OnLine Power Constant Power 3 User Manual

Technical
Publications

Constant Power 6
Constant Power 3
Mini-Power

Document #: 6002-034
Revision C

Operating Documentation

OnLine Power

Congratulations on selecting one of the fine products from OnLine Power, the Leader in Power
Protection Technology. Our wide product offering includes Uninterruptible Power Systems (UPS),
Power Conditioners, Automatic Voltage Regulators and Specialty Transformers (e.g. computer-grade,
medical-grade). Since our beginnings in 1975, OnLine Power has shipped thousands of these fine
products around the world, to discerning customers, for use on sensitive equipment and critical
applications. Our customers, both new and long-time, continue to enjoy security and peace of mind as
they realize what it means to ”Stay On Line with OnLine Power”.

One of our goals is to make these manuals both comprehensive and easy to use. This new-format
Manual is the result of ideas and inputs from customers who have taken an active interest in our
continued success. We invite constructive feedback on our products and documentation via fax, mail
or telephone.

HEADQUARTERS FACTORY

OnLine Power, Inc OnLine Power, Inc.
5701 Smithway Street 5940 Triumph Street
Commerce, CA 90040 Commerce, CA 90040

SALES MANUFACTURING

Phone [phone] Phone [phone]
Inside CA [phone] Fax [phone]
FAX No. [phone]

http://www.onlinepower.com

email: [e-mail]

SERVICE

Phone [phone]
FAX No. [phone]

6002-034 REV. C a

OnLine Power

OnLine Power, Inc.

Proprietary Reproduction or Distribution forbidden

NOTICE: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION

This document contains proprietary and confidential information of
OnLine Power, Inc. (”OnLine Power”). In consideration of the receipt of
this document, the recipient agrees not to copy any of its contents, nor
disclose or allow them to be used by any person not currently an OnLine
Power employee or an employee of the recipient having a need to know,
without the express written consent of OnLine Power, and further agrees
to surrender this document to OnLine Power when the reason for its
receipt has terminated.

6002-034 REV. C b

OnLine Power

CAUTION

SAFETY

Safety precautions are important when operating or servicing electrical equipment. The following
symbols are used extensively throughout this manual. Always heed these precautions since they are
essential to the safe operation and servicing of this product.

DANGER!

THIS DANGER SYMBOL IDENTIFIES A CONDITION OR ACTION WHICH WILL RESULT IN
SEVER INJURY OR DEATH TO AN INDIVIDUAL OR SEVERE DAMAGE TO EQUIPMENT OR
OTHER PROPERTY.

This Caution symbol identifies a condition or action which may result in minor injury to an
individual or minor damage to the equipment or other property.

This unit was designed for specific applications. It should not be modified and/or used for any
application other than for that which it was designed. Optional equipment not described in the sales
literature or this manual should not be installed without first checking with the Service department. If
you have any questions about this unit’s application call the Service department at the number shown on the

previous page.

SAVE THESE INSTRUCTIONS

This technical manual contains important instructions for each model that
should be followed during installation and maintenance of the UPS.

6002-034 REV. C c

OnLine Power

TABLE OF CONTENTS

SECTION PAGE
SECTION 1 - OPERATION 1-1

1-1 INTRODUCTION 1-1

1-1-1 Constant Power 6 1-2

1-1-2 Constant Power 3 and Mini-Power 1-3
1-2 BENEFITS 1-4
1-3 TRANSFORMER 1-4
1-4 PRODUCT FEATURES 1-4

