Mitsubishi Electronics 9800A User Manual
MITSUBISHI ELECTRIC AUTOMATION, INC
UNINTERRUPTIBLE POWER SUPPLY SYSTEM
9800A SERIES
OWNERS / TECHNICAL MANUAL
(For parallel operation possible model only.)
MITSUBISHI ELECTRIC 9800A SERIES UPS
Revision 2.01 Feb. 4, 04
ALN-H0776
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Preface
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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 OPERATION OVERVIEW ......................................................................... 1-5
1.4 SPECIFICATIONS .................................................................................... 1-12
2.0 OPERATION CONTROLS AND INDICATORS ........................................ 2-1
2.1 LED DISPLAY ........................................................................................... 2-2
ii
2.2 EPO BUTTON ........................................................................................... 2-2
2.3 LIQUID CRYSTAL DISPLAY ..................................................................... 2-3
2.4 EXTERNAL SIGNAL TERMINAL BLOCK ................................................. 2-8
2.5 EXTERNAL COMMUNICATION CONNECTOR ....................................... 2-12
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 ........................................... 3-2
3.4 OPERATING PROCEDURES ................................................................... 3-24
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 ................................................................... 1-12
Table 1.2 UPS Module Information.............................................................. 1-12
Table 1.3 Detail of Specifications ................................................................ 1-13
Table 1.4 Rating of Contactor and Fuses .................................................... 1-14
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 Maximum Permitted Fault Current............................................... 3-2
Table 3.4 Recommended Cable Sizes ........................................................ 3-5
Table 3.5 Crimp Type Compression Lug ..................................................... 3-6
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)............................................................. 1-10
Figure 1.6 External I/F circuit PCB IOAU-04 .......................................................... 1-10
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......................................................... 2-12
Figure 3.1 UPS Terminal Designation .................................................................... 3-6
Figure 3.2 Diagram of input/output bus bars and terminal blocks .......................... 3-7
Figure 3.3 Diagram of Rectifier Cabinet & Inverter Cabinet Inter-connect ............. 3-19
Figure 3.4 Diagram of Power and Control Wire Connect (Parallel Connection) ...... 3-21
Figure 3.5 Operation Procedures: Start Up/Shut Down Procedure.......................... 3-24
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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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1.0 INTRODUCTION
Your Mitsubishi Uninterruptible Power 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 9800A SERIES Uninterruptible Power
Supply Systems 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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WARNING 2
This UPS does not include a Bypass input circuit breaker (MCCB) to
protect bypass circuit. The Bypass input circuit breaker (MCCB) is to be
field supplied and installed. Recommended Breaker (MCCB)'s
Specifications are as follows:
Capacity (kVA) Bypass Voltage (Vac) Bypass Rating (Aac) Breaker (A)
100 480 120 150
600 96 125
150 480 180 225
600 144 200
225 480 271 350
600 217 275
300 480 361 500
600 289 400
375 480 451 600
600 361 500
500 480 601 800
600 481 600
750 480 902 1200
600 722 900
AC input and AC output overcurrent protection and disconnect devices shall be field
supplied and installed. The DC output MCCB shall be field supplied and installed. The
overcurrent protection device should be installed in the Battery cabinet and rated as
indicated in TABLE 1.4.
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1.1 GENERAL
The Mitsubishi 9800A 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 9800A SERIES UPS is available in seven kVA sizes-100, 150, 225, 300, 375, 500 and
750kVA. Specifications for each kVA model appear in Section 1.4. The principles of
operation described herein are applicable to all models.
This manual provides an overview of the 9800A 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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1.2 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 Rectifier, 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 Rectifier and Inverter assemblies which, under the direction of the
internal control system and operator controls, provide specified AC power to a load.
RECTIFIER - 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 Rectifier, 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.
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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.
A) Normal operation: Load power supplied by each system UPS inverter.
Figure 1.1 Single Line Diagram - Normal Operation: Load powered by UPS inverters
AC Bypass
In
AC input
CB
User supplied
MCCB
CB1
RECTIFIER
CB3
INVERTER
Static Transfer
Switch
52S
Output
52C
CB2
Power Flow
Not in Use
UPS ModuleBattery cabinet
During normal operation, the path through the UPS inverters is used to power the load.
Referring to Figure 1.1: For each system UPS, the Input AC power is converted to DC by
the Rectifier. 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 power drawn by the critical load is equally shared between all system UPS.
In the event of a UPS module failure, the critical load power will be continually supplied
and shared by all other system UPS.
In the event of a load overcurrent, all system UPS will transfer to bypass without
interruption to the critical load.
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The 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)
B) Bypass Operation: Load Power supplied through each system UPS internal static
bypass line.
