OnLine Power Power Wave 4 User Manual

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Page 1

Power Wave 4

Emergency Lighting Inverter (ELI) 10 – 160 KVA

*200 - 500 KVA

User Manual

Installation Operation

Maintenance

Doc #. 6005-145

Rev. A

Due to continuous product improvement this document is subject to change without prior notice.

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CAUTION!

HAZARDOUS VOLTAGE EXISTS INSIDE THE ELI (INCLUDES THE CONNECTION TERMINALS). CABLE CONNECTION AND MAINTENANCE SHOULD BE DOBE BY PROFESSIONAL OR QUALIFIES PERSONNEL. THE ELI HAS ITS OWN INTERNAL POWER SOURCE (BATTERIES). THE OUTPUT TERMINALS MAY BE LIVE EVEN WHEN THE ELI IS NOT CONNECTED TO THE AC SUPPLY. DC CAPACITORS ARE EMPLOYED IN THIS UNIT. HAZARDOUS VOLTAGE STILL EXITS EVEN WHEN THE UNIT IS NOT ENERGIZED. DO NOT TOUCH ANY PART OF THE INSIDE OF THE ELI.

WARNING!

BE SURE TO OPERATE THE ELI WITHIN THE RATED POWER LEVEL. PREVENT DIRECT EXPOSURE TO DIRECT SUNLIGHT, RAIN OR CONTAMINATING ENVIRONMENT. ONLY QUALIFIED TECNICIANS SHOULD REPLACE THE BATTERIES. SINCE BATTERIES HAVE HIGH SHORT-CIRCUIT CURRENT CAPACITY, MISTAKES IN CONNECTION OR DISCONNECTION CAN CAUSE SEVERE BURS OR DEATH TO SERVICING PERSONNEL.

6005-145 Rev. A a

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TABLE OF CONTENTS

CONTENTS …………………………………………….……………………….……………………….Page SAFETY

SYSTEM OVERVIEW

1.1. Construction of the ELI ............................................................................................................................... 1-1

1.2. Features and Advantages............................................................................................................................. 1-5

1.3. Rectifier ....................................................................................................................................................... 1-8

1.4. Inverter ....................................................................................................................................................... 1-10

1.5. Static Switch ..............................................................................................................................................1-11

1.6. Maintenance Bypass ................................................................................................................................. 1-12

1.7. Main Input Circuit Breaker ....................................................................................................................... 1-12

1.8. Main Output Circuit Breaker .................................................................................................................... 1-12

1.9. Battery Circuit Breaker ............................................................................................................................. 1-12

..................................................................................................................... a

............................................................................................. 1-1

1.10 Battery ....................................................................................................................................................... 1-12

1.11 Single Line Diagram (120/208Y) ............................................................................................................ 1-13

1.12 Single Line Diagram (277/480Y) ............................................................................................................ 1-14

1.13 Dimensions & Drawings .......................................................................................................................... 1-15

1.14 Front Panel ................................................................................................................................................ 1-21

TECHNICAL SPECIFICATION

2.1. Specification for 208/120V Unit ............................................................................................................................... 2-1

2.2. Specification for 480/277V Unit ............................................................................................................................... 2-2

2.3 Model Number Chart .................................................................................................................................... 2-3

INSTALLATION

3.1. Site & Environment Consideration ............................................................................................................ 3-1

3.2. Unpacking .................................................................................................................................................... 3-4

3.3. Cable Selection ............................................................................................................................................ 3-5

3.4. Input/Output Protective Device Rating Chart ............................................................................................ 3-6

3.5. Terminal Connection ................................................................................................................................... 3-7

OPERATIONS

............................................................................................................................................. 3-1

.................................................................................................................................................. 4-1

................................................................................................. 2-1

4.1. Start-up Procedure ....................................................................................................................................... 4-1

4.2. Shutdown Procedure .................................................................................................................................... 4-2

4.3. From Inverter to Maintenance Bypass Procedure ..................................................................................... 4-3

4.4. From Maintenance Bypass to Inverter Procedure ..................................................................................... 4-4

4.5.

Green mode selection

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.................................................................................................................................... 4-5

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CONTENTS ................................................................................................................................................. Page

LCD DISPLAY

5.1. Menu 0 – Main Menu ................................................................................................................................ 5-1

5.2. Menu 1 – Select Menu .............................................................................................................................. 5-2

5.3. Menu 2 – Status / Warning Menu .................................................................................................................... 5-3

5.4. Menu 3 – Real Time Data Menu ...................................................................................................................... 5-4

5.5. Menu 4 – Historical Event Menu .............................................................................................................. 5-5

5.6. Menu 5 – Parameter Setting Menu ........................................................................................................... 5-6

5.7. Menu 6 – Rectifier Data Menu .................................................................................................................. 5-7

5.8. Menu 7 – Output Data Menu ..................................................................................................................... 5-8

5.9. Menu 8 – Other Data Menu ....................................................................................................................... 5-8

5.10. Menu 9 – Reserve Data Menu ......................................................................................................................................... 5-9

5.11. Menu 10 – Boost Charge Setting Menu ................................................................................................................ 5-9

5.12. Menu 11 – Data Time Setting Menu ........................................................................................................................... 5-11

5.13. Menu 12 – Other Setting Menu ........................................................................................................................... 5-12

.................................................................................................................................. 5-1

INTERFACE CONNECTIONS

6.1. Dry Contacts .............................................................................................................................................. 6-1

6.2. External Shutdown ..................................................................................................................................... 6-4

6.3. DB9 Connection ......................................................................................................................................... 6-4

OPTIONS

7.1. Emergency Power Off Switch (EPO) ....................................................................................................... 7.1

7.2. Remote Control Panel ................................................................................................................................ 7.1

7.3. Software for PC Monitoring ...................................................................................................................... 7.2

7.4. Auto Dialing Module ................................................................................................................................. 7.2

7.5. Battery Monitoring Module - DCMAN .................................................................................................... 7.2

7.6. Input Transient Voltage Surge Suppressor (TVSS) ................................................................................. 7.2

7.7. Web/SNMP Card ........................................................................................................................................ 7.3

7.8. Output AUX Circuit Breakers ................................................................................................................... 7.3

7.9. Higher Kaic Circuit Breakers .................................................................................................................... 7.3

7.10. Delta Input ................................................................................................................................................ 7.3

................................................................................................ ..................................... 7-1

................................................................................................ .. 6-1

7.11. Dual Input ................................................................................................................................................. 7.3

7.12. Seismic Bracket. ....................................................................................................................................... 7.3

7.13. Factory Set Green Mode .......................................................................................................................... 7.3

7.14. Battery Cabinet and Battery run time...................................................................................................... 7. 4

7.15. Battery Cabinet Arrangement Drawings ................................................................................................. 7.6

7.16. Replaceable Parts List ............................................................................................................................ 7.11

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CONTENTS ................................................................................................................................................. Page

REDUNDANCY

8.1. Serial Redundancy ....................................................................................................................................... 81

8.2. Parallel Redundancy .................................................................................................................................. 8-4

MAINTENANCE

9.1. Safety and Precautions .............................................................................................................................. 9-1

9.2. When to call ............................................................................................................................................... 9-3

9.3. Step to take ................................................................................................................................................. 9-3

9.4. Preventive Maintenance ............................................................................................................................ 9-4

9.4.1 Maintenance Log ..................................................................................................................................... 9-4

9.4.2 Periodic Testing of Unit .......................................................................................................................... 9-5

.............................................................................................................................................. 8-1

............................................................................................................................................ 9-1

9.4.3 Maintaining Batteries .............................................................................................................................. 9-5

9.4.4 Battery Cabinets ...................................................................................................................................... 9-7

9.4.5 Power Connections .................................................................................................................................. 9-7

9.4.6 Battery Terminals .................................................................................................................................... 9-8

9.5. Online Power Customer Service and Support ......................................................................................... 9-8

9.5.1 Start-Up Services ..................................................................................................................................... 9-8

9.5.2 Maintenance Agreements........................................................................................................................ 9-8

9.5.3 Warranties ................................................................................................................................................ 9-8

9.5.4 Help .......................................................................................................................................................... 9-9

Appendix A

Battery Exerciser setting ................................................................................................................................ 9-15

6005-145 Rev. A d

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OnLine Power, Inc.

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 to disclose them to 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. Due to continuous product improvement this document is subject to change without prior notice.

6005-145 Rev. A e

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Serial Number:

KVA/Power Rating:

Input Voltage:

Output Voltage:

Manufacturer Date:

Congratulations on selecting one of the fine products from OnLine Power, the leader in power protection technology. Our wide product offering includes UPS (Uninterruptible Power Systems), power conditioners, automatic voltage regulators and specialty transformers (e.g., computer-grade, medical-grade). Since our founding in 1972, OnLine Power has shipped many of these fine products to discerning customers around the world for use on sensitive equipment and in critical applications.

One of our goals is to make our manuals both comprehensive and easy to use. The new format of our user manual is the result of ideas and inputs from customers like you who have taken an active interest in our continued success. We invite and appreciate your feedback on our products and documentation via e-mail, fax, mail, or telephone.

HEADQUARTERS OnLine Power 5701 Smith Street Commerce, CA 90040

SALES

Phone: (800) 227-8899 FAX No: (323) 721-5017 E-mail: [email protected]

Office Hours are 7:00 AM to 5:00 PM PST SERVICE

If you require assistance, please call our 24-hour toll free hot line 800-PWR- SRVC (800-797-7782) or email to [email protected]. Please have the

following information from your unit’s nameplate available to speed

assistance:

Due to continuous product improvement this document is subject to change without prior notice.

6005-145 Rev. A f

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Danger!

ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT TO INSTALL OR REPAIR THE UNIT OR ITS BATTERY SYSTEM. IMPROPER INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT CAUSE OF START-UP PROBLEMS. HIGH AC AND DC ELECTRICAL VOLTAGES ARE PRESENT THROUGHOUT THE UNIT (S) AND INCORRECT INSTALLATION OR SERVICING COULD RESULT IN ELECTROCUTION, FIRE, EXPLOSION, OR EQUIPMENT MALFUNCTION.

Danger!

READ THIS MANUAL IN ITS ENTIRETY BEFORE PERFORMING INSTALLATION, START-UP, OPERATION, AND MAINTENANCE OF THE UNIT OR BATTERY SYSTEMS. FAILURE TO DO SO COULD RESULT IN ELECTROCUTION, FIRE, EXPLOSION, OR EQUIPMENT MALFUNCTION.

Caution

SAFETY

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

Boxes labeled with the “ Danger!” symbol indicate that there is a high risk of personal injury or death if instructions are not followed.

Warnings labeled with the symbol indicate that there is a high probability of equipment malfunction, damage, or destruction if instructions are not followed.

6005-145 Rev. A g

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Danger!

EXERCISE EXTREME CARE WHEN HANDLING UNIT AND BATTERY CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL. CABINETS WEIGH SEVERAL HUNDRED POUNDS.

Danger!

ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT. WIRING MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL ELECTRICAL CODES. IMPROPER WIRING MAY CAUSE DAMAGE TO THE EQUIPMENT, INJURY OR DEATH OF PERSONNEL. VERIFY THAT ALL HIGH AND LOW VOLTAGE INPUT POWER CIRCUITS ARE DE-ENERGIZED AND LOCKED OUT BEFORE INSTALLING CABLES OR MAKING ANY ELECTRICAL CONNECTIONS.

Danger!

OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION OR SERVICE OF THE UNIT OR BATTERIES. EVEN WITH THE BATTERY CIRCUIT BREAKER IN THE OFF POSITION, THE DANGER OF ELECTROCUTION MAY STILL BE PRESENT. THE BATTERY POWER TO THE

UNIT MUST BE LOCKED AND TAGGED “OFF” BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT. THE BATTERY MANUFACTURER’S

SAFETY INFORMATION AND MATERIAL SAFETY DATA SHEET IS LOCATED IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UNIT. FAILURE TO FOLLOW INSTRUCTION LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION, FIRE, EQUIPMENT MALFUNCTION, OR ELECTROCUTION.

Danger!

TEST LIFT AND BALANCE THE CABINETS BEFORE MOVING. MAINTAIN MINIMUM TILT FROM VERTICAL AT ALL TIMES. THE BOTTOM STRUCTURE WILL SUPPORT THE UNIT ONLY IF THE FORKLIFT FORKS ARE COMPLETELY UNDERNEATH THE UNIT.

6005-145 Rev. A h

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Danger!

ALL POWER TO THE UNIT MUST BE LOCKED AND TAGGED “OFF” BEFORE

PERFORMING ANY SERVICE OR WORK ON THE UNIT. FAILURE TO DO SO COULD RESULT IN ELECTROCUTION.

Danger!

EXTREME CAUTION IS REQUIRED WHEN PERFORMING MAINTENANCE. LETHAL VOLTAGES EXIST WITHIN THE EQUIPMENT DURING OPERATION. OBSERVE ALL WARNINGS AND CAUTIONS IN THIS MANUAL. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH. OBTAIN QUALIFIED SERVICE FOR THIS EQUIPMENT AS INSTRUCTED.

Danger!

BE CONSTANTLY AWARE THAT THE UNIT SYSTEM CONTAINS HIGH DC AS WELL AS AC VOLTAGES. WITH INPUT POWER OFF AND THE BATTERY, DISCONNECTED, HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS. HOWEVER, POWER CIRCUIT MALFUNCTIONS CAN OCCUR, SO YOU SHOULD ALWAYS ASSUME THAT HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN. VERIFY THAT POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING CONTACT.

Danger!