1-4-1 Bypass Switch 1-8

1-4-2 Main INput Circuit Breaker (IMCB) 1-8

1-4-3 Power ON Indicator 1-8

1-4-4 Input Power Cord 1-8

1-4-5 Output Filter 1-9
1-5 REGULATOR COMPONENTS 1-10
1-6 STARTING THE UNIT 1-11
1-7 OPERATION 1-12

1-7-1 Normal Condition 1-12

1-7-2 Non-Regulating Condition 1-12

SECTION 2 - PREINSTALLATION 2-1

2-1 LOCATION CONSIDERATIONS 2-1

SECTION 3 - INSTALLATION 3-1

3-1 INSTALLATION 3-1

3-4-1 Unpacking Constant Power 6 3-1

3-4-2 Unpacking Constant Power 3 and Mini-Power 3-2

3-4-3 Inspection 3-2

3-4-4 Input power connection for Constant Power 6 3-3

3-4-5 Input power connections for Constant Power 3 or Mini-Power 3-4

3-4-6 Output power connection for Constant Power 6 3-4

3-4-7 Ouptut power connections for Constant Power 3 3-5

3-4-8 Output power receptacles for Mini-Power 3-5

3-4-9 Constant Power 6 with 208-220 or 240 volt input 3-5

3-4-10 Start-up for the Constant Power 6, Constant Power 3, and Mini-Power 3-6
3-2 CONFIGURATION 3-6
3-3 RENEWAL PARTS 3-7

3-4-1 Renewal Parts (Constant Power 6) 3-7

3-4-2 Vendor Parts List, Constant Power 6 3-8

3-4-3 Renewal Parts (Constant Power 3 and Mini-Power) 3-9

3-4-4 Vendor Parts List, Constant Power 3 and Mini-Power 3-9
3-4 SERVICE 3-10

3-4-1 Calibrate Control Logic Board (Constant Power 6) 3-10

3-4-2 Calibrate Control Logic Board 3-10

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OnLine Power

SECTION PAGE
SECTION 4 - OPTIONS 4-1

4-1 CONSTANT POWER 6 OPTIONS 4-1

4-1-1 Output Circuit Breakers and Receptacles 4-1

4-1-2 Remote Emergency Power OFF 4-2

4-1-3 Thermo Remote Emergency Power OFF 4-3

4-1-4 Manual Restart 4-3

4-1-5 Hardware 4-5

APPENDIX A - SPECIFICATIONS A-1
GLOSSARY G-1

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OnLine Power

LIST OF ILLUSTRATIONS

ILLUSTRATION PAGE

1-1 REGULATED SYSTEM RESPONSE 1-1
1-2 CONSTANT POWER 6 1-2
1-3 CONSTANT POWER 3 1-3
1-4 MINI-POWER 1-3
1-5 CONSTANT POWER 6 COMPONENT LAYOUT 1-5
1-6 CONSTANT POWER 3 COMPONENT LAYOUT 1-6
1-7 MINI-POWER COMPONENT LAYOUT 1-7
1-8 CONSTANT POWER 6 OUTPUT FILTER 1-9
1-9 CONSTANT POWER 6 OUTPUT FILTER 1-9
1-10 CONSTANT POWER 6 FUNCTIONAL BLOCK DIAGRAM 1-10
1-11 CONSTANT POWER 3 FUNCTIONAL BLOCK DIAGRAM 1-11

3-1 200 VAC INPUT REFERENCE TRANSFORMER 3-6
3-2 CONSTANT POWER 6 PARTS LIST 3-7
3-3 CONSTANT POWER 3 AND MINI-POWER PARTS LIST 3-9
3-4 SCR DRIVER BOARD 3-11
3-5 CONTROL LOGIC BOARD 3-12

4-1 REMOTE EMERGENCY POWER OFF (REPO) STATION 4-2
4-2 REMOTE EMERGENCY POWER OFF (REPO) STATION SCHEMATIC DIAGRAM 4-2
4-3 THERMO REPO STATION SCHEMATIC DIAGRAM 4-3
4-4 MANUAL RESTART (CP6) 4-4

LIST OF TABLES

TABLE PAGE

1-1 PRODUCT FEATURES 1-4
1-2 INPUT CONFIGURATIONS 1-8

2-1 CONSTANT POWER 6 SITE PLANNING SPECIFICATIONS 2-1
2-2 MINI-POWER AND CONSTANT POWER 3 SITE PLANNING SPECIFICATIONS 2-2