FIGURE 1.2 Single Line Diagram - Bypass Operation: Load fed through Internal static
bypass line.
AC Bypass
In
AC input
CB
User supplied
MCCB
CB1
Static Transfer
Switch
CB3
RECTIFIER
INVERTER
CB2
52S
Output
52C
Power Flow
Not in Use
UPS Module Battery cabinet
Referring to Figure 1.2: The Internal Static Bypass line is a Hard wired line through CB3
and contactor 52S which supplies the critical load with unconditioned input power.
Each system UPS internal static bypass line will equally share the power supplied to the
critical load.
The internal static bypass line will route power to the critical load while the UPS module is
de-energized during Start-up and before the system is fully operational.
Bypass operation will occur In the event of a load overcurrent, with all system UPS
transferring to bypass without interruption to the critical load.
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) Battery operation: Load Power supplied by each system UPS battery and inverter.
FIGURE 1.3 Single Line Diagram - Battery Operation
1-7
AC Bypass
In
AC input
CB
User supplied
MCCB
CB1
Static Transfer
Switch
CB3
RECTIFIER INVERTER
CB2
52S
Output
52C
Power Flow
Not in Use
UPS Module Battery cabinet
Referring to Figure 1.3: In the event of AC input source failure or interruption, each
system UPS rectifier will de-energize and each UPS battery will immediately discharge
and supply DC 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 rectifier 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, each system UPS Rectifier
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 (100kVA, 150kVA, 225kVA)
Page Number:
1-8
AC capacitors
UPS module
FRONT VIEW
Inverter
Chopper
unit
DC
Rectifier unit
capacitors
1. CPM
52S
CB3
CB1
2. External I/F
circuit PCB
IOAU-04
52C
3. Grounding Bar
FIGURE 1.4-b UPS Parts Location (300kVA,375kVA)
3. Grounding
UPS module
FRONT VIEW
Bar
CB1
CB3
AC capacitors
Rectifier
unit
52S
52C
2. External I/F
circuit PCB
IOAU-04
1.CPM
Inverter
Chopper
unit
DC
capacitors
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FIGURE 1.4-c UPS Parts Location (500kVA)
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1-9
4. Grounding Bar
CB1
Rectifier
unit
AC capacitors
1.CPM
UPS module
FRONT VIEW
2. External I/F circuit PCB
IOAU-04
52S
AC capacitors
52C
CB3
Capacitors
DC
Inverter
Chopper
unit
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FIGURE 1.4-d UPS Parts Location (750kVA)
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1-10
5. Grounding Bar
52S
CB1
1.CPM
CB3
AC capacitors
UPS module
FRONT VIEW
3. External I/F circuit PCB
IOAU-04
AC capacitors
52C
Rectifier
unit
DC
Capacitors
Inverter
Chopper
unit
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FIGURE 1.5 UPS Parts Location (Continued)
UPS module
REAR OF FRONT DOOR (Right side)
6
INVERTER
START
|
SYNC.LED
INVERTER
STOP
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1-11
7
|
FIGURE 1.6 External I/F circuit PCB IOAU-04
|
FAULT
RESET
8
|
MAINTENANCE
SWITCH
9
|
TEST
SWITCH
10
4. External contact signal terminal
|
BOOT
SWITCH
11
IOAU-04
5. RS232C D-sub connector
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Description of Figures 1.4, 1.5, and 1.6:
1. CPM - Circuit protector for control power supply.
2. Switches on IFGR-G board : FOR SERVICE PERSONNEL ONLY (FIGURE 1.6):
- (4) External contact signal terminal
- (5) RS232C communication connector
3. Grounding bar (G)
4. 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 2.4 for
details.
5. RS232C communication connector - Refer to Figure 2.18 section 2.5 for details.
6. 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 +12%,-12% of nominal.
* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at
the time of asynchronous operation.
7. “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 +12%,-12% of nominal.
* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at
the time of asynchronous operation.
8. “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.)
9. Maintenance (Set) button (FOR SERVICE PERSONNEL ONLY) - This switch sets the
UPS menu parameters.
10. “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).