IN A FIRE INVOLVING ELECTRICAL EQUIPMENT, ONLY USE CARBON DIOXIDE FIRE EXTINGUISHERS, OR THOSE APPROVED FOR USE ON ELECTRICAL EQUIPMENT. USE OF WATER ON FIRES INVOLVING HIGH VOLTAGE ELECTRICAL CIRCUITS COULD RESULT IN ELECTROCUTION .

Danger!

SOME COMPONENTS WITHIN THE CABINETS ARE NOT CONNECTED TO CHASSIS GROUND. ANY CONTACT BETWEEN FLOATING CIRCUITS AND THE CHASSIS IS A LETHAL SHOCK HAZARD.

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Danger!

LEAD-ACID BATTERIES CONTAIN HAZARDOUS MATERIALS. BATTERIES MUST BE HANDLED, TRANSPORTED, AND RECYCLED OR DISCARDED IN ACCORDANCE WITH FEDERAL, STATE, AND LOCAL REGULATIONS. BECAUSE LEAD IS A TOXIC SUBSTANCE, LEAD-ACID BATTERIES MUST BE RECYCLED OR DISCARDED AS HAZADEROUS WAIST.

HARMFUL TO THE SKIN AND EYES AND MAY BE TOXIC.

OF ELECTRICAL SHOCK. THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED WHEN WORKING ON BATTERIES:

1. REMOVE WATCHES, RINGS OR OTHER METAL OBJECTS.

2. USE TOOLS WITH INSULATED HANDLES.

3. WEAR RUBBER GLOVES AND BOOTS.

4. DO NOT LAY TOOLS OR METAL PARTS ON TOP OF BATTERIES.

5. DISCONNECT CHARGING SOURCE PRIOR TO CONNECTING OR DISCONNECTING BATTERY TERMINALS.

6 DETERMINE IF BATTERY IS INADVERTENTLY GROUNDED. IF SO,

REMOVE THE SOURCE OF THE GROUND. CONTACT WITH ANY PART OF A GROUNDED BATTERY CAN RESULT IN ELECTRICAL SHOCK. THE LIKELIHOOD OF SUCH SHOCK WILL BE REDUCED IF SUCH GROUNDS ARE REMOVED DURING INSTALLATION AND MAINTENANCE.

7 LEAD-ACID BATTERIES CAN PRESENT A RISK OF FIRE BECAUSE THEY

GENERATE HYDROGEN GAS. THE FOLLOWING PROCEDURES SHOULD BE FOLLOWED:

1. DO NOT SMOKE WHEN NEAR BATTERIES.

2. DO NOT CAUSE FLAME OR SPARK IN BATTERY AREA.

8 DISCHARGE STATIC ELECTRICITY FROM YOUR BODY BEFORE

TOUCHING BATTERIES BY FIRST TOUCHING A GROUNDED SURFACE.

Danger!

INTERNAL BATTERY STRAPPING MUST BE VERIFIED BY THE CUSTOMER PRIOR TO MOVING THIS UNIT.

THIS UNIT CONTAINS NON-SPILLABLE BATTERIES. KEEP THE UNIT UPRIGHT. DO NOT STACK. DO NOT TIP. ALWAYS FOLLOW THE BATTERY

MANUFACTURER’S SAFETY INFORMATION LOCATED IN A POCKET

ATTACHED TO THE INSIDE OF THE LEFT DOOR OF YOUR UNIT TO PREVENT AN ACCIDENT THAT COULD RESULT IN INJURY OR DEATH.

6005-145 Rev. A j

................................................................................................. 6-4

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6005-145 Rev. A 1-1

1. SYSTEM OVERVIEW

1.1. Construction of the ELI

General Topology

The ELI system is composed of input breakers, input filter & protection network, rectifier, battery bank, inverter, static switch, bypass breaker, isolation transformer and output filter. The basic topology is shown in the diagram above. Under normal AC mode, energy from the AC source is converted to DC power and supplied to the inverter to charge the batteries to its full capacity all the time, ready to support the output load in case of AC source failure.

Although the principle and operation of a ELI seems simple and straightforward, the requirement for a reliable and intelligent ELI makes the design and manufacturing of a high power ELI one requiring advanced technology, intelligence, experience and most important, consideration of the user interface. Many years have been spent in designing the most rugged, intelligent and reliable ELI for the market, and a safe and convenient ELI for the user.

Choosing the best and most suitable ELI for a given application can be easy or difficult, depending on the client’s knowledge of key parameters. The most obvious specification, output power, depends on the size of the load. Often, an allowance of 50% more power is added to the present load requirement, both for tolerance and for future expansion.

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6005-145 Rev. A 1-2

Another important issue is reliability. The prime aim of a ELI is to protect your load. Therefore, the ELI should be much more reliable than the AC source. An unreliable ELI may suffer the problem of frequent break down, even more frequent than AC failure, and the cost of repair may become more than the cost of the unit itself.

Generally, there are four different modes of operation, the NORMAL OPERATION MODE, the BACK-UP (BATTERY) MODE, the RESERVE MODE and the MAINTENANCE BYPASS MODE. These are explained below.

Normal Operation Mode:

The rectifier converts the AC input to DC power to supply the inverter and charge the batteries simultaneously. All the fluctuations, surges and spikes of the AC input are removed during AC to DC conversion. Therefore, the AC supplied by the inverter is clean and stable.

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6005-145 Rev. A 1-3

Back-up Mode:

Since the batteries are connected directly to the DC bus, when the AC fails, the batteries change immediately from receiver to donor, supplying energy to the inverter instead of receiving energy from the rectifier. The output AC is not interrupted. Therefore, the load connected to the output is protected.

Reserve Mode:

When the inverter is in an abnormal condition, such as over temperature, short circuit, abnormal output voltage or overloaded for a period exceeding the inverter’s limit, the inverter will automatically shut down in order to protect itself from damage. If the utility power is normal, the static switch shall transfer the load to the reserve source without interruption of AC output.

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6005-145 Rev. A 1-4

Maintenance Bypass Mode:

In case of ELI maintenance or battery replacement, and where the load cannot be interrupted, the user can turn off the inverter, close the bypass breaker and then open the rectifier and reserve breakers. The AC output will not be interrupted during manual bypass transfer procedure. Therefore, the maintenance bypass switch keeps continuously supplying power to the load. Electricity will not exist in ELI except the output transformer, thus ensuring the safety of service personnel.

Generally, the ELI is expected to run 24 Hours a day in normal operation mode once it is installed, except when the utility power fails, under overload conditions, or during maintenance.

Normal operation with batteries connected provides clean, stable, regulated and uninterrupted power to the load, free from any spikes and surges. Therefore, the ELI can be regarded as a perfect AC power source, limited in back-up time, under mains failure, only by the capacity of the batteries.

Green Mode:

Hybrid design allows customer to select this operation mode for higher efficiency (fast transfer less than 2ms).

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6005-145 Rev. A 1-5

1.2. Features and Advantages (a) Reliable input protection: Circuit breakers are placed in each individual

input loop to ensure power can continue through another loop in case of breaker trip caused by an abnormal condition in either rectifier or load.

(b) Input surge protection: An MOV (surge protector) is added at the input,

providing protection to both ELI and the load from any lightning surges, or surges caused by neighboring large loads.

limits. Therefore, very low noise is emitted, and no interference is supplied to other equipment connected to the same AC source.

(d) Ruggedness: The rectifier employs phase control technology to regulate

the DC bus voltage. This is the most efficient method to charge the batteries. The SCR used are inherently rugged. Additionally, a large inductor is added at the input to avoid deforming the AC source waveform.

(e) High frequency design: The inverter uses high frequency, high efficiency

IGBT, PWM methodology to convert the DC power to AC power. Therefore, the number of components is fewer, reliability is improved, and the size and weight of ELI is reduced, performance is improved, and acoustic noise is minimized.

(f) True Galvanic isolation: An isolation transformer is placed at the output.

This can solve the problem of poor input grounding, can allow a different ground between input and output, can avoid the annoying problem of ground leakage current, and can be tied to any potential provided on site. The AC output is isolated under every mode of operation. Additionally, the user gets the bonus of attenuation of common mode noise from the output isolation transformer.

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6005-145 Rev. A 1-6

(g) Plug & Play Modular design: The power circuit is separated into several

modules plugged into slots in the ELI, which are easy to pull out, permitting quick maintenance and easier trouble shooting.

(h) Cold start function: the ELI can be started without an AC source, that is,

can be started with battery power only. This is possible because current limit circuitry is added, preventing the problem of large inrush current blowing the battery fuse and damaging the DC capacitors when batteries are connected to an empty DC bus (before the DC bus is energized).

(i) Multi-CPU design: Several CPUs are employed in the control circuit, and

critical functions are designed with parallel redundancy to improve reliability. Therefore, in case of one CPU failure, the other CPUs keep the ELI operational, and the output AC is not affected.

(j) Protection against misuse: The ELI is designed with breaker on/off

sensor, power supply sensor, etc. Therefore, any operational mistake made by the user causes no harm to the ELI.

(k) Accepts wide input range: The ELI is designed to accept a wide input

range, so that it can work effectively under an unstable AC source. All of the input components used are specifically selected to handle extreme high voltage and high current.

(l) Operating environment: Each component of the ELI is chosen with large

safety margin to accommodate extreme environments, such as temperature, humidity, altitude, shock or contamination.

(m) Intelligent charger: The ELI will automatically recharge (boost charge)

the batteries every time the batteries are depleted to a voltage level equal to 2V/Cell. Thus, the batteries can be restored to full capacity as soon as possible, and made ready for the next back-up requirement. In order to keep the batteries in the best condition, the ELI will boost charge the batteries for several hours (selectable) automatically every month. To avoid over charging the batteries, boost charge will stop when the ambient temperature is over 35oC (95oF).

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6005-145 Rev. A 1-7

(n) Intelligent battery test: The batteries are tested after every boost

(initiated by battery discharge or by the monthly boost charge cycle). This is done without interrupting the operation of the rectifier, preventing the risk of output AC failure in case of a bad battery. The user is informed of the battery condition, so that action can be taken before the full capacity of the batteries is needed.

(o) Huge charging power: The charging power is selectable (Lo/Me/Hi)

according to Ah rating of the batteries, and can charge up battery banks providing more than 8Hrs back-up time without adding an extra charger.

(p) MTBF of fans are extended: Fans used to cool the ELI, are designed to

slow down under light load, so that the life expectancy of the fans is extended beyond the normal.

(q) Redundant power supply: A supplemental power supply is added to

provide redundancy for supplying power to the static switch, so that there will be AC output no matter what happens to the ELI.

(r) Variety of accessory (options): With built-in intelligent communication

interface as well as output ports of RS-232, RS-485, and dry contacts, there are several options are hence available such as remote control panel, 3 phases software for PC monitoring, auto dialing module, battery monitoring module, 3 phases SNMP card.

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6005-145 Rev. A 1-8

6-PULSE FULL CONTROL RECTIFIER

INPUT

RECTIFIER

BREAKER INDUCTOR

CAPACITOR

SCR

OUTPUT

1.3. Rectifier

The main function of a rectifier is to convert the AC input to DC power, and supply it to the inverter. The inverter then converts the DC power to AC power for the load. The ELI use the DC power to charge the batteries as well, which is the most efficient method of charging.

ELIs in the sizes 10KVA to 100KVA use 6-pulse fully controlled rectification (optional 12-pulse). An inductor is added before the rectifier to improve the power factor, smooth the current waveform and eliminate the harmonic current. The control circuit regulates the DC bus within 1%. Soft walk-in circuitry (approximately 20sec.) and current limit circuitry is used to prevent over current or instantaneous surge current.

Extra under-voltage and over-voltage protections are added to improve reliability and to shutdown the rectifier in case of abnormal conditions. The DC bus is adjustable to fit different types of batteries. The power component used in the rectifier is specially selected to handle extreme high voltage and high current. The rectifier is designed to operate under a wide range of AC input, from 177 to 300VAC, to operate under the poor power conditions found in some areas.

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12-PULSE FULL CONTROL RECTIFIER

INPUT

RECTIFIER

BREAKER INDUCTOR

CAPACITOR

SCR

OUTPUT

SCR

PHASE SHIFT

TRANSFORMER

In order to further improve the power factor and reduce harmonic current drawn by the rectifier, ELI at 120KVA and above, use the 12-pulse full controlled rectifier. The total current harmonic current can be reduced to around 15%, and power factor improved to over 0.8. A phase shift transformer is added to achieve this performance. The input inductor is retained also to obtain the best result. Although this results in higher cost, the unit is much more reliable and rugged. Users do not need to increase the input breaker and cable sizes, since input KVA and harmonic current drawn is minimized, fulfilling the worldwide energy saving requirements.

The harmonic current can be further lowered by adding harmonic filters (factory installation available). The total harmonic current can be reduced to approximately 9%.

Another alternative method to reduce the harmonic current (especially for very large KVA unit) is to employ 18-pulse full controlled rectifier (available as an option). The total harmonic current can be reduced to approximately 7%.

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6005-145 Rev. A 1-10

DC+

DC-

IGBT INVERTER

1.4. Inverter

The inverter is composed of IGBT, inductor, capacitor, snubber, control circuitry and protection circuitry. The inverter converts the DC power from the DC bus to AC power to supply the output load. The ELI uses IGBT technology which switches at frequencies beyond the audible range, therefore producing no audible noise.

