

Note: A Note notice icon indicates when the user should make a reference of

information regarding the UPS operation, load status and display status.

Such information is essential if Mitsubishi field service group assistance and

correspondence is required.

Safety Recommendations: If any problems are encountered while following this manual,

Mitsubishi field service group assistance and correspondence is recommended.

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1-1

1.0 INTRODUCTION

Your Mitsubishi Uninterruptible Power Supply System (UPS) is designed to provide many

years of reliable protection from power failure, brown-outs, line noise, and voltage transients.

To ensure optimum performance of the equipment, follow the manufacturer's instructions. This

manual contains descriptions required to operate the UPS. Please read this manual carefully

and retain it for future reference.

IMPORTANT SAFETY INSTRUCTIONS

RETAIN THESE INSTRUCTIONS

This manual contains important instructions for the 2033D Series Uninterruptible Power Supply

System that should be followed during installation and maintenance of the UPS and batteries.

WARNING 1

Lethal voltages exist within the equipment during operation. Observe all

warning and cautions in this manual. Failure to comply may result in

serious injury or death. Obtain qualified service for this equipment as

instructed.

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1-2

WARNING 2

This UPS does not include a Bypass input circuit breaker (MCCB) to protect bypass

circuit. Bypass input circuit breaker (MCCB) are to be field supplied and installed.

Recommended Breaker (MCCB)'s Specifications are as follows:

Recommended

Capacity (kVA) Bypass Voltage (Vac) Bypass Rating (Aac)

Breaker (Aac)

30 480 36 45

50 480 60 80

80 480 96 125

AC input and AC output over current protection and disconnect devices shall be field

supplied and installed. DC output over current protection and disconnect device shall

be field supplied and installed. The over current protection device shall be rated as

indicated in TABLE 1.4.

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1-3

1.1 GENERAL

The Mitsubishi 2033D Series UPS is designed to provide continuous and clean electrical

power to a critical load. Additionally the UPS monitors power conditions affecting the load.

In the event of an input power failure, the UPS will supply power to the critical load for the

specified battery time.

If the input power is not restored promptly, back up power from the UPS battery permits

the orderly shutdown of equipment supported by the UPS. The UPS is simple to start-up,

operate and maintain.

The 2033D Series UPS is available in three (3) kVA sizes-30, 50 and 80kVA, and also in

two (2) output voltages - 208V and 480V. Specifications for each kVA and voltage model

appear in Section 1.4. 30kVA model have batteries included in the UPS module cabinet.

50 and 80kVA models have external batteries. The principles of operation described herein

are applicable to all models.

This manual provides an overview of the 2033D Series components and their functions.

The appearance and purpose of operator controls and indicators is described with

procedures for operation, start-up, shutdown and basic maintenance included.

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1-4

1.2 Definitions

UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS

Module Cabinet and associated batteries that function as a system to provide continuous,

conditioned AC power to a load. This is sometimes referred to as the "System".

UPS MODULE CABINET - The metal enclosure which contains the Converter, the Inverter,

the Chopper, the Static Transfer Switch, the Internal Bypass line, the operator controls,

and the internal control system required to provide specified AC power to a load.

UPS MODULE - The Converter and Inverter assemblies which, under the direction of the

internal control system and operator controls, provide specified AC power to a load.

CONVERTER/BOOSTER - The UPS components which contain the equipment and

controls necessary to convert input AC power to regulated DC power required for battery

charging and for supplying power to the Inverter.

INVERTER - The UPS components which contain the equipment and controls necessary

to convert DC power from the Converter, or the battery, to AC power required by the

critical load.

CHOPPER - The UPS components which contain the equipment and controls necessary

to charge the battery and supply power to the Inverter from battery.

STATIC TRANSFER SWITCH - The device which connects the critical load to the bypass

line when the UPS module cannot supply continuous power.

BYPASS LINE - The line which conducts electricity directly from the input power source to the

critical load during Maintenance or whenever the UPS is not completely operational.

INPUT POWER - Power provided by the electrical utility company, or auxiliary generator,

which is connected to the UPS for supplying the critical load.

BATTERY - The rechargeable battery strings which supply DC power to the inverter to

maintain continuous AC power to the load during AC input power failure conditions

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1.3 Overview

The UPS provides two power paths between the utility source and the critical load.

Figure 1.1 shows the path for normal operation, with the load powered from the inverter.

Figure 1.2 shows the path for bypass operation, with the load supplied through the static

bypass line.

Figure 1.3 shows the path for battery operation, with the load supplied from the inverter.

A) Normal Operation.

FIGURE 1.1 Single Line Diagram - Normal Operation. Load powered by inverter

User su

lied

52RC

52RS

CONVERTER

Static Transfer

Switch

INVERTER

52C

52CS

AC Bypass

AC input

BATTERY

72B

50kVA, 80kVA: External Battery

Power Flow

Not in Use

UPS Module

Maintenance Bypass Switch

Output

During normal operation, the path through the inverter is used to power the load.

Referring to Figure 1.1: Input AC power is converted to DC by the Converter. DC power is

utilized to charge the UPS battery and to provide power to the Inverter. The Inverter

converts the DC power to clean AC power to supply the critical load.

The conversion - inversion process eliminates any voltage transients or fluctuations

existing in the input power before it reaches the critical load.

* The AC Bypass Input circuit breaker (MCCB) for protection of the UPS and cables are field

supplied and field installed. (See WARNING 2 on page 1-2)

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B) Internal Static Bypass Line

FIGURE 1.2 Single Line Diagram- Bypass Operation. Load fed through static bypass line.

