OnLine Power Protector 3 User Manual

0

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Price $50.0

Protector 3

Three Phase Uninterruptible Power System
10 – 62.5 kVA

User Manual

Installation
Operation

Maintenance

Doc #. 6002-1874

Rev. B

OnLine Power

TABLE OF CONTENTS

SECTION

PAGE
REVISION HISTORY c
PROPRIETARY d
SECTION 1 - SAFETY 1-1
SECTION 2 - OVERVIEW 2-1

2.1 INTRODUCTION 2-1
Illustration 2.1: Protector 3 `2-1

2.2 BENEFITS 2-2

2.3 PRODUCT FEATURES 2-2
Illustration 2.2: Unit Component Layout 2-4
Illustration 2.3: Sub Assembly Component Location 2-5

2.4 FUNCTIONAL DESCRIPTIONS 2-6
Illustration 2.4: Functional Block Diagram for Single Input Power System 2-7
Illustration 2.5: Functional Block Diagram for Dual Delta Input Power System 2-8

Illustration 2.6: Functional Block Diagram for Dual Wye Input Power System 2-8

2.5 THEORY OF OPERATION 2-9

2.6 OUTPUT LOADS 2-10

2.7 OPTIONS (See more detail on Section 6) 2-10

SECTION 3 - INSTALLATION 3-1

3.1 SITE PLANNING AND PREPARATION 3-1
Table 3-A: Site Planning Specifications 3-1
Illustration 3-1: Cable Access and Mounting 3-2

3.2 EQUIPMENT UNPACKING 3-3

Illustration 3.2: Fork lifting 3-3

3.3 UNIT INSTALLATION 3-4

Illustration 3-3: Protector Customer’s Connection 3-5

3.4 REMOTE SIGNALLING CONNECTIONS (OPTIONAL) 3-6

3.5 STORAGE 3-7

SECTION 4 - OPERATION 4-1

4.1 START-UP PROCEDURES 4-1

4-2 OPERATION 4-3

4.3 FIELD REPLACEABLE UNITS 4-3

Illustration 4-1: Heat Sink Assembly (FRU) 4-4

4.4 RENEWAL PARTS 4-5

SECTION 5 - MAINTENANCE 5-1

5.1 SAFETY PRECAUTIONS 5-1

5.2 WHEN TO CALL 5-3

5.3 STEPS TO TAKE 5-3

5.4 PREVENTIVE MAINTENANCE 5-3

5.5 ONLINE POWER CUSTOMER SERVICE AND SUPPORT 5-6

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OnLine Power

SECTION

PAGE

SECTION 6 – SYSTEM OPTIONS 6-1

6.1 MAINTENANCE BYPASS SWITCH 6-2

Illustration 6-1: External Maintenance Bypass Switch Diagram 6-2
Illustration 6-2: Maintenance Bypass Switch 6-3

6.2 AUDIO ALARM WITH SILENCE SWITCH 6-5

6.3 REMOTE UPS STATUS PANEL 6-5

6.4 FORM “C” CONTACTS FOR ALARMS 6-5

6.5 TRANSIENT VOLTAGE SUPPRESSOR SYSTEM 6-6

6.6 NORMALLY ON/OFF NORMALLY OUTPUT AUX. CIRCUIT BREAKERS 6-6

6.7 EXTERNAL OUTPUT AUX. CB’S IN PANEL BOARD 6-6

6.8 10% INPUT CURRENT HARMONIC FILTER 6-7

6.9 5% INPUT CURRENT HARMONICS FILTER 6-7

6.10 EMI FILTER 6-7

6.11 HIGHER KAIC NORM ON/OFF OUTPUT CB 3 AND 3-PHASE 6-7

6.12 DUAL INPUT SYSTEM WYE/WYE 6-8

6.13 DUAL INPUT SYSTEM DELTA/WYE 6-8

6.14 DUAL INPUT SYSTEM DELTA/DELTA 6-8

6.15 SEISMIC MOUNTING BRACKET 6-8

6.16 STACKABLE RACK 6-8

6.17 POWER FLOW MIMIC 6-8

Illustration 6-3: Power Flow Mimic 6-8

6.18 GLOBAL MONITORING SYSTEM 6-9

6.18.1 Local on UPS - Event Log 6-9

Illustration 6-4: Logged Events 6-9
Illustration 6-5: Status Screen 6-9
Illustration 6-6: System Info 6-10