The ELI uses voltage regulation circuitry to limit the voltage variation within 1%. Special compensation circuitry is added to eliminate the output distortion. Every component is oversized to accept the wide DC input range (from 285 to 420VDC), so that the output waveform remains sinusoidal throughout the range. With the aid of dynamic feedback loop the inverter will keep a sine waveform even under non-linear load.

An independent inverter is used for each phase. Although it is more expensive, each inverter has its independent feedback, so that the voltage is unaffected when load is added to the adjacent phase, producing excellent voltage regulation under 100% unbalanced load.

The IGBT is operated in its optimal condition to obtain best efficiency, so as to minimize the power cost of the user.

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6005-145 Rev. A 1-11

FILT E R

TO L O A D

RESERVE

FILT E R

TO L O A D

INVERTER

RESERVE

INVERTER

RESERVE MODE INVERTER MODE

Usually, the most frequent failures of the ELI occur at the inverter. Therefore, we have added redundant protection circuitry to protect the inverter. A strong snubber is added to suppress the spikes and noise, oversized, high quality components are used throughout, semi-conductor fuses are provided, and ventilation is maximized. The result of this design is a more rugged, reliable and high efficient inverter. At the same time, the inverter can sustain overload and high peak current drawn by the load. Additionally, a longer MTBF is achieved.

1.5. Static Switch

The static switch is composed of two pairs of SCRs, connected back-to-back. The switch can transfer the load from reserve to inverter or from inverter to reserve without losing power at the output. Therefore, it is a very important portion of a ELI.

Detection circuitry is added to the control circuit to achieve zero dead time transfer. Extra detection logic is employed to control when the static switch should transfer. For example, when output is short circuited, under normal mode operation, the ELI detects the short circuit and stops the inverter. The static switch will not transfer power to the reserve circuit, which might damage the reserve breaker. In case of an overload, the ELI will stop the inverter after a period the inverter can endure, and then transfer the load to the reserve circuit, since the overload capability of the static switch is higher than the inverter.

The transfer action is determined according to the reserve-input voltage and frequency to protect supplying incorrect power to the load. Finally, there is a double check by the CPU as to whether the transfer is successful or not.

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6005-145 Rev. A 1-12

1.6. Maintenance Bypass

Unlike other ELI, the maintenance bypass switch is already installed inside the ELI for convenience. It should be open under normal operation, and only closed during maintenance. For the sake of safety of maintenance personnel, all power supplies inside the ELI should be disconnected before touching any parts inside the ELI. Thus, the maintenance bypass switch is a necessity to maintain AC power at the output and yet keep maintenance personnel safe at the same time. If the bypass breaker is closed under normal operation, the inverter will stop and the load will be automatically transferred to reserve to prevent the inverter connecting directly to the AC source. Of course, you cannot switch on the inverter as long as the maintenance bypass breaker is closed.

To properly use the maintenance bypass breaker, switch off the inverter first. The static switch will automatically transfer the load to reserve without dead time. Then one can close the maintenance bypass breaker, then open the reserve breaker, so that the load gets power from the output without interruption.

1.7. Main Input Circuit Breaker

The main input circuit breaker provides the unit with incoming power isolation as a well as means of disconnect and input over current protection.

1.8. Main Output Circuit Breaker

1.9. Battery Circuit Breaker

1.10. Battery

The battery bank; Provides the reserve energy to sustain the load when suitable AC input power is not present. The batteries are designed and tested to meet UL 924 requirements. The standard VRLA (Valve Regulated Lead Acid) batteries are sealed and maintenance-free.

Page 24

6005-145 Rev. A 1-13

1.11. SINGLE LINE DIAGRAM – (120/208Y)

Page 25

6005-145 Rev. A 1-14

1.12. SINGLE LINE DIAGRAM – (277/480Y)

Page 26

6005-145 Rev. A 1-15

1.13 Dimension & Drawings (electronic cabinet, off white), for

battery cabinet refer to section

CABINET

10KVA - 60KVA

OUTLINE DRAWING

Page 27

6005-145 Rev. A 1-16

80KVA - 160KVA

OUTLINE DRAWING

Page 28

6005-145 Rev. A 1-17

200KVA - 320KVA

OUTLINE DRAWING

Page 29

6005-145 Rev. A 1-18

400KVA

OUTLINE DRAWING

Page 30

6005-145 Rev. A 1-19

500KVA

OUTLINE DRAWING

Page 31

6005-145 Rev. A 1-20

INTER-PCB DIAGRAM

Page 32

6005-145 Rev. A 1-21

～

INVERTER

ENTER

TRUE GALVANIC ISOLATED UPS

DATA LINE

EMERGENT

STOP

BATTERY

TEST

150

% LOAD

125

% LOAD

110

% LOAD

～

LCD

DOWN

OFF

BOOST

CHARGE

HIGH DC

RECTIFIER

SHUTDOWN

ROTATION

ERROR

RECT AC FAIL

BATTERY LOW

SHUTDOWN

BATTERY LOW

RESERVE

FREQ FAIL

RESERVE

AC FAIL

FUSE/OVER

TEMP SD

% LOAD

OVERLOAD

SHUTDOWN

HIGH DC

SHUTDOWN

BYPASS ON

SHUTDOWN

INVERTER FAIL

SHUTDOWN

SHORT CIRCUIT

INVERTER SS

INVERTER ON

～

FUSE / TEMP

OVERLOAD

BAT LOW STOP

FAULT

RESERVE FAIL

RECT AC FAIL

WARNING

BAT LOW

HIGH DC

～

INVERTER

ENTER

TRUE GALVANIC ISOLATED UPS

DATA LINE

EMERGENT

STOP

BATTERY

TEST

150

% LOAD

125

% LOAD

110

% LOAD

～

LCD

DOWN

OFF

BOOST

CHARGE

HIGH DC

RECTIFIER

SHUTDOWN

ROTATION

ERROR

RECT AC FAIL

BATTERY LOW

SHUTDOWN

BATTERY LOW

RESERVE

FREQ FAIL

RESERVE

AC FAIL

FUSE/OVER

TEMP SD

% LOAD

OVERLOAD

SHUTDOWN

HIGH DC

SHUTDOWN

BYPASS ON

SHUTDOWN

INVERTER FAIL

SHUTDOWN

SHORT CIRCUIT

INVERTER SS

INVERTER ON

～

FUSE / TEMP

OVERLOAD

BAT LOW STOP

FAULT

RESERVE FAIL

RECT AC FAIL

WARNING

BAT LOW

HIGH DC

1.14 Front Panel

Page 33

6005-145 Rev. A 1-22

The front panel is located at the front of the PCB holder. It gathers the real time information of the ELI and shows them clearly to the user. It also provides switches for controlling and setting the ELI. Through this panel, the ELI can be not only a stand alone machine supplying the load, but also closely monitored by the user. Each part of the panel is explained below.

A: LCD display: Real time status, data or historical events are displayed on the

LCD. The ELI parameters, real time clock, inverter, and buzzer also can be set through this LCD. The LCD is back-lighted by LEDs to provide a sharp

display. In order to lengthen the LED’s life time, the LED are automatically

shut off 3 minutes after no key is activated, but will light up again when one of the up/down/enter key is pushed.

B: Status LEDs: 24 LEDs, representing all of the important information of the

ELI, provide the most up to date information to the user. Therefore these LEDs are especially important when abnormal conditions occur. The 24 information items are as shown below:

INVERTER ON – inverter is running. INVERTER SS – inverter static switch conducts while the reserve static

switch is opened.

SHORT CIRCUIT – ELI output is in short circuit state. FUSE/OVER TEMP SD – inverter shutdown due to either fuse broken

or over temperature condition.

INVERTER FAIL SHUTDOWN – inverter shutdown due to inverter

output voltage too low.

BYPASS ON SHUTDOWN – inverter shutdown due to bypass breaker

being closed while the inverter is running.

HIGH DC SHUTDOWN – inverter shutdown due to overly high DC

bus voltage condition while the inverter is running.

OVERLOAD SHUTDOWN – inverter shutdown due to overload of the

inverter for a period over that which the inverter can endure; will restart 7 seconds after overload removed.

70% LOAD – load connected to the output is at or over 70% of the ELI rating.

Page 34

6005-145 Rev. A 1-23

110% LOAD – load connected to the output is over 110% of the ELI rating.

125% LOAD – load connected to the output is over 125% of the ELI rating.

150% LOAD – load connected to the output is over 150% of the ELI rating.

RESERVE AC FAIL – reserve AC magnitude is out of range. RESERVE FREQ FAIL – reserve frequency is out of range. BATTERY LOW – DC bus (or battery) is lower than 320VDC, low

battery shutdown is approaching.

BATTERY LOW SHUTDOWN – inverter shutdown due to DC bus (or

battery) lower than 295VDC (lower than the acceptable DC voltage of the inverter).

RECT AC FAIL – rectifier AC magnitude is out of range. ROTATION ERROR – rectifier AC phase rotation is incorrect. RECTIFIER SHUTDOWN – rectifier shutdown due to DC bus too high

(over 445VDC), will automatically restart 30 seconds after abnormal situation has been cleared.

HIGH DC – DC voltage over 430VDC and the bus voltage will be

limited at this voltage.

BOOST CHARGE – the batteries are being boost charged by the rectifier.

BATTERY TEST – batteries are being tested. EMERGENCY STOP – inverter shutdown due to emergency stop

switch pushed.

DATA LINE – blinks when data is transmitted to or received from the

communication port.

C: Warning LEDs: When abnormal condition happens, these LEDs will light

to warn the user according to the cause of the faulty condition. Therefore all these LEDs should be extinguished under normal condition. These LEDs are as shown below:

RECT AC FAIL – rectifier AC input is abnormal either due to AC

magnitude out of the range or phase rotation error, rectifier shutdown.

RESERVE FAIL – reserve AC input is abnormal either due to AC

magnitude out of range or frequency out of range.

Page 35

6005-145 Rev. A 1-24

FUSE/TEMP –Inverter fuse is blown or over temperature condition

exists.

OVERLOAD – output is overloaded by over 110%, 125% or 150%. HIGH DC – the LED will light as long as the DC voltage is over

430VDC.

BAT LOW – the LED will light as long as the DC voltage is lower than

320VDC.

BAT LOW STOP – the LED will light as long as the DC voltage is lower

than 295VDC, inverter cannot start.

FAULT – the inverter is shutdown due to abnormal conditions such as

overload, short circuit, high DC, fuse over temperature, bypass breaker on or emergency stop.

Since these LEDs are located behind the transparent window, the user can see them clearly without opening the door.

D: Audible (buzzer) alarm: The user should not be expected to watch the ELI

all the time. Therefore, when abnormal conditions occur, an audible sound should be emitted to warn the user to check the status of the ELI. The alarm buzzer will beep under any one of the following conditions:

INVERTER IS OVERLOADED-

>110%, beep once / 3 seconds >125%, beep once / second >150%, beep twice / second

BACK- UP

>320VDC, beep once / 3 seconds <320VDC, beep twice / second <295VDC, no beeping

INVERTER IS SHORT CIRCUITED - beep continuously FUSE BROKEN - beep continuously HEAT SINK OVER TEMPERATURE - beep continuously HIGH DC SHUTDOWN - beep continuously BYPASS ON STOP - beep continuously EMERGENCY STOP – (emergency power off) beep continuously

The buzzer will also beep once every time the inverter is switched on or off to acknowledge to the user that his key is valid and accepted.

Page 36

6005-145 Rev. A 1-25

E. Bypass LED: This LED will light when the maintenance bypass breaker is

closed. When the maintenance bypass breaker is closed, the inverter cannot be switched on and will stop immediately even when inverter is already running.

F. Reserve LED: This LED will light when the reserve breaker is closed, and

there is AC power supply present at the reserve terminal.

G. Rectifier LED: This LED will light when the rectifier is operating normally,

meaning the rectifier Mains are within the range specified, the rotation sequence of three phases is correct, the rectifier breaker is closed, and no high DC voltage is on the bus.

H. Back-up LED: This LED will light when the ELI is in back-up mode. This

is also as the indicator for battery test result. If the battery test does not pass, this LED will flash even if the ELI is not in back-up mode, to prompt the user to change the batteries.

I. Inverter LED: This LED will light when the inverter is switched on,

indicating whether the inverter is running or not.

J. Inverter SS LED: This LED will light when the inverter static switch is

turned on and the reserve static switch is turned off, i.e., the load is supplied from the inverter. Usually this LED will light 7 seconds after the inverter is switched on.

K. Reserve SS LED: This LED will light when the reserve static switch is

turned on and the inverter static switch is turned off, i.e., the load is supplied from the reserve. Since the reserve static switch and inverter static switch will never both turn on simultaneously, the Inverter SS LED and the Reserve SS LED should never both be lit simultaneously.

L. Output LED: This LED will light when there is AC power present at the

output terminal. This is an important indication to the user at to whether AC is available at the output or not.

Page 37

6005-145 Rev. A 1-26

M. Up key: This is a LCD control key. It is for moving the cursor one item

upward when items are being selected or for changing the number/character forward when data or parameter of the ELI is being set.

N. Down key: This is a LCD control key. It is for moving the cursor one item

downward when items are being selected or for changing the number/ character backward when data or parameter of the ELI is being set.

O. Enter key: This is a LCD control key. It is for changing backward to the

previous page, and also for confirming the number/character /item is selected.

P. Inverter on switch: This is an inverter control switch. When this key is

pushed with the control key simultaneously, the inverter will be switched on.

Q. Inverter control switch: This is an inverter control switch. When this key is

pushed with the inverter on key simultaneously, the inverter will be switched on. Similarly, when this key is pushed with the inverter off key simultaneously, the inverter will be switched off. Thus, this key is a guard for mistaken key strokes.