3-1 BYPASS SWITCH AND CURRENT TRANSFORMER PARTS LIST 3-8
4-1 OPTIONAL OUTPUT RECEPTACLE CHART 4-1

6002-034 REV. C f

OnLine Power

SAG

CORRECTED

IN 1 CYCLE

SURGE

CORRECTED

IN 1 CYCLE

CONSTANT POWER 6:
REGULATED TO +/- 3% OF NOMINAL TYPICAL
CONSTANT POWER 3 AND MINI-POWER:
REGULATED TO +/- 5% OF NOMINAL TYPICAL

SAG

SURGE

120

-120

0

120

-120

0

INPUT

OUTPUT

SECTION 1 - OPERATION

1-1 INTRODUCTION

This manual provides installation, operating and maintenance information for the Constant Power 6, the Constant
Power 3, and the Mini-Power voltage regulator units. A detailed description of each product is provided in the
following subsections.

All components used are of the highest quality and specifically selected to achieve the highest level of
performance. These units are UL listed and conform to the National Electric Code (NEC) and Occupational
Safety and Health Act (OSHA) standards.

The Constant Power 6, Constant Power 3 and the Mini-Power are tapped electronic voltage regulators. The
Constant Power 6 has six taps on the primary winding of the transformer. The Constant Power 3 and Mini-Power
have three taps on the primary winding of the transformer. Each tap is controlled by a silicon controlled rectifier
(SCR) switch can become active at any time. Input line-to-line voltage and line current are monitored. Peak
voltage is compared with a desired reference. Depending on this comparison, the regulation logic activates the
proper SCR switch when the phase current becomes zero. This changes the primary-to-secondary turns ratio
which corrects the output voltage to the desired nominal. The correction process starts in less than one cycle.
See Illustration 1-1.

6002-034 REV. C 1-1

REGULATED SYSTEM RESPONSE

ILLUSTRATION 1-1

OnLine Power

1-1-1 Constant Power 6

The Constant Power 6 is designed to provide the reliable, high-quality power necessary to suit the needs of
today’s sensitive electronics.

The single-phase, 60 hertz, self contained modular unit provides isolation and regulation of AC power. The zero
current tap switching voltage regulation circuitry automatically adjusts for an input voltage range between +10%
surge and -26% sag about the nominal rated voltage with an output voltage range of +/-3% typical to +/-4%
maximum.

The Constant Power 6 is available with input voltages of 120, or 208/220/240, or 480 VAC and output voltages of
120 or 120/240 VAC. These units are available in sizes ranging from 3 kVA to 15 kVA. The specific rating
information for your unit is provided on the label plate located on the rear panel at the bottom center.

The Constant Power 6 is shown in Illustration 1-2.

6002-034 REV. C 1-2

CONSTANT POWER 6

ILLUSTRATION 1-2

OnLine Power

1-1-2 Constant Power 3 and Mini-Power

The computer-grade Constant Power 3 power conditioner is designed to provide the reliable, high-quality power
necessary to suit the needs of today’s sensitive computer systems.

The single phase, 60 hertz, self-contained modular unit provides isolation and regulation of AC power. The zero­current tap switching voltage regulation circuitry automatically adjusts for an input voltage range between +7%
surge and -23% sag about the nominal rated voltage with an output voltage range of +/-5% typical to +/-6%
maximum.

The Constant Power 3 and Mini-Power is available in input voltages of 120, 208, or 240 VAC and output voltages
of 120 or 120/240 VAC. The Constant Power 3 is available in sizes ranging 1 to 3 kVA. The Mini-Power is
available in sizes 1, 1.5, and 2 kVA. The specific rating for the unit is provided on the label plate located on the
rear panel of the regulator.

The Constant Power 3 is shown in Illustration 1-3. The Mini-Power is shown in Illustration 1-4.