6.18.2 Local on UPS – Aux.CBs Trip Monitor with Event Log 6-10

Illustration 6-7: Auxiliary CB Trip 6-10

6.18.3 Local on PC via RS 232 6-11

Illustration 6-8: Sample PC Screen 6-11

6.18.4 Local on PC via RS 485 6-11

6.18.5 Gms Remote dial up Monitor 2000 6-12

Illustration 6-9: Monitoring 2000 Front View 6-12
Illustration 6-10: Manager 2000 Screen 6-12

6.18.5.2 GMS Operation, Status, Alarm, Events Log, E-mail 6-13 to 6-18

6.18.6 GMS WEB/SNMP (GWS)Status , Event log 6-19 to 6-38

6.19. ECC – EMERGENCY CIRCUIT CONVERTER 6-39

6.20 ECC – EMERGENCY CONTROL MODULE 6-40

6.21 EVENT LOG WITH 1625-344-01 PCBD ASSY. 6-41 TO 6-46

APPENDICES

APPENDIX A – SPECIFICATIONS A-1
APPENDIX B – BATTERY CONNECTIONS B-1
APPENDIX C - LCD DISPLAY MENU & TROUBLESHOOTING GUIDE C-1
APPENDIX D – INPUT & OUTPUT AMPACITY FOR VARIOUS MODELS D-1
APPENDIX E – DRAWINGS & TABLES, REQUEST FOR TURN ON E-1

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REVISION HISTORY

REV DATE PRIMARY REASON FOR CHANGE

A Mar. 05, 2007 Production Release.
B Jan 19, 2009 Production Release.

LIST OF EFFECTIVE PAGES

PAGE REV

Title Page B
a to e B
1-1 to 1-4 B
2-1 to 2-10 B
3-1 to 3-7 B
4-1 to 4-5 B
5-1 to 5-6 B
6-1 to 6-14 B
A-1 to A-3 B
B-1 to B-5 B
C-1 to C-2 B
D-1 to D-1 B
E-1 to E-24 B

PAGE REV PAGE REV PAGE REV PAGE REV

c

OnLine Power

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.

© 2007 OnLine Power, Inc. – All rights reserved

d

OnLine Power

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, medical­grade). 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: [phone]
FAX No: [phone]
E-mail: [e-mail]

Office Hours are 7:00 AM to 5:30 PM PST

SERVICE

If you require assistance, please call our 24-hour toll free hot line 800-PWR-SRVC (800-797-

7782). Please have the following information from your unit’s nameplate available to speed
assistance:

Serial Number:
kVA/Power Rating:
Input Voltage:
Output Voltage:
Manufacturer Date:

e

OnLine Power

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.

SECTION 1 - SAFETY

Warnings labeled with the symbol indicate that there is a high

Caution

probability of equipment failure, damage, or destruction if instructions are not
followed.

Danger!

ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT
TO INSTALL OR REPAIR THE UPS 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 FAILURE.

Danger!

READ THIS MANUAL IN ITS ENTIRETY BEFORE PERFORMING THE
INSTALLATION, START-UP, OPERATION, OR MAINTENANCE OF THE UPS
(Uninterruptible Power System) OR BATTERY SYSTEMS. FAILURE TO DO SO
COULD RESULT IN ELECTROCUTION, FIRE, EXPLOSION, OR EQUIPMENT
FAILURE.

If you require assistance, call toll free 800-PWR-SRVC (800-797-7782). Please have the

following information from your unit’s nameplate available to speed assistance:

Serial Number:

kVA/Power Rating:

Input Voltage:

Output Voltage:

Manufacturer Date:

1-1

OnLine Power

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 EQUIPMENTS, 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.