11. “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
100kVA / 80kW
150kVA / 120kW
225kVA / 180kW
300kVA / 270kW
375kVA / 338kW
500kVA / 450kW
750kVA / 675kW
Input voltage
3 phase / 3 wire
480V
480V
480V
480V
480V
480V
480V
Bypass input voltage
3 phase / 4 wire
480V or 600V
480V or 600V
480V or 600V
480V or 600V
480V or 600V
480V or 600V
480V or 600V
Output voltage
3 phase / 3 or 4 wire
480V or 600V
480V or 600V
480V or 600V
480V or 600V
480V or 600V
480V or 600V
480V or 600V
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]
100 BOTTOM 43.3 / 1100 29.8 / 758 79.7 / 2025 2100 / 950 22.0
150 BOTTOM 47.2 / 1200 29.8 / 758 79.7 / 2025 2820 / 1275 33.0
225 BOTTOM 55.1 / 1400 29.8 / 758 79.7 / 2025 3310 / 1500 45.0
300 TOP 76.8 / 1950 37.7 / 958 79.7 / 2025 4990 / 2260 68.0
375 TOP 76.8 / 1950 37.7 / 958 79.7 / 2025 5250 / 2380 84.0
500 TOP 114.2 / 2900 37.7 / 958 79.7 / 2025 6930 / 3140 98.0
750 TOP 129.9 / 3300 49.5 / 1258 79.7 / 2025 9655 / 4380 136.1
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TABLE 1.3 Detail of Specifications
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Rated Output kVA 100 150 225 300 375 500 750
Rated Output kW 80 120 180 270 338 450 675
AC INPUT
Configuration 3 phase, 3 wire
Voltage 277/480 V, 346/600 V +15% to -15%
Frequency 60 Hz +/-5%
Reflected Current THD 6% max. at 100% load; 9% max. at 50% load
STATIC BYPASS INPUT
Configuration 3 phase, 4 wire
Voltage 277/480 V, 346/600 V +/-10%
Frequency 60 Hz
BATTERY
Type Lead Acid
Ride Through Application Specific
Nominal Voltage 480 Vdc
Minimum Voltage 400 Vdc
Number of Cells 240
AC OUTPUT
Configuration 3 phase, 4 wire
Voltage 277/480 V, 346/600 V
Voltage Stability
+/-1%
Frequency 60 Hz
Frequency Stability
+/-0.05% in free running mode
Power Factor 0.8 nominal 0.9 nominal
Power Factor range 0.8 to 1.0 lagging (within output kW rating)
Voltage THD 2% maximum THD at 100% Linear Load
5% maximum THD at 100% non-linear load
Transient Response
+/-2% maximum at 100% load step
+/-1% maximum at loss/return of AC power
+/-5% maximum at load transfer to/from static bypass
Transient Recovery Less than 20ms
Voltage Unbalance 1% maximum at 100% unbalanced load
Phase Displacement 1deg. maximum at 100% load
Inverter Overload 125% for 10 minutes; 150% for 1 minute
System Overload 1000% for 1 cycle
(with bypass available)
500% for 1 cycle
(with bypass available)
Bypass Overload 125% for 10 minutes
Withstand Rating 65kA* * : with optional fuse
ENVIRONMENTAL
Cooling Forced Air
Operating Temperature
32ﾟF to 104ﾟF ( 0ﾟC to 40ﾟC).
Recommended : 68ﾟF to 86ﾟF ( 20ﾟC to 30ﾟC)
Relative Humidity 5% ~ 95% Non Condensing
Altitude 0 to 9000 feet No Derating
Location Indoor (free from corrosive gases and dust)
Paint Color Munsell 5Y7/1 (Beige)
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TABLE 1.4 Rating of Contactors and Fuses
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NUMBER APPLICATION
100kVA 150kVA 225kVA 300kVA 375kVA 500kVA 750kVA
480V 600V 480V 600V 480V 600V 480V 600V 480V 600V 480V 600V 480V 600V
F
U
S
E
S
CB1 AC input contactor 135A 200A 350A 450A 660A 660A 910A
CB2 Battery disconnect
breaker
CB3 STS contactor 135A 260A
52C Inverter output
contactor
52S Bypass contactor 135A 200A 350A 450A 450A 660A 910A
88RC Control circuit contactor 90A
FCU, FCV, FCW AC input fuse 200A/660V 250A/660V 315A/660V
FIU, FIV, Inverter output fuse 250A/660V 200A/660V 315A/660V 315A/660V 315A/660V 315A/660V 315A/660V
FUA, FUB, FUC Control power fuse 30A/600V
(OPTION)
FSU, FSV, FSW
FZS1, 2, 3 Bypass input ZNR fuse 16A/500V
FBS1, 2, 3 Control power fuse 10A/600V
FZR1, 2, 3 AC input ZNR fuse 16A/500V
FPU, FPV, FPW Parallel control
Bypass input fuse 200A/
circuit fuse
400A 600A 800A 1200A 1600A (MEAU) (MEAU)
135A 200A 350A 450A 450A 660A 910A
660V
- 315A/
660V
- 250A/
OUTPUT CAPACITY OF EQUIPMENT
660V
- 250A/
660V
10A/600V
- 315A/
660V
- 315A/
660V
*Rating would be changed.
315A/
660V
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