AC Bypass

Static Transfer

Switch

52RS

AC input

User su

lied

52RC

CONVERTER

INVERTER

72B

52C

BATTERY

50kVA, 80kVA: External Battery

Maintenance Bypass Switch

Output

52CS

Power Flow

Not in Use

UPS Module

Referring to Figure 1.2, the Internal Static Bypass line is a Hard wired line through Static

Transfer Switch which supplies the critical load with unconditioned input power. The

purpose of this line is to route power to the critical load while the UPS module is

de-energized during Start-up before the system is fully operational.

The internal control system determines the operation of the two paths, with the load

powered from the inverter being the normal operation.

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C) Inverter supply at battery operation

FIGURE 1.3 Single Line Diagram - Battery Operation

User su

lied

52RC

52RS

CONVERTER

Static Transfer

Switch

INVERTER

52C

AC Bypass

AC input

BATTERY

72B

50kVA, 80kVA: External Battery

Referring to Figure 1.3: In the event of AC input source failure or interruption, the

converter will de-energize and the battery will immediately discharge and supply DC

Maintenance Bypass Switch

Output

52CS

Power Flow

Not in Use

UPS Module

power to the inverter to maintain continuous AC power to the load. This operation will

continue until:

a) The battery capacity expires and the inverter turns off, or

b) Input power is restored after which the converter will power the inverter and critical

load and simultaneously recharge the batteries.

A fully charged battery will provide power for the specified time at the rated load, or longer,

at a reduced load.

When power is restored after a low battery shutdown, the converter automatically restarts

operation, recharges the batteries and the Inverter is automatically restarted without

operator intervention. Load is automatically assumed by the inverter without operator

intervention.

The power drawn by the load is equally shared between all system UPS during battery

operation.

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FIGURE 1.4-a UPS Parts Location (30kVA)

UPS module

FRONT VIEW

Converter Unit

Chopper Unit

52RS

52RC

72B

1. External I/F Circuit PCB IOAU-05

Parallel I/F PCB

GND GND ELEC

TERM

FIGURE 1.4-b UPS Parts Location (50kVA, 80kVA)

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1-8

Inverter unit

DC Capacitor

52CS

52C

2. Grounding Bar

Converter Chopper Unit

52RS

52RC

1. External I/F Circuit PCB IOAU-05

UPS module

FRONT VIEW

GND

Inverter unit

52C

52CS

72B

Parallel I/F PCB

2. Grounding Bar

GND ELEC TERM

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FIGURE 1.5 UPS Parts Location (Continued)

UPS module

BACKSIDE OF FRONT DOOR(Right side)

INVERTER

START

Page Number:

SYNC.LED

INVERTER

STOP

1-9

FIGURE 1.6 External I/F PCB IOAU-05

4. RS232C D-sub Connector

| FAULT RESET

MAINTENANCE

BUTTON

TEST

SWITCH

3. External Contact Signal Terminal

IOAU-05

BOOT

SWITCH

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Description of Figures 1.4, 1.5, and 1.6:

1. External I/F Board (IOAU-05) : FOR SERVICE PERSONNEL ONLY (FIGURE 1.6):

- (3) External contact signal terminal

- (4) RS232C communication connector

2. Grounding Bar (E)

3. External Contact Signal Terminal Block - Terminal block to connect contact signal

input/output lines to and from the external devices. Refer to Figure 2.15 section 2.5 for

details.

4. RS232C Communication Connector - Refer to Figure 2.18 section 2.6 for details.

5. “INVERTER” START Switch - This switch is used to transfer the UPS from static bypass

to inverter during maintenance purposes. Transfers will lock-out if the bypass voltage is

more than +10%,-10% of nominal.

* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at

the time of asynchronous operation.

6. “INVERTER STOP” Switch - This switch is used to transfer the UPS from inverter to static

bypass during maintenance purposes. Do not operate it under normal operation. Transfers

will lock-out if the bypass voltage is more than +10%,-10% of nominal.

* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at

the time of asynchronous operation.

7. “FAULT RESET” Switch (FOR SERVICE PERSONNEL ONLY) - This switch resets

errors resulting from alarm conditions. (Do not operate this switch while inverter and

converter are in operation.)

8. Maintenance (Set) Button (FOR SERVICE PERSONNEL ONLY) - This switch sets the

UPS menu parameters.

9. “Test mode” Switch (FOR SERVICE PERSONNEL ONLY) - This switch changes system

operation to the test-mode. (This switch should not be operated by personnel other than

an Authorized Service Engineer).

10. “BOOT” Switch (FOR SERVICE PERSONNEL ONLY) - This switch boots the processor

in the main control circuit resulting from alarm conditions. (Do not operate this switch

while inverter and converter are in operation).

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1.4 Specifications

The UPS name plate displays the rated kVA as well as nominal voltages and currents. The

name plate is located on the inside of the UPS front door.

TABLE 1.1 Power Specifications

Rated output

Power

30kVA / 24kW

50kVA / 40kW

80kVA / 64kW

Input voltage

3 phase / 3 wire

480V

Bypass input voltage

3 phase / 3 wire

480V

Output voltage

3 phase / 3 or 4 wire

208V or 480V

TABLE 1.2 UPS Module Information

UPS

[kVA]

CABLE

ENTRY

WIDTH

[in / mm]

DEPTH

[in / mm]

HEIGHT

[in / mm]

WEIGHT

[lb./ kg]

HEATING

[kBTU/h]

30 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 2060 / 930 9.1

50 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 1810 / 820 13.5

80 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 1990 / 900 21.6

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