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

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.

Danger!

Danger!

Danger!

OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION
OR SERVICE OF THE UPS 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 UPS.
FAILURE TO FOLLOW THOSE INSTRUCTIONS AND THE INSTRUCTION
LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN
EXPLOSION, FIRE, EQUIPMENT FAILURE, OR ELECTROCUTION.

Danger!

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OnLine Power

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.

IN CASE OF FIRE INVOLVING ELECTRICAL EQUIPMENT, ONLY CARBON
DIOXIDE FIRE EXTINGUISHERS, OR THOSE APPROVED FOR USE ON
ELECTRICAL EQUIPMENT, SHOULD BE USED. USE OF WATER ON FIRES
INVOLVING LIVE HIGH VOLTAGE ELECTRICAL CIRCUITS COULD PRESENT

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!

Danger!

Danger!

Danger!

BE CONSTANTLY AWARE THAT THE UPS 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 FAILURES 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!

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

1-3

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INTERNAL BATTERY STRAPPING MUST BE VERIFIED BY THE CUSTOMER

Danger!

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 UPS TO PREVENT
AN ACCIDENT THAT COULD RESULT IN INJURY OR DEATH.

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 SHOULD
BE RECYCLED RATHER THAN DISCARDED.

DO NOT DISPOSE OF BATTERIES IN A FIRE, THE BATTERIES MAY

Danger!

EXPLODE.
DO NOT OPEN OR MUTILATE THE BATTERIES. RELEASED ELECTROLYTE

IS HARMFUL TO THE SKIN AND EYES AND MAY BE TOXIC.
A BATTERY CAN HAVE A HIGH SHORT CIRCUIT CURRENT AND PRESENT A

RISK 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. CONT ACT 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.

1-4

OnLine Power

2.1 INTRODUCTION

The Protector 3 UPS system is designed for switch mode power supplies, computer loads, with no
derating, drawing sine-wave input current that is power factor corrected. The Protector 3 meets or
exceeds life safety codes of UL1778. These codes were established to allow the UPS to provide power
during a power failure.

When input power to the Protector 3 is lost during a power outage, the system will automatically draw
power from its internal battery supply without any interruption. The critical load will receive only clean
sine wave power. The optional output transformer allows multiple output voltages as well as input
voltages that are different than output voltages. The internal VRLA (valve regulated lead-acid),
maintenance-free batteries provide specified time of backup power.

Upon restoration of input power, the Protector 3 automatically resumes normal operation, and
immediately begins to recharge the batteries.

The Protector 3 has an internal bypass circuit, which maintains the power to the load in case of internal
UPS failure.

SECTION 2 – OVERVIEW

The Protector 3 provides comprehensive monitoring capabilities. In addition to the LCD display, it
provides five dry relay contacts for remote monitoring capabilities. The Protector 3 contains, as standard
features, an AS 400, RS 232 protocol interface, RS485 data transmission ports and many other
communication options.

The Protector 3 is an on-line three phase PWM inverter available in output rating of 10, 15, 20, 25, 30, 40,

50, and 62.5 kVA. The Protector 3 is listed for compliance to UL1778, UL924A and CSA107.1 Standards.
The Protector 3 is available with an input or output voltages of 480Y/277 or 208Y/120 VAC, three phase.
This information is provided on the nameplate located on the inside front door of the UPS. See Appendix
A for a complete listing of the Protector 3 specifications.

ILLUSTRATION 2-1 PROTECTOR 3

2-1

OnLine Power

2.2 BENEFITS

Electrical disturbances can come from practically anywhere: from the incoming power lines and even from
within a building. Outside electrical disturbances include lightning strikes, utility switching, brown-outs,
and accidents. Electrical disturbances in a facility can be caused by load cycling (elevators, HVAC
systems, etc.), fault conditions, welders, and other electrically noisy equipment. Whether the electrical
disturbances are generated outside or within the facility, the following power problems can occur:

Complete power outages;
Brown-outs including momentary sags;
Voltage surges;
Transients including common-mode and transverse-mode noise;
Frequency shifts and fluctuations.