R. Inverter off switch: This is an inverter control switch. When this key is

pushed with the control key simultaneously, the inverter will be switched off.

Page 38

2-1

2 TECHNICAL SPECIFICATION

2.1 For 208/120V Unit.

6005-145 Rev. A

Page 39

2-2

2.2 For 480/277V Unit.

6005-145 Rev. A

Page 40

2-3

kVA/kW

MODEL NO.

INPUT

VOLTAGE

OUTPUT

VOLTAGE

10KVA/8KW

PW010B05ATT3

208Y/120

PW010H09ATT3

480Y/277

20KVA/16KW PW020B05ATT3

208Y/120

PW020H09ATT3

480Y/277

30KVA/24KW PW030B05ATT3

208Y/120

PW030H09ATT3

480Y/277

40KVA/32 KW

PW040B05ATT3

208Y/120

PW040H09ATT3

480Y/277

50KVA/40KW PW050B05ATT3

208Y/120

PW050H09ATT3

480Y/277

60KVA/48KW PW060B05ATT3

208Y/120

PW060H09ATT3

480Y/277

80KVA/64KW PW080B05ATT3

208Y/120

PW080H09ATT3

480Y/277

100KVA/80KW

PW100B05ATT3

208Y/120

PW100H09ATT3

480Y/277

120KVA/96KW

PW120B05ATT3

208Y/120

PW120H09ATT3

480Y/277

160KVA/128KW

PW160B05ATT3

208Y/120

PW160H09ATT3

480Y/277

*200KVA/160KW

PW200B05ATT3

208Y/120

PW200H09ATT3

480Y/277

*240KVA/192KW

PW240B05ATT3

208Y/120

PW240H09ATT3

480Y/277

*300KVA/240KW

PW300B05ATT3

208Y/120

PW300H09ATT3

480Y/277

*400KVA/320KW

PW400B05ATT3

208Y/120

PW400H09ATT3

480Y/277

*500KVA/400KW

PW500B05ATT3

208Y/120

PW500H09ATT3

480Y/277

2.3 Model number charts

6005-145 Rev. A

*Available upon request only.

Page 41

3-1

INSTALLATION

3.1 Site & Environment Considerations

The main function of the ELI is to provide a safe, clean independent electrical supply to the sensitive load so that it is free from any random variations, disturbances or interruptions of the utility mains. The ELI also provides a constant power which is perfectly regulated in both voltage and frequency. When the mains are not available, the ELI provides optimal back-up time depending on the battery bank capacity connected to it.

The life expectancy of the ELI is 10 years and greater. Batteries are not included, because life expectancy of the batteries depend on the type of battery, the temperature and humidity of the environment in which it is installed, and the type of charger that is applied to the battery. Therefore optimal life expectancy of the ELI can be achieved by careful consideration of the site and environment.

The following precautions and recommendations should be checked in considering the site and environment of the ELI:

(a) The ELI should be located in a place with adequate ventilation (refer to the

specification of the heat dissipation of the ELI). If the ELI is installed indoors, care must be taken to insure the evacuation of heat from a closed room will be exhausted.

(b) Adequate space (at least 1M) should be allowed to open the door, and

unobstructed by other objects for operation or maintenance. Adequate space (at least 1M) should be allowed at the top of the ELI, to assure heat dissipation is ventilated through the openings.

not locate the ELI near any heat source, machinery which produce metallic dust or powder, or any facility that will produce corrosive substances or vapor.

(d) Protect the ELI from accidental damage from fire extinguishing (sprinkler)

systems. Protect the ELI from abnormal conditions with a dedicated cutoff from the incoming power.

6005-145 Rev. A

Page 42

3-2

(e) It is necessary to guarantee the temperature and humidity values of the site

into which the ELI will be installed. These should be within the range allowed by the specification. The ELI is capable of continuous normal operation within a temperature range of 0°(32°) to 40° (104°). For optimal performance and reliability, and to prolong lifetime, it is recommended to keep the environment temperature below 25°, and humidity below 80%.

(f) If the ELI is installed outdoors, avoid direct exposure of the ELI to the

sunlight, wind, and rain. Avoid any exposure to sand or dust.

(g) The floor loading capacity should be high enough to endure the weight of the

ELI. The ELI is mounted on four right-angled steel angles. Insert corresponding bolts and nuts (dia. 1/2”) into the floor for securing the ELI on the floor when it is located in an area where earthquakes is possible, or where motion may occur, e.g. vehicle mounted. Layout dimensions are shown below.

6005-145 Rev. A

Page 43

3-3

(h) Walls, ceilings, and floors near the ELI should be preferably constructed of non-

combustible materials. A portable fire extinguisher should be accessible nearby in case of hazard.

(i) Avoid accumulating combustible materials of any sort in or around the ELI system.

The floor area surrounding the ELI should be kept clean so that foreign materials are not sucked into the unit, thus causing a short circuit and damage to the system.

(j) Access to the ELI room should be limited to a minimum number of operation and

maintenance personnel only. The doors should be kept locked and the keys should be confined to authorized personnel only.

(k) Personnel who operate or maintain the ELI system should be proficient in normal

and emergency operational procedures. New personnel should be trained and qualified prior to operating the equipment.

(l) Although the ELI has passed International EMC tests, it is recommended that the

ELI not be installed near any equipment that is susceptible to electro-magnetic interference, such as computer systems, monitors, radios, etc.

(m) It is preferable to place the ELI near to the source rather than near to the load.

6005-145 Rev. A

Page 44

3-4

3.2 Unpacking

Carefully unpack the ELI, and then carefully locate the ELI onto the site which has selected, with all the points in section 3.1 kept in mind.

The ELI has had detailed production and QC testing of all the electrical and mechanical characteristics prior to shipment from the factory. Therefore, the ELI should be in proper condition upon receipt. Once received, the ELI should be first checked visually to determine if any physical damage has occurred during transportation.

Then check to insure that all the accessories/options (match with your purchase order) have been included.

- DOOR KEY

- THIS INSTRUCTION MANUAL

- BATTERY FUSE (FOR BATTERY CABINET ONLY)

- SPARE SCREWS FOR COVER PLATE

- SPARE SCREWS FOR CONNECTION TERMINALS etc.

Lastly, check to insure that the specification of the ELI is identical to the specification of your order. The key items in the specification you must check are:

- RATED POWER OF THE ELI,

- INPUT VOLTAGE & FREQUENCY

- OUTPUT VOLTAGE & FREQUENCY

- NO. OF OUTPUT PHASES (1Φ OR 3Φ)

- BATTERY VOLTAGE OR CELL NO.

Also check to insure that the necessary documentation is attached:

- GUARANTEE CARD

- AGENT/SERVICE CENTER INFORMATION

6005-145 Rev. A

Page 45

3-5

3.3. Cable Selection

The following tables list typical information concerning the KVA of the ELI versus the size and rating of the cables. Inadequate cable size or over sized breakers will create risk of fire or damage of insulation. Therefore, please use the following tables to determine the input circuit breaker rating and the size of cable for input, output and battery connections. All rating must comply with local electrical codes.

6005-145 Rev. A

Page 46

3-6

3.4 Input/Output protective device rating and BTU/HR with floor loading chart.

6005-145 Rev. A

Page 47

3-7

RR RS RT IN IR IS IT OR OS OT ON B+ B-

RESERVE

INPUT

RECTIFIER

INPUT

UPS

OUTPUT INPUT

BATTERY

INPUT

RECTIFIER & RESERVE

IN IR

UPS

OUTPUT

ORITIS OS OT

BATTERY

INPUT

B-ON B+

3 PHASE INPUT / 3 PHASE OUTPUT TERMINAL WITH TWO SOURCE

ELI

3.5 Terminal Connection

Although different sizes of ELI may have slightly different cable connection terminal blocks, all ELI connection terminal alignments falls into one of the following types:

3 PHASE INPUT / 3 PHASE OUTPUT

TERMINAL WITH SINGLE SOURCE

Note: Tree extra terminals are installed for convenience of changing the unit to separate reserve input.

6005-145 Rev. A

Page 48

4. OPERATIONS

After all cables have been connected, and power source is available at the input terminals, the ELI is ready to operate. Before turning on any switch or breaker, once again check the following:

(a) Check that the input voltage conforms to the ELI’s rated input voltage. (b) Check that the input frequency conforms with the ELI’s rated input

frequency. (c) Check that the load at the output is switched off. (d) Check that all breakers and the battery disconnects are opened. (e) Check that no foreign material is inside the ELI.

4.1. Startup Procedure

To start the ELI from complete shutoff to normal operation, follow the steps below to turn on the ELI.

(a) In case there is an extra input breaker for some special specification, please close

the input breaker first.

(b) Close the reserve breaker – The reserve and output LED on the mimic panel will

light up, indicating the reserve static switch loop is energized. Therefore the output has power now. The supply of power in the ELI is established and the fans will operate.

source connected is correct. Wait 30 sec for DC bus voltage to rise until the warning LEDs of “BAT LOW” and “BAT LOW STOP” go off (on the front panel). Now, the DC is already ready for the inverter.

(d) Close the (optional) battery breaker - For safety purposes, a breaker (or fuse) is

employed between the batteries and the DC bus. Now the batteries will take over to supply the DC bus if rectifier mains fail.

6005-145 Rev. A

4-1

Page 49

MIMIC DISPLAY UNDER NORMAL OPERATION

(e) Push inverter ON switch – To turn on the inverter, the inverter ON switch ( ) and

the control switch ( ) must be pressed simultaneously. The inverter will start working and inverter output will be established in 4 seconds. The load will automatically be transferred to the inverter 3 seconds later. Now the ELI is in normal operation.

(f) Check if the mimic LED is correct, as shown in the figure, above. All warning

LEDs on the right side are off, two LEDs: ‘INVERTER ON’ and ‘INVERTER SS’ on the left side should be lit. If the load is over 70%, the ‘70% LOAD’ LED will

also be lit.

4.2. Shutdown Procedure

If you want to shutdown the ELI completely (no power at output or inside), please follow the steps below.

(a) Switch off the inverter – The inverter can be switched off by pressing the inverter

OFF switch ( ) and the control switch ( ) simultaneously. The load will be automatically transferred to reserve without interruption.

6005-145 Rev. A

Page 50

(b) Open the (optional) battery breaker – If you want to shutdown all the power of the

ELI, continue to open the battery breaker. Now the DC bus is only supported by the rectifier.

power source away from the DC bus, and the DC bus will start to drop slowly. After 5 minutes, the DC bus will drop to a safe level (< 20VDC).

(d) Open the reserve breaker – Before opening the reserve breaker, power exists at

the output. After opening the reserve breaker, the output (or load) will no longer have power. Therefore, before opening the reserve breaker, insure there is no

critical load connected to the output. (e) If there is input breaker, open it accordingly. (f) At this point, all power has been cut off, and there should none of the LED’s or

LCD’s lit. The ELI now is completely shut off.

4.3. From Inverter to Maintenance Bypass Procedure

If you want to stop the ELI for maintenance and do not stop the power supply from the load, you can follow the steps below to turn the ELI to maintenance bypass mode without interrupting the output power supply.

(a) Switch off the inverter – The inverter can be switched off by pressing the inverter

OFF switch ( ) and the control switch ( ) simultaneously. The load will be

automatically transferred to reserve without interruption. (b) Open the (optional) battery breaker – You have to shutdown the power inside the

ELI. Therefore, continue to open the battery breaker.

6005-145 Rev. A

Page 51

source away from the DC bus, causing the DC bus to drop slowly. After 5 min.,

the DC bus will drop to a safe level (<20VDC). (d) Close the bypass breaker – The reserve breaker and reserve static switch are still

conducting. Therefore, when the maintenance bypass breaker is closed, power

will flow through the bypass loop instead of the reserve loop because of the lower

impedance of bypass loop. (e) Open the reserve breaker – You can now open the reserve breaker to free the ELI

from any power supply.

4.4. From Maintenance Bypass to Inverter Procedure

If the ELI is in maintenance bypass mode, and you want to turn the ELI to normal mode without interrupting the output AC, please follow the steps below.

(a) Close the reserve breaker – The reserve and output LED on the mimic will light,

indicating the reserve static switch loop is energized, and the output has power.

The power supply in the ELI is also established, and the fans will operate. (b) Open the bypass breaker – The inverter cannot be switched on while the

maintenance bypass breaker is closed (because the CPU will sense the breaker

and prevent the inverter from connecting directly to AC source). Since the reserve

breaker is already closed, power goes through the reserve loop if the bypass

breaker is open. Thus, AC at the output will not be interrupted. (c) Close the rectifier breaker - The rectifier will be automatically started if the power

source connected is correct. Wait 30 sec for DC bus voltage to rise until the

warning LEDs of “BAT LOW” and “BAT LOW STOP” go off (on the front

panel). Now, the DC is already ready for the inverter.

6005-145 Rev. A

Page 52

(d) Close the (optional) battery breaker – For safety purposes, a fuse is employed in

the battery to the DC bus. Now the battery will take-over to supply the DC bus if the rectifier mains fail.

(e) Push inverter ON switch – To turn on the inverter, the inverter ON switch ( ) and

4.5. Green Mode: customer selectable for green mode (fast transfer less than 2ms).

(a) Menu 1 – Select Menu

The Select Menu is for the user to select, via the cursor (→), the type of data the user wants to view, such as, inverter on/off, buzzer on/off, charging time and magnitude, date/time etc. The cursor (→) can be moved upward by the UP(↑) key, and can be moved downward by the DOWN(↓) key. The selection is confirmed by pressing the ENTER key (←┘), and change to the menu at which the cursor is

pointing. If the item “PARAMETER SET” is selected, the LCD will jump into a

screen which will ask the user to key in the password. See the figure below.