6002-034 REV. C 1-3

CONSTANT POWER 3

ILLUSTRATION 1-3

MINI-POWER

ILLUSTRATION 1-4

OnLine Power

OPTIONS

CP6

CP3

MINI-

POWER

BYPASS SWITCH

S S S

MAIN INPUT CIRCUIT BREAKER

S S S

POWER ON INDICATORS

S S S

OUTPUT FILTER

S S S

INPUT POWER CORD (6 FEET)

S S S

CASTERS

S

N/A

N/A

K-FACTOR RATING

O O O

LOCKING INPUT PLUG

O O O

MATCHING INPUT RECEPTACLE

O O N/A

SPECIAL PAINT

O O O

REMOTE EMERGENCY POWER OFF STATION

WITH 50 FEET CABLE

O

N/A

N/A

THERMO REMOTE EMERGENCY POWER OFF

STATION WITH 50 FEET CABLE

O

N/A

N/A

MANUAL RESTART SHUNT-TRIP MAIN OUTPUT

CIRCUIT BREAKER WITH REPO PLUG

O

N/A

N/A

SHUNT-TRIP MAIN INPUT CIRCUIT BREAKER

WITH REPO PLUG

O

N/A

N/A

1-2 BENEFITS

The Constant Power 6, Constant Power 3, and Mini-Power voltage regulators protect electronic equipment from
over voltage conditions during line power surges and undervoltage conditions during sags. In addition, the units
protect equipment loads by attenuating transients present on utility power lines. Over voltage, overcurrent, and
transient conditions stress electronic components and decrease system reliability.

1-3 TRANSFORMER

The transformer contained in the unit is designed for convection cooling by means of free circulation of air through
the bottom, and sides of the unit. Maximum ambient temperatures should not exceed 104F (40C).

1-4 PRODUCT FEATURES

Sections 1-4 and 1-5 describe the features of the Constant Power 6, Constant Power 3, and Mini-Power. Some
features described in Section 1-4 are standard on all models while other features are offered as options. Refer to
Table 1-1 to determine if the features described in this section are applicable to your unit. Refer to Section 5.
Options for information on optional features.

TABLE 1-1

PRODUCT FEATURES

TABLE KEY: S = Standard equipment, O = Available as an option, N/A = Not available for this model.

6002-034 REV. C 1-4

OnLine Power

C
I
R
C
U
I
T

1

C
I
R
C
U
I
T

2

C
I
R
C
U
I
T

3

C
I
R
C
U
I
T

4

C
I
R
C
U
I
T

5

C
I
R
C
U
I
T

6

EQUIPM ENT
GROUND

REPO

INPUT
POWER

OPTIONAL OUTPUT
RECEPTACLES (5 pl's)

STANDARD OUTPUT
CIRCUIT BREAKER

INPUT POW ER CORD

REMOTE EMERGENCY
POWER OFF INTERFACE
CONNECTOR (O PTIONAL)

EXT ERNAL CHASSIS
EQUIPMENT GRO UND

STANDARD OUTPUT
RECEPTACLE (5-20R2)

OPTIONAL OUTPUT
CIRCUIT BREAKER (5 pl's)

MAIN I NPUT

BREAKER

PWR ON

OPERATING

RANGE

INDICATORS

SERVI CE
REQUIRED

AUTO

MAN

BYPASS

SWITCH

MAIN INPUT

BREAKER

POWER ON

INDICATOR

VOLTAG E RANGE

INDICATORS

1 9.5 "

2 5.5 "

1 4.5 "

MAIN INP UT

BRE AKER

PW R ON

SE RVICE
REQUIR ED

AUTO

MAN

BYP ASS S W ITC H

OUTPUT FILTERS

MAIN POWER
TRANSFO RMER

OUTPUT
TERMINAL BLOCKS

REFERENCE
TRANSFO RMER

REGULATION
CONTROL
LOG IC BOARD

(1) HEATSINK
(6) SCR
(6) SCR SNUBBER BOARD

SCR DRIVER
BOARD

EQUIPMENT GRO UND/
NEUTRAL BUS

INPUT
TERMINAL BLOCK

CAST ER

X1

N

X2

6002-034 REV. C 1-5

CONSTANT POWER 6 COMPONENT LAYOUT

ILLUSTRATION 1-5