Sensitive equipment needs protection from power problems. Without power protection, users of sensitive
equipment may experience:

Loss of data;
Database corruption;
Rebuilding of files;
Equipment and component deterioration;
Premature equipment failures;
Unexpected equipment malfunctions;
Missed deadlines, especially during batch processing;
Loss of real time transaction processing;
Loss of employee productivity

It offers significant advantages over other alternatives.

The convection cooled, OnLine PWM inverter system, is virtually silent and can be installed anywhere.

On-line PWM technology provides switchover from utility to battery power without any interruption.

The Protector 3 is designed to fit the needs of virtually all power conditioning and UPS applications. It
has been designed to power all forms of modern data processing, communication, and process control
equipment. The Protector 3 does not require any de-rating, as other UPS products may, when powering
100% electronic loads including switching mode power supplies.

The Protector 3 protects sensitive electrical equipment, such as computer servers, telecommunication
networks, LANs, multi-user, and instrumentation systems from electrical interference including problems
associated with poor quality AC power sags and complete power outages.

2.3 PRODUCT FEATURES

The following describes the major blocks within the Protector 3. Please refer to Illustration 2-3

Subassembly Component Location to find specific items.

2-2

OnLine Power

2.3.1 Input Contactor K1 (Illustration 2-3, Item 20)

The input contactor is multifunctional. First, it provides connections for the input power to the UPS.
Secondly, the contactor disconnects the input line when an outage occurs so that there is no back feeding
of power into the power line. Finally, the contactor allows for automatic UPS operation upon a complete
discharge of the batteries. No operator intervention is required when power to the UPS is restored after a
complete battery discharge.

2.3.2 Input Transformer (T3) (Illustration 2-2, Item 2)

The input transformer adjusts the input voltage for proper rectifier DC voltage, depending on UPS rated
power and back-up capacity.

2.3.3 Battery Charger (Illustra tion 2.3, Electronics Tray)

The battery charger maintains the batteries at full charge. After a battery discharge, the charger will
automatically recharge the batteries upon restoration of input power. This circuit is on the Power Board.

2.3.4 Power Board Assembly with IGBT’s (Illustration 2.3, Item 3)
The Power Board is bolted onto the IGBT (Insulated Gate Bipolar Transistor) blocks that are mounted on a

heat sink. The complete Heat Sink Assembly with IGBTs and Power Board is replaceable as a single part.

This FRU (Field Replaceable Assembly) converts all the power, i.e. input AC power converted to DC bus,

battery power boosted to DC bus, and finally DC bus power converted to output AC power using PWM
technology for a smooth AC sine wave. In case of a catastrophic failure, the complete Heat Sink Assembly
is easily replaceable using only a screwdriver. The Power Board also contains the housekeeping power
supplies and drivers for the IGBTs. The entire assembly provides the landing place for all internal input,
output, DC cables and metering devices for control and monitoring of the unit input and output currents.

2.3.5 Control Board (Illustration 2.2, Item 10)

The microprocessor with unit specific firmware and control circuitry is located on the Control Board. The
Control Board is mounted on the cabinet door and communicates with the Power Board (A2) via a ribbon
cable. It monitors the input and output voltages and generates the command to close or open the input
contactor and to sense and change the status of the bypass static switch. The Control Board sends data to
the LCD panel located on the door where actual status and parameters are displayed. It additionally has
AS400, RS232 and RS485 output capabilities and supports various communication options.

2.3.6 Output Static S witch (Illustration 2.3, Item 18)

This SCR solid-state switch connects the output of the inverter (UPS) to the load. It is connected on the
primary side of the optional output isolation transformer. This switch shuts off in case of a problem or
failure within the UPS and transfers the load directly to the utility input via the bypass static switch. It
maintains its status opposite to that of bypass switch.