The password is a 4 digit number which can be changed upward or downward by the

6005-145 Rev. A

Page 53

UP(↑) or the DOWN(↓) key, and can be confirmed by the ENTER(←┘) key. The selection will continue if the correct password is entered, or will go back to MENU 0, the MAIN MENU, if no correct password is entered after 3 trials. The password for entering the < PARAMETER SET > menu is 1-2-3-4.

The entering of MENU 12, the OTHER SETTING menu, is permitted by another password, to be used by maintenance personnel. Users can obtain this password from

the manufacturer for user’s maintenance technicians.

If “EXIT” is selected (blinking instead of pointed by cursor), the screen will return

to MENU 0.

Go to Model Selection Screen

Then, Select the MODE=ECONOMIC.

Note:If you wan to Set the Operating Mode Back to NOMAL MODE, then go to

the Mode Selection Screen, and then Select the MODE=NORMAL.

6005-145 Rev. A

Page 54

W E L C O M E T O U S E T H E E

L I

P / N : 5 0 3 3 A

S ／ N : 1 2 3 4 5 6 7 8 9 0

I D : 0 1

5 0 K V A I : 2 2 0 ／ 3 8 0 V ／ 5 0 H Z O : 2 2 0 ／ 3 8 0 V ／ 5 0 H Z

2 0 0 2 ／ 0 2 ／ 0 1

T U E

0 8 : 0 0 A M

5. LCD DISPLAY

The LCD can display much more information than can the LEDs. In order to make the display sharp and readable, the LCD is back-lighted by LEDs. But to further prolong the life of the LEDs, the CPU will cut off power to the LEDs 3 minutes after the last keystroke of UP, DOWN or ENTER is pressed. The backlighting will resume if the UP, DOWN or ENTER key is subsequently pressed. Page displays of the LCD are described below. This screen will refresh once the system power is enabled (i.e. the default screen).

5.1. Menu 0 – Main Menu

The first row will display the greeting text set by the factory. Changing the text of this row is not recommended. The parameter no. (P/N), serial number (S/N), and the identification number (ID) are displayed in the second row. While the third row will display the KVA rating, input rating and output rating of the ELI. Changing the parameter number of the second row will also change the rating displayed in the second row (rating is automatically generated by CPU inside the ELI according to the P/N number).

WARNING: Never change the parameter number yourself, because some

parameters will be changed accordingly.

6005-145 Rev. A

5-1

Page 55

＜ S E L E C T M E N U ＞

→ S T A T U S ／ W A R N ／ F A U L T

P A R A M E T E R S E T

R E A L T I M E D A T A

H I S T O R I C A L D A T A

E X I T

P A S S W O R D : 1 2 3 4

Serial number is set by factory for the convenience of maintenance personnel who may need to refer to the serial number of the ELI serviced. The identification number is set only when an external control module is connected to more than one ELI. Each ELI must have a unique number to identify itself, and it should be set by installation technical personnel after installation. The YEAR/MONTH/DATE, DAY OF THE WEEK, HOUR: MINUTE and AM (PM), from the real time clock inside the ELI, are displayed in the fourth row for user’s reference and date/time stamping in the historical data when abnormal conditions occur. Pressing one of the UP, DOWN or ENTER keys will change the LCD to the MENU 1 screen.

5.2. Menu 1 – Select Menu

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＜ S T A T U S

＞

＜ W A R N I N G ＞

R E C T I F I E R = O N

I N V E R T E R = O F F

L O A D

O N

I N V E R T E R

＜ S T A T U S

＞

＜ F A U L T ＞

R E C T I F I E R = O N

S H O R T C I R C U I T ！

I N V E R T E R = O F F

L O A D

O N

I N V E R T E R

The password is a 4 digit number which can be changed upward or downward by the UP(↑) or the DOWN(↓) key, and can be confirmed by the ENTER(←┘) key. The selection will continue if the correct password is entered, or will go back to MENU 0, the MAIN MENU, if no correct password is entered after 3 trials. The password for entering the < PARAMETER SET > menu is 1-2-3-4. The entering of MENU 12, the OTHER SETTING menu, is permitted by another password, to be used by maintenance personnel. Users can obtain this password from the

manufacturer for user’s maintenance technicians.

If “EXIT” is selected (blinking instead of pointed by cursor), the screen will return

to MENU 0.

5.3. Menu 2 – Status / Warning Menu

This menu is displayed when STATUS/WARN/FAULT is selected from MENU 1. The left hand side of this menu shows the real time status of the rectifier, inverter and static switch. The right hand side shows the warning or fault conditions, if any. Therefore, under normal conditions, the LCD display should be exactly as shown above. When minor abnormal conditions occur, these will be shown under the title < WARNING >. These will be overridden by a fault message if more serious abnormal conditions occur, and the title < WARNING > will change to < FAULT >. For example, if short circuit occurs at the output, this screen will display the following:

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＜ R E A L

T I M E D A T A ＞

→ R E C T I F I E R D A T A

O T H E R D A T A

R E S E R V E D A T A

O U T P U T D A T A

E X I T

The inverter should be shut off under a short circuit condition. Since the CPU will detect a short circuit, and in order to avoid unnecessary tripping and damage to the breaker, the static switch remains connected to the inverter (will not transfer to reserve). Listed below are all the warning conditions that can be displayed (arranged in order of priority, starting with the highest priority):

1st row : BYPASS ON / RECT AC FAIL / RECTIFIER PHASE ERROR /

RESERVE FREQ. ERROR

2nd row : 170% OVERLOAD / 150% OVERLOAD / 125% OVERLOAD /

110% OVERLOAD

3rd row : BATTERY LOW STOP / BATTERY LOW / BATTERY BAD /

BATTERY GND FAULT / BATTERY TESTING

Lists below are all the fault conditions that can be displayed:

1st row : HIGH DC SHUTDOWN

2nd row: SHORT CIRCUIT! / FUSE/OVERHEAT / OVERLOAD

SHUTDOWN / EMERGENCY STOP / INVERTER ABNORMAL

3rd row : BYPASS ON SHUTDOWN

The UP (↑) or DOWN (↓) key has no function in this menu. The screen will go

back to MENU 1 – the SELECT menu, when ENTER (←┘) is pressed.

5.4. Menu 3 – Real Time Data Menu

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＜ D A T E ／ T I M E ／ E V E N T S

R U N : 2 1 Y R 0 3 M O

2 0 0 0 \ 0 3 \ 2 9

0 9 : 3 2

S H O R T C I R C U I T ！

2 0 0 0 \ 1 2 \ 0 1

2 2 : 1 5

S H O R T C I R C U I T ！

2 0 0 1 \ 0 1 \ 1 0

1 5 : 4 7

H I G H D C S H U N T D O W

This menu is displayed when the REAL TIME DATA is selected from MENU 1. The cursor (→) is used to select the type of real time data the user wants to view, such as, RECTIFIER DATA, RESERVE DATA, OUTPUT DATA, OTHER DATA etc. The cursor (→) can be moved upward by the UP (↑) key, and can be moved downward by the DOWN (↓) key. The selection is confirmed by pressing the ENTER (←┘), changing the menu to that at which the cursor is pointing.

If “EXIT” is selected (blinking instead of pointed by cursor), the screen will go back

to the MENU 1- the SELECT MENU.

5.5. Menu 4 – Historical Event Menu

This menu is displayed when HISTORICAL DATA is selected from MENU 1. The records stored in EEPROM when abnormal events occur are displayed in this menu. The record display starts with the date/ time stamp of the abnormal condition, making it is possible for the user or maintenance personnel to trace the occurrence. Seventy-seven (77) records can be stored in one EEPROM, which can be increased to 154 records with a second EEPROM. These records will not be erased by cutting off of the power supply or complete shutdown of the ELI, i.e., they will be kept in EEPROM until overwritten by the 78th (or the 155th) record. Three records can be displayed concurrently on the screen. The records displayed (once this menu is opened) are the three most recent records in the EEPROM. The displayed records will move one record upward when the UP (↑) key is pressed, and move one record downward when the DOWN (↓) key is pressed.

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＜ P A R A M E T E R S E T T I N G ＞

→ I N V E R T E R = O N / O F F

D A T E / T I M E

B U Z Z E R = O N / O F F

B O O S T C H A R G E

E X I T

The abnormal conditions that can be displayed are listed below:

HIGH DC SHUTDOWN / SHORT CIRCUIT! / FUSE/OVERHEAT / OVERLOAD SHUTDOWN / EMERGENCY STOP / INVERTER ABNORMAL / BYPASS ON SHUTDOWN

Also, in the top right corner the screen, the ELI run time is displayed in year/month for the reference of the user or maintenance personnel. This can be used to estimate recurring maintenance intervals. The screen will go back to MENU 1- SELECT MENU by pressing the ENTER (←┘) key.

5.6. Menu 5 – Parameter Setting Menu

This menu is displayed when < PARAMETER SET > is selected from MENU 1, and the correct password has been entered. The cursor (→) is used to select the parameter the user wants to set, e.g., INVERTER ON/OFF, BUZZER ON/OFF, BOOST CHARGE, DATE/TIME etc. The cursor (→) can be moved upward by the UP (↑) key, and can be moved downward by the DOWN (↓) key. The selection is confirmed by pressing the ENTER (←┘) key.

The first item that can be set is the INVERTER ON/OFF. When this is selected,

“INVERTER ON/OFF” will be displayed, where the “ON” will blink if the inverter status is on, and the “OFF” will blink if the inverter status is off. The intended status can be changed by UP (↑) or DOWN (↓) key, and is confirmed by ENTER (←┘) key. Then “INVERTER = ON” will be displayed if “ON” is selected or “INVERTER = OFF” will be displayed if “OFF” is selected, the ELI will switch the

inverter on or off according to the selection.

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＜ R E C T I F I E R D A T A

R E C T I F I E R F R E Q U E N C Y = X X

H Z

R - N = X X X V a c

S - N = X X X V a c

T - N = X X X V a c

The second item that can be set is the BUZZER ON/OFF. When selected,

“BUZZER ON/OFF” will be displayed, where the “ON” will blink if the buzzer status is on, and the “OFF” will blink if the buzzer status is off. The intended status can be changed by UP (↑) or DOWN (↓) key, and is confirmed by ENTER (←┘) key. Then “BUZZER = ON” will be displayed if “ON” is selected or “BUZZER = OFF” will be displayed if “OFF” is selected, and the ELI will switch on or off the

buzzer according to your selection.

The third item that can be set is the BOOST CHARGE. When this is selected, the screen will jump to MENU 10, the BOOST CHARGE SETTING MENU (the setting method will be explained later).

The forth item that can be set is the DATE/TIME. When this is selected, the screen will jump to MENU 11, the DATE TIME SETTING MENU (the setting method will be explained later).

If “EXIT” is selected (blinking instead of pointed by cursor), the screen will go back

to the MENU 1- the SELECT MENU.

5.7. Menu 6 – Rectifier Data Menu

This menu is displayed when <RECTIFIER DATA> is selected from MENU 3 – the REAL TIME DATA MENU. It is a data display menu which shows real time data on the rectifier, such as, RECTIFIER FREQUENCY, R-N/S-N/T-N VOLTAGE, etc. The phase to phase voltage display is also available when input is a delta (△) connected source.

The UP (↑) or DOWN (↓) keys have no function in this menu. The screen will go back to MENU 3 – the REAL TIME DATA menu, when ENTER (←┘) is pressed.

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＜ O U T P U T

D A T A ＞

O U T P U T

F R E Q U E N C Y = X X

H Z

L O A D : R = X X X

% S = X X X % T = X X X %

R - N = X X X V a c

S - N = X X X V a c

T - N = X X X V a c

＜ O T H E R D A T A

＞

T E M P E R A T U R E = X X C

D C V O L T A G E = X X X

V d c

C H A R G E

C U R R E N T = X X X A

5.8. Menu 7 – Output Data Menu

This menu is displayed when <OUTPUT DATA> is selected from MENU 3 – the REAL TIME DATA MENU. It is a data display menu, which shows real time data on the output and load, such as, OUTPUT FREQUENCY, LOAD % OF R/S/T, OUTPUT R-N/S-N/T-N VOLTAGE, etc. The phase to phase voltage display is also available when input is a delta (△) connected source. The UP (↑) or DOWN (↓) keys have no function in this menu. The screen will go back to MENU 3 – the REAL TIME DATA menu, when ENTER(←┘) is pressed.

5.9. Menu 8 – Other Data Menu

This menu is displayed when <OTHER DATA> is selected from MENU 3 – the REAL TIME DATA MENU. It is a data display menu, which shows real time data on the ELI, such as, TEMPERATURE, DC VOLTAGE, CHARGE OR DISCHARGE CURRENT etc. If the ELI is in normal operation mode, the data in the last row is the charging current of the batteries. The label is “CHARGE CURRENT =” (see the figure shown above). If the ELI is in back-up mode, the data in the last row will be the discharging current of the batteries, and the title will be “DISCHARGE CURRENT =” (see the figure shown below).