2.3.7 LCD Display Panel (Illustration 2.2, Item 11)
The LCD (Liquid Crystal Display) panel provides all the input, output, battery metering and alarm data, and

UPS status for customer use on a constantly scrolling set of 2 default screens with continuous update.

2-3

OnLine Power

2.3.8 Output Isolation Transformer (Illustration 2.2, Item 1)

The output isolation transformer provides isolation between the inverter and protected output. The power
to the primary of this transformer is received from UPS and is transformed to required output voltage
levels.

2.3.9 Maintenance Bypass Switch (Illustration 2.2, Item 28)
The MBS (Maintenance Bypass Switch) removes the UPS from the power grid providing utility input

directly to the load in case of a problem with the UPS.

2.3.10 Battery Bank – located in External Battery Cabinet(s)

The battery bank consists of sealed, maintenance-free batteries. The batteries provide emergency power
during power outages. The battery bank includes a breaker for over current protection and DC disconnect.

2.3.11 System Component Layout

ILLUSTRATION 2-2: COMPONENT LAYOUT

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OnLine Power

1. Output Transformer (T1)

2. Auto-Transformer (T3)

3. Power Board Assembly (A1)

4. Input/Output/Battery/DC Buss
Terminal Block

5. Output Inductor (L2)

6. Diode Bridge

7. DC Choke (L4)

8. Input Inductors (L1)

9. High Frequency Noise Filter
Capacitors, Output and Battery
Power

10. Control Board (A2)

11. LCD Display Board

12. Output High Frequency Filter
(Optional) (C5, C6, C7)

13. Terminal Block to remove heat
sink assembly (TB4)

14. Control Power Transformer (T2A)

15. Fan Fuse (F3 - F6)

16. IGBT Heat Sink Assembly

17. Control Fuses (F2, F1)

18. Heat Sink (Bypass SCR)

19. Fan(s) (B1 - B6)

20. Input Contactor (K1)

21. Ground Terminal

22. Input Breaker (CB1)

23. Battery Breaker (CB2)

24. Output Breaker (CB3)

25. Output Distribution Breakers
(Optional)

26. Neutral Bus

27. Customer Input/Output
Connection Terminal Blocks

28. Maintenance Bypass Switch
(SW1)

29. SCRs and Snubbers

30. Contactor Coil Transformer (T5)

31. Fan Transformer (T4)

32. Inverter Test Switch

33. RS232 (Option)

34. TVSS (Option)

35. TVSS Fuse (Option)

36. 5 Form “C” Alarm Terminal
(Option)

37. MBS S –1 Toggle Switch

ILLUSTRATION 2-3: SUB-ASSEMBLY COMPONENT LOCATION

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OnLine Power

2.4 FUNCTIONAL DESCRIPTION

Illustrations 2-4 thru 2-7 depict functional block diagrams of the Protector 3. These diagrams provide an
excellent tool for identifying the major building blocks within the Protector.

2.4.1 Main input circuit breaker - optional

The main input circuit breaker provides Protector 3 with incoming power isolation and input overcurrent
protection.

2.4.2 Input Contactor

Input contactor controls power applied to the unit. The microprocessor control circuit verifies that the UPS
is in “normal” and not at a “fault” condition and that the input voltage and frequency are within an
acceptable range. Only then it energizes the contactor closing coil via control transformer and fuse.

2.4.3 Input Inductors

The input inductors are a 3 phase input filter.

2.4.4 Inverter

When the AC input power is not available to power the load, the inverter converts the energy stored in the
battery bank to AC power to supply power to the load. The pulse width modulated (PWM) inverter utilizes
high speed, high efficiency IGBTs for fast response, sinusoidal power.

2.4.5 Battery charger

The battery charger converts AC power into regulated DC power to re-charge and to maintain the charge
on the battery bank. The charger is fully automatic with a current tapering feature so that battery damage
will be prevented in case of a charger malfunction or increased battery temperature. The charger is sized
to maintain a full charge even when the input voltage is at the low line limit for indefinite periods of time.

2.4.6 Battery

The battery bank, consists of 16, 24, 26 or 46, 12 Volt batteries, providing the reserve energy to sustain
the load when suitable AC input power is not present. The batteries are sealed, maintenance-free, VRLA

(Valve Regulated Lead Acid) construction.

2.4.7 DC Choke

The DC choke helps boost battery voltage to a higher internal DC bus voltage.

2.4.8 Output AC Inductor

The Output AC Inductor acts as a filter circuit component to reduce high frequency noise to the output
transformer.

2.4.9 Output Transformer

The Output Transformer performs two critical functions. First, it provides excellent common mode and
normal mode noise isolation of the load from the input or inverter power. Secondly, it provides voltage
transformation and tight regulation of the output voltage while the Protector is operating from its internal
inverter.

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2.4.10 Inverter Test Switch

The Inverter Test Switch is a momentary push button for testing the Protector #3 and its batteries for
proper operation. With Protector 3 in operation, test switch is pushed and held, the unit will automatically
transfer to battery operation. The UPS will continue to run on batteries until the switch is released. Upon
release, the Protector 3 transfers back from battery to inverter and resumes normal operation.

2.4.11 DC Supply Transformer

The step down transformer, protected with fuse supplies DC rectifier which produces voltages for power
system boards. The primary of this transformer has various taps that need to be matched to the actual
main input voltages.

2.4.12 Maintenance bypass switch

This MBS can be used for maintenance when the inverter fails or PM is required. This MBS will transfer
the input power directly to critical load. Before switching the MBS to maintenance position, first turn on S1
(toggle switch), then switch to maintenance (MAN) position. Refer to the operation label on the unit. After
repair or PM, the MBS can be switched to UPS position. First turn-off S1 (toggle switch), then switch MBS
to UPS (AUTO) position.

TVSS

2

TB10

1

2

3

4

N

INPUT

POWER

3 PHASE

Optional

Line removed when External Reserve Input Power is in use.

1

Use for different Input and Output Voltage unit.

2

NOTE: Optional External Wrap-around Bypass Switch is available.

INPUT

CIRCUIT

BREAKER

INPUT

CONTACTOR

INPUT
XFMR

Batt.
Cab 1

1

BATTERY
CIRCUIT
BREAKER

Batt.
Cab 2

Batt.
Cab 3

OUTPUT

XFMR

Batt.
Cab 4

STATIC
SWITCH

INVERTER

STATIC

SWITCH

Batt.
Cab 5

OUTPUT
CIRCUIT

BREAKER

AUX OUTPUT CBs

BATTERY
CABINET

INPUT

MAINT.
BYPASS
SWITCH

TB11

1

2

3

N

4

OUTPUT

POWER

3 PHASE

ILLUSTRATION 2-4: FUNCTIONAL BLOCK DIAGRAM FOR SINGLE INPUT POWER

2-7

OnLine Power

1

* Cabinet 1, 48 inch tall

RESERVE
INPUT
POWER

(plus Gnd)

MAIN
INPUT
DELTA

GND

1

/ WYE

2

XFMR

3

GND

4

TVSS

TB10

Optional External ∆ - WYE XFMR

1

when the reserve is 3 wire Delta input.

INPUT

CIRCUIT

BREAKER

1

2

3

4

INPUT

CONTACTOR

1

2

3

4

1

2

3

(N)

4

RESERVE

BYPASS POWER

From Internal

Transformer

INPUT
XFMR

Batt.
Cab 1

CONTACTOR

BATTERY
CIRCUIT

Batt.

Batt.