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＜ O T H E R D A T A

＞

T E M P E R A T U R E = X X C

D C V O L T A G E = X X X

V d c

S C H A R G E

C U R R E N T = X X X A

< R E S E R V E D A T A

R E S E R V E F R E Q U E N C Y = X X

H Z

R - N = X X X V a c

S - N = X X X V a c

T - N = X X X V a c

＜ B O O S T C H A R G E S E T T I N G ＞

→ A U T O - B O O S T ( M O N T H ) = 0 4

A U T O - B O O S T ( B A T T L O W ) = 0 8 C H A R G E C U R R E N T = L O

E X I

The UP (↑) or DOWN (↓) keys have no function in this menu. The screen will go back to MENU 3 – the REAL TIME DATA menu, when ENTER(←┘) is pressed.

5.10. Menu 9 – Reserve Data Menu

This menu is displayed when <RESERVE DATA> is selected from MENU 3 – the REAL TIME DATA MENU,. It is a data display menu, which shows real time data of the reserve input, such as, RESERVE FREQUENCY, R-N/S-N/T-N VOLTAGE,

etc., for the user’s reference. The phase to phase voltage display is also available

when reserve input is a delta (△) connected source.

The UP (↑) or DOWN (↓) keys have no function in this menu. The screen will go back to MENU 3 – the REAL TIME DATA menu, when ENTER (←┘) is pressed.

5.11. Menu 10 – Boost Charge Setting Menu

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＜ B O O S T C H A R G E S E T T I N G ＞

→ A U T O - B O O S T ( M O N T H ) = 0 4 0 8 1 2 1 6 2 0 2 4

A U T O - B O O S T ( B A T T L O W ) = 0 4

C H A R G E C U R R E N T = L O

E X I

＜ B O O S T C H A R G E S E T T I N G ＞

A U T O - B O O S T ( M O N T H ) = 0 4

→ A U T O - B O O S T ( B A T T L O W ) = 0 4 0 8 1 2 1 6 2 0 2 4

C H A R G E C U R R E N T = L O

E X I

＜ B O O S T C H A R G E S E T T I N G ＞

A U T O - B O O S T ( M O N T H ) = 0 4

A U T O - B O O S T ( B A T T L O W ) = 0 4

→ C H A R G E C U R R E N T = L O

E X I

This menu is displayed when the item < BOOST CHARGE > is selected from MENU 5, the PARAMETER SETTING menu. The user can change the charger parameters through this menu. The cursor (→) can be moved upward by the UP (↑) key, and can be moved downward by the DOWN (↓) key. The selection is confirmed by pressing the ENTER (←┘) key. See in the above figure.

When AUTO-BOOST (MONTH) is selected, all the values that can be selected will be shown (04/08/12/16/20/24). The battery will be boost charged once every month. The boost charge time is set by this row, with the values being “hours”. The current value (or the value being selected) will flash, and is confirmed by the ENTER (←┘) key. Longer times are selected for bigger batteries according to the needs of the user. Refer to the figure above.

When AUTO-BOOST (BATT LOW) is selected, all the value that can be selected will be shown (04/08/12/16/20/24). The battery will be boost charged every time the battery has been discharged to below 12V/battery or 2V/cell. The boost charge time

is set by this row, with the values being “hours”. The current value (or the value

being selected) will flash and is confirmed by the ENTER (←┘) key. Longer times are selected for bigger batteries according to the need of the user. See the figure above.

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＜ D A T E

T I M E

S E T T I N G ＞

→ Y E A R

= X X X X

H O U R ( 2 4 H ) = X X

M O N T H = X X

M I N U T E = X X

D A Y = X X

D A Y O F

T H E W E E K = M O N

E X I T

When CHARGE CURRENT is selected, the values that can be selected will be shown (LO/ME/HI). When the batteries are being boost-charged for whatever the reason, the charging current will be limited by a value according the setting in this row. The current value (or the being selected) will flash, and is confirmed by the ENTER (←┘) key.

The value can be selected by a rules listed below:

BACK-UP TIME SETTING 10 – 30 MIN LO 30MIN – 1HOUR ME > 1 HOUR HI

If “EXIT” is selected (blinking instead of pointed by cursor), the screen will go back to the MENU 5- the PARAMETER SETTING menu.

5.12. Menu 11 – Date/Time Setting Menu

This menu is displayed when the item < DATE/TIME > is selected from MENU 5, the PARAMETER SETTING menu. The user can change the YEAR/MONTH/DAY/, HOUR/MINUTE/DAY OF THE WEEK of the real time clock through this menu. Once this menu is opened, the present value in the real time clock will be shown. The cursor (→) can be moved upward by the UP(↑) key, and can be moved downward by the DOWN(↓) key to the item the user wants to change. The selection is confirmed by pressing the ENTER (←┘) key. See the figure above. The values to be entered are

numbers except the DAY OF THE WEEK (MON, TUE… provided for user

selection). The values that can be entered are restricted to certain values according to which item is being set (the values are listed below).

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＜ O T H E R S E T T I N G ＞

→ T I T L E :

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

P / N : 5 0 3 3 A

S ／ N : X X X X X X X X X X

I D : X X

E X I T

- YEAR : 1998 – 2097

- MONTH : 01-12

- DAY : 01 – 31

(internal calendar will correct an error if 31 is entered to a 30 day

month)

- HOUR : 0 – 23

- MINUTE : 0 - 59

- DAY OF THE WEEK : MON, TUE, WED, THU, FRI, SAT, SUN

The value can be increased upward by the UP (↑) key, and can be decreased downward by the DOWN (↓) key. The value will flash as it is being set. One can continue to push the UP(↑) or the DOWN (↓) key until the desired value is displayed. Again, the selection is confirmed by pressing the ENTER(←┘) key. Thus, the values in the real clock will be changed according to the values entered.

If “EXIT” is selected (blinking instead of pointed by cursor), the screen will go back

to the MENU 5- the PARAMETER SETTING menu.

5.13. Menu 12 – Other Setting Menu

This menu is displayed when the item PARAMETER SET is selected from MENU 1, the SELECT MENU and the correct password is entered. Note that this is a different password from the password used to enter PARAMETER SETTING menu, and should only be available to maintenance personnel. This menu can change the TITLE, P/N, S/N, ID etc. Once this menu is opened, the current value in the EEPROM will be shown. The cursor (→) can be moved upward by the UP (↑) key, and can be moved downward by the DOWN (↓) key to the item one wants to change. The selection is confirmed by pressing the ENTER (←┘) key.

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See the figure above. Once either one of the items is selected, the values of that item are cleared; now waiting for new values to be entered. The values to be entered are either alpha or numeric, except the ID for which only numbers are allowed. The values that can be entered are restricted to certain values according to which item is being set (the values are listed below).

- TITLE : □, A – Z, 0 - 9

- P/N : □, A – Z, 0 - 9

- S/N : □, A – Z, 0 - 9

- ID : 0 - 31 ** where □ means blank

If “EXIT” is selected (blinking instead of pointed by cursor), the screen will go back

to the MENU 5, the PARAMETER SETTING menu.

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6. INTERFACE CONNECTIONS

All interfaces are connected from 3R PCB. See the figure below.

6.1. Dry Contacts

8 terminals of dry contacts are provided. These terminals are normally open (nonconducting). When an event occurs, the terminal will close (conduct). Maximum contact rating is 16A/250VAC(16A/30VDC). The events are shown below.

INVON – Closed whenever the inverter is on, open when the inverter is off. OVL – Closed whenever the ELI is overloaded.

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FAULT –

Closed when the ELI encounters a fault condition, such as high DC shutdown, short circuit, fuse/over-heat, overload shutdown, emergency stop, inverter abnormal, bypass on shutdown. The contact is latched until manual reset (off switch) or 30 seconds after the fault condition is removed.

SS – Closed when the inverter static switch is conducting, open when the reserve

static switch is conducting (The two static switches will never conduct simultaneously).

BYPASS – Closed when the maintenance bypass breaker is closed, open when the

breaker is opened.

BACK-UP –Closed when the inverter (running) is being backed up by the battery. BATL – Closed when the inverter is using battery power and the batteries are about to

be exhausted.

COM –

This contact can be configured as the OR result of the signals described above. SWR2-1 (dip-switch pin 1) ~ SWR2-7 (dip-switch pin 7) can select one of the seven signals described above and SWR2-8 is the COM enable switch. Please refer to the dip-switch of SWR2 on the 3R PCB and the following examples and diagram.

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4321

SWR2-1

SWR2-2

SWR2-3

SWR2-4

SWR2-5

SWR2-6

SWR2-7

SWR2-8

RELAY CNR15

RELAY CNR20

RELAY CNR19

RELAY CNR14

RELAY CNR16

RELAY CNR13

RELAY CNR17

RELAY CNR12 INVON

INTERNAL

CIRCUIT

OVL

FAULT

BYPASS

BACK-UP

BATL

COM

SWR2-DIP SWITCH ON 3R PCB

Example 1:

If two contacts for BACK-UP are required. Switch on SWR2-6 & SWR2-8, then both CNR19 & CNR15 will close when the unit goes to back-up.

Example 2: If one contact for OVL & FAULT is required. Switch on SWR2-2 & SWR2-3, then the

CNR15 will close when either OVL or FAULT condition happens. Of course CNR17 will close when OVL happens and CNR13 will close when FAULT happens.

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6.2. External Shutdown

2 pairs of terminals CNR 16 are provided for external shutdown. 10mA is needed for turning on the internal photo-coupler. The user can use this terminal to shutdown the ELI when emergency conditions occur, such as fire, short circuit etc.

6.3. DB9 Connection

Four RS-485 and one RS-232 are provided to communicate with more sophisticated (option) modules. Each connector is especially dedicated to one type of external module. The following are some connection examples of optional modules.

CNR21 (RS-232)  ELICOM- Software for PC Monitoring、SNMP Card CNR9 (RS-485)  DCMAN- Battery Monitoring Module

CNR10 (RS-485)  ELICAN- Remote Control Panel CNR12,13,14,15,17,18,19 (RS-485)  ELICALL- Auto Dialing Module CNR11  for transferring RS-485 into RS-232

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7. OPTIONS

This chapter supplies a brief introduction to all the options that are available for the 3 Phase ELI. Similar products from other manufacturer will not fit into this ELI. Additionally, the installation of each option needs professional, trained personnel.

7.1 Emergency Power Off Switch (EPO) – OPTION FOR UL 1778 ONLY.

An emergency power off (EPO) switch is available as an option, installed outside but nearby the ELI, for stopping the ELI output in case of emergency, such as electrical shock, burning of the load or any emergency conditions where one wants to stop the AC output immediately. When the EPO switch button is pushed, the inverter immediately stops running, but the static switch remains tied to the inverter. Therefore there will be no AC supply at the output. This shutdown condition will be latched until it is manually reset by pressing the OFF () switch and inverter control switch () simultaneously.

Therefore, please first switch off INVERTER ( push right & middle of inverter switch simultaneously) and then on INVERTER again (left & middle of inverter switch simultaneously) to restart the ELI after the EPO is triggered.

7.2. Remote Control Panel – ELICAN

ELICAN, remote control panel, is a hand held display module with LCD (the same as the LCD of the ELI). It is used to switch, on or off, any or all of the ELI systems. When any ELI encounters an emergency condition, the system will warn the user immediately. All the ELI status, data or commands are transmitted to external modules through 4 RS-485 ports (for long distance communication under harsh environment).

ELICAN can monitor 1 to 99 units of ELIs with DB9 connections in series from distance of up to 1000M.

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7.3. Software for PC Monitoring – ELICOM

ELICOM is a hardware/software combination installed on a PC to monitor multiple ELIs with DB9 connection in series. The connector on the ELI’s side is RS-485 (for long distance transmission); therefore an RS-485  RS-232 adapter (hardware) is required to modify the signal. The software and hardware together form a package called ELICOM. See the ELICOMTM specification for further information.

7.4. Auto Dialing Module – ELICALL

In case abnormal situations occur, ELICALL

will automatically dial specified phone numbers to inform management to take prompt action. The module, with built-in 23A12V battery, consumes power only when in the process of dialing so as to be operated under AC source failure. Furthermore, with functions of multiple phone number setting and dialing, ELICALLTM has no need of dedicated lines, and can offer user a prompt and convenient way for monitoring the ELI. See the ELICALLTM specification for further information.

7.5. Battery Monitoring Module - DCMAN

DCMAN is an intelligent module for watching each individual battery in the battery bank in a simple and direct way. DCMAN can distinguish for repair the initially aged battery under safe conditions, thus prolonging the battery life

expectancy. One module can monitor up to 64 pieces of 12V battery. DCMAN will sound an alarm in case of an abnormal situation, such as battery failure, cable abnormal disconnection, or if the remaining battery charge is less than the parameter set in the module. See the DCMAN specification for additional information.

7.6. Input Transient Voltage Surge Suppressor (TVSS)

TVSS is a DIN rail mounted device, connected to the Inverter input. Its plugin phase modules are easily replaceable. The device contains energy absorbing components and has a two-stage protection. When a protection component is damaged by absorbed transient, the module will display a flag indicating a need for replacement.

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7.7 Web/SNMP Card:

This option is a web enabled monitoring device for a unit with Internet or network connection. The SNMP/Web card can monitor the Inverter on the network through a standard web browser.

7.8 Output Aux Circuit breakers

7.9 Higher kAIC Circuit breakers

7.10 Delta Input

7.11 Dual input

7.12 Seismic Bracket

7.13 Factory Set Green Mode

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7.14 Battery cabinet and battery run time.

90 minutes (UL924) battery charts.

(Battery cabinets, painted black)

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BATTERY CONFIGURATION, UL 1778: 5 MIN~60 MIN

PART NO.

7050-384

7050-385

7050-386

7050-387

7050-388

KVA

10KVA

20KVA

30KVA

40KVA

50KVA

8KW

16KW

24KW

32KW

40KW

TIME IN MINUTES

-005

29X17AH

29X25AH

29X35AH

29X50AH

29X65AH

-010

29X17AH

29X35AH

29X50AH

29X80AH

2C OR D

29X90AH 2C OR D

-015

29X25AH

29X35AH

29X50AH

29X90AH

2C OR D

29X100AH

2C OR D

-020

29X25AH

29X50AH

29X80AH

2C OR D

29X100AH

2C OR D

29X120AH

2C OR D

-030

29X35AH

29X65AH

29X100AH

2C OR D

29X120AH

2C OR D

58X80AH 3C OR D

-045

29X50AH

29X100AH

2C OR D

58X80AH

3C OR D

58X100AH

3C OR D

58X120AH

3C OR D

-060

29X50AH

29X110AH

2C OR D

58X80AH

3C OR D

58X110AH

3C OR D

87X100AH

4C OR 2D

CB / FUSE

30A

70A

100A

125A

175A

MAX DC CURRENT

29.2A

58.5A

87.7A

116.3A

145A

DC VOLT

348V

PART NO.

7050-389

7050-390

7050-391

7050-392

7050-393

7050-XXX

KVA

60KVA

80KVA

100KVA

120KVA

160KVA

200KVA

48KW

64KW

80KW

96KW

128KW

160KW

TIME IN MINUTES

-005

29X80AH

2C OR D

29X90AH

2C OR D

29X120AH

2C OR D

58X80AH

3C OR D

58X90AH 3C OR D

58X120AH

3C OR D

-010

29X90AH

2C OR D

29X120AH

2C OR D

58X90AH

3C OR D

58X90AH

3C OR D

58X120AH

3C OR D

87X100AH

4C OR 2D

-015

29X120AH 2C

OR D

58X90AH

3C OR D

58X100AH

3C OR D

58X120AH

3C OR D

87X100AH

4C OR 2D

87X120AH

4C OR 2D

-020

58X80AH

3C OR D

58X100AH

3C OR D

58X120AH

3C OR D

87X100AH

4C OR 2D

87X 120AH

4C OR 2D

116X100AH

5C OR 2D

-030

58X100AH

3C OR D

58X120AH

3C OR D

87X100AH

4C OR 2D

87X120AH

4C OR 2D

116X120AH

5C OR 2D

145X120AH

6C OR 3D

-045

87X90AH 4C OR 2D

87X120AH

4C OR 2D

116X120AH

5C OR 2D

145X120AH

6C OR 3D

145X150AH

8C OR 4D

174X150AH

9C OR 4D

-060

87X120AH

4C OR 2D

116X100AH

5C OR 2D

145X100AH

6C OR 3D

145X120AH

6C OR 3D

145X200AH

174X150AH

9C OR 4D

CB / FUSE

200A

250A

300A

375A

500A

700A

MAX DC CURRENT

175A

232A

289A

347A

463A

579A

DC VOLT

348V

C=Cabinet dimensions 39w X 68h X 18d

D=Cabinet dimensions 51w X 70h 30.5d

Standard battery cabinet configuration, depending on customer spacing other size cabinet or racks could be useds

Other than 90 minutes, UL1778

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7.15 Battery Cabinets Arrangement Drawings.

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(continue) Battery Cabinets Arrangement Drawings.

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(continue) Battery Cabinets Arrangement Drawings.

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(continue) Battery Cabinets Arrangement Drawings.

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(continue) Battery Cabinets Arrangement Drawings.

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7.16 Replaceable parts list.

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ELI 1

ELI 2

8. REDUNDANCY

Redundancy can be roughly divided in two types: serial (hot standby) redundancy and parallel (active) redundancy. The ELI series adopts mainly serial redundancy.

8.1. Serial Redundancy

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ONE TO ONE SERIAL REDUNDANCY

Serial (hot standby) redundancy consists of two ELI with one ELI’s (ELI1) connected to the reserve/bypass input of the other ELI (ELI2). See the above figure. Both ELIs are running in normal mode under normal conditions. When one of them has a problem, the load will still have protection from the inverter and battery. If ELI1 fails and ELI2 is running normally, the load is unaffected, and supplied from ELI2. If ELI2 fails and ELI1 is running normally, ELI2 will transfer the load to ELI1 and the load will continue to be protected by the inverter and battery of ELI1. If both of them are running normally, ELI2 takes up all load and ELI1 bears no load. Therefore, ELI1 has a longer MTBF than ELI2 (can be interchanged after a period of time), and their MTBF multiplies to a very large MTBF.

This type of redundancy is employed most frequently. When mains fail, ELI2 is the first to contribute its battery to back-up the load. When ELI2’s batteries are exhausted, the load is transferred to ELI1. Therefore, this topology can make full use of the batteries of both units. Users get a system that has redundant protection and double the back-up time.

Another less expensive solution (see the figure below) is available if the load is separated. A user may intend to install two ELIs, each with the same power, and supplying half the load. A third ELI can be installed as backup to two main ELIs. It is statistically improbable that both main ELIs concurrently break down. Therefore, the third ELI can serve as a hot standby to two ELIs.

These topologies make full use of the resources to create the best protection and longest MTBF.

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ELI 2

ELI 1

ELI 3

ONE TO TWO SERIAL REDUNDANCY

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ELI 1

ELI 2

8.2. Parallel Redundancy

The parallel redundancy configuration, like below figure, is designed to increase both the capacity and reliability. And all the ELI are sharing with equal load.

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Danger!

READ AND UNDERSTAND THIS SECTION THOROUGHLY BEFORE PERFORMING ANY MAINTENANCE WORK ON OR AROUND THE UNIT. READ

THE BATTERY MANUFACTURER’S MANUAL AND MATERIAL SAFETY DATA

SHEETS BEFORE WORKING ON OR NEAR THE BATTERIES. ONLY NORMAL SAFETY PRECAUTIONS ARE REQUIRED WHEN THE UNIT IS

OPERATING WITH ALL CABINET DOORS CLOSED. HOWEVER, THE UNIT AND BATTERY CABINETS MUST BE KEPT FREE OF STANDING PUDDLES OF WATER, EXCESS MOISTURE, OR DEBRIS. DEBRIS CONSISTING OF EXCESSIVE DUST IN AND AROUND THE UNIT WILL BE PULLED INTO THE UNIT BY THE COOLING FANS.

Danger!

ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT TO INSTALL OR REPAIR THE UNIT OR ITS BATTERY SYSTEM. IMPROPER INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT CAUSE OF START-UP PROBLEMS. SERVICE PERSONNEL SHOULD WEAR INSULATING SHOES FOR ISOLATION FROM DIRECT CONTACT WITH THE FLOOR (EARTH GROUND), AND SHOULD MAKE USE OF RUBBER MATS WHEN PERFORMING MAINTENANCE ON ANY PORTION OF THE UNIT WHILE IT IS UNDER POWER. HIGH AC AND DC ELECTRICAL VOLTAGES ARE PRESENT THROUGHOUT THE UNIT (S) AND INCORRECT INSTALLATION OR SERVICING COULD RESULT IN ELECTROCUTION, FIRE, EXPLOSION, OR EQUIPMENT MALFUNCTION.

Danger!

SPECIAL SAFETY PRECAUTIONS AND LOCKOUT TAGOUT PROCEDURES ARE REQUIRED FOR ALL OPERATIONS INVOLVING THE HANDLING, INSTALLATION, OR MAINTENANCE OF THE UNIT SYSTEM AND ANY ASSOCIATED BATTERY CABINETS. FAILURE TO FOLLOW SAFETY PROCEDURES COULD RESULT IN DEATH, INJURY OR DAMAGE TO EQUIPMENT.

MAINTENANCE

9.1 SA

FETY PRECAUTIONS

The ELI requires regularly schedule periodic maintenance.

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Danger!

THIS EQUIPMENT CONTAINS CIRCUITS THAT ARE ENERGIZED WITH HIGH VOLTAGES. ONLY TEST EQUIPMENT DESIGNED FOR TROUBLESHOOTING HIGH VOLTAGES SHOULD BE USED, PARTICULARLY FOR OSCILLOSCOPES AND PROBES.

ALWAYS CHECK WITH AN AC AND DC VOLTMETER TO ENSURE SAFETY BEFORE INITIATING CONTACT OR USING TOOLS. EVEN WHEN THE POWER IS OFF, DANGEROUSLY HIGH POTENTIAL VOLTAGES MAY EXIST AT CAPACITOR BANKS. ALWAYS OBSERVE BATTERY PRECAUTIONS WHEN OPERATING NEAR ANY BATTERIES.

FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN DEATH, INJURY OR DAMAGE TO EQUIPMENT.

Danger!

AND TAGGED “OFF” BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT. THE BATTERY MANUFACTURER’S SAFETY INFORMATION AND

MATERIAL SAFETY DATA SHEET IS LOCATED IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UNIT. FAILURE TO FOLLOW THOSE INSTRUCTIONS AND THE INSTRUCTION LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION, FIRE, EQUIPMENT MALFUCTION, OR ELECTROCUTION.

Danger!

BE CONSTANTLY AWARE THAT THE UNIT SYSTEM CONTAINS HIGH DC AS WELL AS AC VOLTAGES. WITH INPUT POWER OFF AND THE BATTERY DISCONNECTED, HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS. HOWEVER, POWER CIRCUIT MALFUNCTIONS CAN OCCUR, SO YOU SHOULD ALWAYS ASSUME THAT HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN. VERIFY THAT POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING CONTACT.

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Danger!

LETHAL VOLTAGES ARE PRESENT INSIDE THE EQUIPMENT EVEN WHEN THERE APPEARS TO BE NO INPUT POWER TO THE UNIT. PROTECT YOURSELF FROM THE RISK OF ELECTROCUTION BY REFERRING SERVICE TO QUALIFIED PERSONNEL ONLY.

9.2 WHEN TO CALL (1-800-PWR-SRVC – 1-800-797-7782)

Call for service if you encounter any of the following conditions:

1) Repeated start-up attempts are unsuccessful.

2) A unit fault occurs which cannot be cleared.

3) Normal operation of the critical load repeatedly causes an overload condition. This is not a unit fault but a qualified person must analyze the total load connected to the unit to prevent malfunction. Momentary overload conditions will be handled within the parameters of the unit but sustained overloads will cause failure.

4) Any indicators or alarms operate abnormally or continuously.

5) Any other abnormal function of the system occurs.

6) If any abnormal battery condition is detected.

7) When you are unsure of what action to take.

9.3 STEPS TO TAKE

If any of the above occur:

1) Consult Appendix C, LCD Display Menu and Troubleshooting Guide. Record information on the LCD Display to relay to OnLine Power Customer Service and Support.

2) Call OnLine Power Customer Support at 1-800-797-7782 or 1-800-PWR-SRVC.

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Preventive Maintenance List

Description

Visual inspection

Check Room Temperature

Removal of dust from all electronics

Verification of all electrical connection

Check all Batteries post and connection for corrosion

Check for batteries deformations

Record all batteries Nominal Voltages

Record all batteries Floating Voltages

Functional Test of all major components

Functional test of all electronics

Functional Test of system including batteries

Record all findings

9.4 PREVENTATIVE MAINTENANCE

The unit maintenance consists of the basic tasks listed in this section. Other maintenance functions require OnLine Power factory trained service personnel. In order to comply with the terms of the prorated battery warranty, you must maintain at least an annual individual voltage record of each battery with evidence that the terminal connections have been torque checked.

9.4.1 Maintenance Log

Carefully record keeping will ensure proper maintenance of the unit, and assist in the correction of any abnormal conditions.

At a minimum, the Maintenance log should contain the following information:

 Date of system start-up.  Dates that battery maintenance was performed.  Dates input, output, and battery status readings were checked and the values

displayed for these readings.

 Date of load changes.  Dates and summaries of all communications with OnLine Power service

personnel.

 Every six (6) months or at least annual, individual battery voltage & torque check.

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Danger!

THE BATTERY CIRCUIT BREAKER OPERATES AT THE RATED BATTERY VOLTAGES AT ALL TIMES. A TRIPPED BATTERY CIRCUIT BREAKER INDICATES A SERIOUS PROBLEM THAT MAY RESULT IN SERIOUS INJURY OR DAMAGE TO THE EQUIPMENT; DO NOT CLOSE THE CIRCUIT BREAKER WITHOUT KNOWING WHY IT FAILED. CHECK FOR A SHORT IN BATTERY OR CONNECTIONS. CALL ONLINE POWER CUSTOMER SERVICE AND SUPPORT FOR ASSISTANCE AT 1-800-PWR-SRVC.

Danger!

THE BATTERY ELECTROLYTE IS A DILUTED SULFURIC ACID THAT IS HARMFUL TO THE SKIN AND EYES. IT IS ELECTRICALLY CONDUCTIVE AND CORROSIVE. WEAR FULL EYE AND HAND PROTECTION ALONG WITH PROTECTIVE CLOTHING. IF THE ELECTROLYTE CONTACTS THE SKIN, WASH IT OFF IMMEDIATELY WITH WATER. IF ELECTROLYE CONTACTS THE EYES, FLUSH THOROUGHLY AND IMMEDIATELY WITH WATER. SEEK IMMEDIATE MEDICAL ATTENTION. SPILLED ELECTROLYTE SHOULD ADDRESSED PER APPROPRITE HARADIDEROUS SPILL CLEANUP PROCEDURES.

Danger!

DO NOT DISPOSE OF A BATTERY OR BATTERIES IN A FIRE. THE BATTERIES MAY EXPLODE CAUSING DEATH OR SERIOUS INJURY.

9.4.2 Periodic Testing of unit

The unit should be manually exercised on a periodic basis (once every three months, for example). This forces the unit to transfer to the battery and return to main power. This process activates self-diagnostic testing, which may reveal conditions that require attention.

9.4.3 Maintaining the Batteries

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Caution

Danger!

DO NOT GROUND BATTERY POSITIVE OR NEGATIVE

Caution

Do not substitute batteries from other manufacturers without the express approval of OnLine Power Customer Service personnel.

● The use of any battery other than Online-Power may cause damage to the

inverter and voids your Online-Power warranty.

Lead-acid batteries contain hazardous materials and must be handled, transported, and recycled or scrapped in accordance with federal, state and local regulations. Since lead is a toxic substance, lead-acid batteries should be recycled rather than scrapped.

A battery can present a risk of electrical short and high short circuit current. The following precautions should be observed when working on or around batteries:

● Remove watches, rings, necklaces, or other metal objects.

● Use only tools with insulated handles.

● Wear rubber insulating gloves and boots.

● Do not lay tools or metal parts on top of batteries.

● Disconnect charging source prior to connecting or disconnecting

battery terminals.

● Verify that battery cabinets are properly grounded.

Lead-acid batteries can present a risk of fire because they generate hydrogen gas. The following safety procedures must be followed:

● DO NOT SMOKE when near batteries.

● DO NOT cause flame or sparks in battery areas.

● Discharge static electricity from your body before touching

batteries by first touching a grounded metal surface.

When replacing batteries, use the same number of batteries, of the same

manufacturer, type and model that was supplied with the unit. To avoid system malfunction, replace all batteries in each string if one or more batteries fail to perform to specifications. Please record all individual cell voltages on the chart.

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Battery part number

Initial torque in LBS

Annual re-torque in LBS

Terminal Type

Hardware

PRC-12150 C

(150AH)

120 IN-LB / 13.6 NM

115 IN-LB / 13.6 NM

Copper Insert

Terminal

¼ - 20 UNC Bolt

UB 12750

88.5 IN-LB / 10 NM

84 IN-LB / 9.5 NM

Z1 "Z" post

type terminal

1 to 1.25" long bolt

w/14mm head, 14mm nut,

8mm washer & lockwasher

UB12900

88.5 IN-LB / 10 NM

84 IN-LB / 9.5 NM

Same as above

UB12110

88.5 IN-LB / 10 NM

84 IN-LB / 9.5 NM

Same as above

Battery part number

Initial torque in LBS

Annual re-torque in LBS

Terminal Type

Hardware

GSLF – 10512

120 IN-LB / 13.6 NM

115 IN-LB / 13.0 NM

Copper Insert

¼ "

GSLF - 12012

120 IN-LB / 13.6 NM

115 IN-LB / 13.0 NM

Copper Insert

¼ "

Ni-Cad P/N

Recommended Torque

Bolt Diameter

BM 112/ 138

66 IN-LB

7.5 NM

BM 148/ 184

177 IN-LB

20 NM

BM 195/231/277

266 IN-LB

30 NM

M10

NOTE: For annual re-torque; reduce 5 IN-LB from recommended torque value.

9.4.4 Battery Cabinets

Although the individual batteries are sealed and require minimal maintenance only, the batteries should be given a periodic inspection and electrical check every six months.

Battery Service Agreements are available through OnLine Power Customer Service and Support at 1-800-PWR-SRVC (800-797-7782).

In order to qualify for battery warranty replacement, you will need to show records of the battery maintenance history including battery numbers, battery voltages (individual cells), terminal torque measurements and dates of maintenance.

9.4.5 Power Connections

 Check for corrosion and connection integrity. Visually inspect wiring for discolored or

cracked insulation. Clean and / or re-torque as required.

 All Battery terminal connections must be tighten with proper torque value set in

accordance with the table or instructions provided by battery manufacturer.

 Use the correct torque tool to tighten the terminal bolts as indicate d in table below and

use all hardware's provided with batteries.

Type – Standard VRLA Battery

Type G – Longer warranty battery

Type N – Nickel-Cad battery (only nickel plated copper cable lugs should be used).

CAUTION: Torque all connections in accordance with the above tables unless provided from battery

manufacturer. Failure to do so may create an unsafe condition or fire hazard.

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9.4.6 Battery Terminals

 Check for discoloration, corrosion and connection integrity. Clean and tighten as

necessary.

 To access battery terminals, remove the top strapping material located at the lower

front of the battery shelf. Pull the battery forward to access the battery connections. Disconnect the cables connected to the battery. Once disconnected, insulate the cables to prevent accidental shorts (Use a protective boot or electrical tape). Before replacing the battery connections clean and re-torque the connection hardware.

 OnLine Power Customer Service personnel must approve use of non-standard batteries.

Please call at 1-800-PWR-SRVC (800-797-7782).

9.5 ONLINE POWER CUSTOMER SERVICE AND SUPPORT

Start-up, unit maintenance, battery maintenance, and preventative maintenance programs are available through your OnLine Power sales representative or through OnLine Power Customer Service and Support. A program of periodic maintenance is recommended once every six months, but is mandatory once every twelve months since heat and cold will effect the compression of the electrical connections and lack of maintenance will shorten the product's life expectancy possibly causing unsafe operating condition.

9.5.1 Start-Up Services

Various start-up services are available. See your sales representative or telephone OnLine Power Customer Service at 1-800-PWR-SRVC (800-797-7782).

9.5.2 Maintenance Agreements

Standard Full Service, 24/7 Full Service, and Extended On or OFF Site Maintenance agreements are available. See your sales representative or telephone OnLine Power Customer Service at 1-800-PWR-SRVC (800-797-7782).

9.5.3 Warranties

Contact OnLine Power Customer Service and Support at 1-800-PWR-SRVC (800-797-

7782) if you have any questions regarding the warranty on your unit, system or batteries.

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Abnormal

Description & Checkpoint

Solution

(1) AC input is correct, but rectifier does not operate and RECT AC FAIL LED lights up.

The rectifier breaker is not switch on.

Switch on the rectifier breaker.

The input voltage is not correct (out of the normal range).

Connect the right AC source.

The phase sequence of AC input is incorrect, input rotation error, and the LCD will display warning message

“RECT PHASE ERROR” in the

STATUS/WARN menu (MAIN menu → SELECT menu → STATUS/WARN menu). ROTATION ERROR LED on left side of the front panel will also light.

Correct the R.S.T. phase sequence. Generally, to exchange any two phases connection can solve this problem. If the abnormality cannot be corrected when the solution actions have been taken.

Refer to PCB LED Detecting Guide and check the 3C PCB.

(2) The ELI shuts down under AC mains failure.

The battery fuse (breaker/holder/disconnector) has not been closed.

Close the battery fuse breaker/holder/disconnector.

(3) No power supply for ELI control circuit and LCD cannot display.

The reserve breaker has not been closed (switched on).

Close the reserve breaker.

3B PCB has problem.

Refer to PCB LED Detecting Guide and check the 3B PCB.

9.5.4 HELP

Followings are some abnormal situations frequently asked and common solution is offered for trouble-shooting.

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Abnormal

Description & Checkpoint

Solution

(4) The voltage difference between NEUTRAL and GROUND has become abnormally high.

There is external wiring error of R.S.T phase and N. G., instead of ELI unit itself,.

Correct the external wiring system.

(5) The inverter cannot start up.

Other than INVERTER SS LED in left side of the front panel, other LEDs still illuminate.

Do trouble shooting according to the LED instruction.

Switch on the inverter before DC bus has been established completely. Normally, it takes around 30 seconds to establish the DC BUS once the reserve and rectifier breakers are closed.

Refer to the switch on procedure. Close the reserve and rectifier breakers and wait around 30 seconds or directly use batteries to establish the DC bus.

Bypass breaker has been closed (switched on).

Open the bypass breaker.

The output is overloaded. The LCD will

display warning message ‘ XXX% OVERLOAD’ in the STATUS/WARN menu (MAIN menu → SELECT menu → STATUS/WARN menu). XXX%

OVERLOAD LED on left side of the front panel and OVERLOAD LED on right side will also light.

Decrease the load to below the ELI’s rated power. In P&P modules1, the temperature sensor sockets on 3G PCB and hest sink are not connected properly. WARNINGLED of FUSE/TEMP still illuminate but LED in

3G PCB doesn’t, indicating DC BUS

may be over 240VDC.

Take out the P&P modules and connect them properly.

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Abnormal

Description & Checkpoint

Solution

(6) Fans do not work while ELI is on.

The fuses positioned behind PCB holder have been blown or are not installed properly.

Replace the fuses or install them properly.

Abnormal voltage output in R phase.

Refer to PCB LED Detecting Guide and check the 3T PCB of R phase.

(7) The rectifier shunt down and HIGH DC LED is lit.

Voltage limit function failure in the 3B, which contributes to the DC voltage, goes over 430V.

Refer to PCB LED Detecting Guide and check the 3B PCB.

3C PCB has problem.

Refer to PCB LED Detecting Guide and check the 3C PCB.

(8) Abnormal voltage in reserve.

RESERVE AC FAIL LED lights up. LCD menu also displays the abnormal voltage in reserve. (REAL TIME DATA menu → RESERVE DATA menu).

Check the reserve wiring and connect with the correct source. Fuse has blown in 3A PCB

Replace the fuse.

If the abnormality cannot be corrected after the solution actions have been taken.

Refer to PCB LED Detecting Guide and check the 3A PCB.

(9) Abnormal frequency in reserve.

RESERVE FREQ FAIL LED lights up. LCD menu also displays the abnormal voltage in reserve. (REAL TIME DATA menu → RESERVE DATA menu).

Check the reserve wiring and connect with the correct source. Fuse has blown in 3A PCB

Replace the fuse.

If the abnormal cannot be corrected after the solution actions have been taken.

Refer to PCB LED Detecting Guide and check the 3A PCB.

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Abnormal

Description & Checkpoint

Solution

(10) The inverter shuts down during operation, while the FAULT LED lights and buzzer beeps continuously.

Bypass breaker has been closed (switched on).

Open the bypass breaker. The inverter will restore running automatically.

The output is short-circuited, including the load itself.

Clear the short circuit at the output, then switch off the inverter.

Secondly, switch on once more to restart the inverter.

The output is overloaded. The LCD will

display warning message ‘ XXX% OVERLOAD’ in the STATUS/WARN menu (MAIN menu → SELECT menu → STATUS/WARN menu). XXX%

OVERLOAD LED on left side of the front panel and OVERLOAD LED on right side will also light.

Decrease the load to under the ELI’s rated power. Then the inverter will restore running automatically.

Heat Sink is over temperature. WARNING LED of FUSE/TEMP still illuminates.

Decrease the load to under the ELI’s rated power, then switch off the inverter. Secondly, switch on once more to restart the inverter.

IBGT-protect fuse has blown in P&P module1 or IGBT damage.

Take out the P&P module and replace fuse or IGBT.

When in battery back-up mode, the inverter shuts down due to battery low (lower than 295VDC).

Within 30 minutes, the inverter will restore running automatically once the AC main is back.

The Emergency Switch has been triggered.

Switch off the inverter first then on once more to restart the inverter.

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Abnormal

Description & Checkpoint

Solution

(11) Transferring failure between reserve and inverter.

DC BUS voltage becomes abnormal during transferring. DCV value can be read in LCD menu.

Take out the P&P module 2 and make sure the SCR drive connection is OK.

3P PCB has problem.

Refer to PCB LED Detecting Guide. Take out the P&P module 2 and check the 3P PCB.

LED A4(OTF) in the 3A PCB lights.

Refer to PCB LED Detecting Guide and check the 3G PCB.

In P&P modules, the temperature sensor sockets on 3G/3P PCB and hest sink are not connected properly. WARNING LED of FUSE/TEMP still illuminates.

Take out the P&P module and connect them properly. Phase sequence error of output transformer.

Change the transformer wiring.

If the abnormal cannot be improved as the aforesaid solution action has been taken.

Refer to PCB LED Detecting Guide and check the 3G and 3P PCB.

(12) Phase lack when AC output.

The mimic output LED in the front panel blinks.

Make sure the signal sockets in 3T PCB are connected properly.

Fuse has blown in 3T PCB

Replace the fuse.

If the abnormal cannot be corrected after the solution actions have been taken.

Refer to PCB LED Detecting Guide and check the 3T PCB.

(13) The mimic battery LED in the front panel blinks.

Batteries become worn out or damaged.

Replace batteries.

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Abnormal

Description & Checkpoint

Solution

(14) All LED in the front panel light up.

CPU inserting error in 3A or 3R PCB

Insert the CPU into correct socket.

(15) Communication interface is not working properly.

Communication cables are connected improperly.

Correct the wiring.

Communication software is not installed successfully.

Reinstall the software. Communication port setup error.

Correct the setup.

CPU inserting error in 3R PCB.

Insert the CPU into right socket.

If the abnormal cannot be corrected after the solution actions have been taken.

Refer to PCB LED Detecting Guide and check the 3R PCB.

(16) The inverter has been turned on but no action of inverter.

The inverter switches of & are not pressed simultaneously.

Try to press these two buttons simultaneously

PCB Connection is not good.

Refer to PCB LED Detecting Guide and check the connection of 3W PCB.

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Appendix A

Battery Exerciser setting

1. CONNECT THE DB9 WIRE FROM UPPER SOCKET OF CNR21 …

2. TO USB OF LAPTOP VIA A RS-232 TO USB CONVERTER.

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