Cab 2

Cab 3

OUTPUT

XFMR

Batt.
Cab 4

STATIC
SWITCH

INVERTER

STATIC

SWITCH

Batt.
Cab 5

BATTERY
CABINET

OUTPUT
CIRCUIT

BREAKER

INPUT

MAINT.
BYPASS
SWITCH

TB11

1

2

3

4

OUTPUT

POWER

3 PHASE

ILLUSTRATION 2-5:

FUNCTIONAL BLOCK DIAGRAM FOR DUAL DELTA INPUT POWER

2-8

OnLine Power

3

RESERVE INPUT
POWER SOURCE

1

2

3

4

N

CONTACTOR

1

TVSS

TB10

1

2

3

4

N

INPUT

POWER

3 PHASE

Optional

Line removed when External Reserve Input Power is in use.

1

Use for different Input and Output Voltage unit.

2

Reserve input voltage must be same as UPS output voltage.

3

NOTE: Optional External Wrap-around Bypass Switch is available.

ILLUSTRATION 2-6:

INPUT

CIRCUIT

BREAKER

INPUT

CONTACTOR

INPUT
XFMR

FUNCTIONAL BLOCK DIAGRAM FOR DUAL WYE INPUT POWER

OUTPUT
CIRCUIT

BREAKER

AUX OUTPUT CBs

BATTERY
CABINET

XFMR

Batt.
Cab 4

STATIC
SWITCH

INVERTER

STATIC

SWITCH

Batt.
Cab 5

2

OUTPUT

BATTERY
CIRCUIT
BREAKER

Batt.

Batt.
Cab 2

Batt.
Cab 3

Cab 1

INPUT

MAINT.
BYPASS
SWITCH

TB11

1

2

3

4

OUTPUT

POWER

3 PHASE

N

2-9

OnLine Power

2.5 THEORY OF OPERATION

2.5.1 Standby Mode

After power is applied, the system is placed in STANDBY mode and a self-check starts. During this
period, the start subroutine checks for the input voltage and proper operation of the inverter and bypass
SCR’s. After the routine is completed and check confirmed OK, the system goes into the NORMAL mode.

2.5.2 Normal Mode

The input contactor K1 receives a closing signal, connecting input power to the DC supply transformer.
The DC rectifier supplies the battery charger, Control Board and the DC/AC inverter circuit. The battery
charger is then activated allowing the batteries to be continuously charged. The on-line DC/AC inverter
converts the DC voltage to a pulse-width-modulation (PWM) waveform. This waveform is filtered and
reconstructed back to a desired AC output.

2.5.3 Response To Input Power Failure

If the system controller senses a change in input frequency of more than +
voltage, it will consider it an input failure and will immediately open the input contactor, isolating the UPS
from the facility. At the same time, the charger is turned off and the battery bank becomes a DC supply
source to the inverter circuit, maintaining an uninterrupted AC supply to the protected load. The LCD
screen will display a ”UPS PROBLEM” message. When the facility power returns, stabilizes and is in
phase with the backup power, the system controller closes the input contactor and the system returns to
NORMAL. If the battery voltage drops below 16% of its nominal value and the facility power remains off,
then the system will assume a FAILURE mode.

2.5.4 UPS Failure

The System controller will issue a FAILURE message on the LCD screen if any of the following conditions
happen:

• Internal failure

• System overheats

• Battery bank undervoltage

During a FAILURE, the system stops its backup operation, inverter SCRs are switched OFF, and bypass
SCRs are switched ON. A summary alarm 5V signal is sent to the hardwired interface. The system
remains in this mode until power is cycled or the system has been repaired when needed. (See page 3-6)

2.5.5 UPS Problem

The System controller will issue a UPS PROBLEM message on the LCD screen if any of the following
conditions occur:

3 Hz or an out of range input

• Input power failure

• Output overload

During a PROBLEM mode, inverter IGBs remain on and an alarm signal may be sent to the signal
interface. The system will reset itself as soon as the problem disappears.

2-10

OnLine Power

2.6 OUTPUT LOADS

The Protector 3 delivers computer-grade, sine-wave power; the preferred power source for all electronic
equipment. There are, however, certain types of loads that exhibit an excessive inrush current when first
turned on or at other times during operation.

The capacity of the Protector 3 may need to be greater than what would be estimated based on the
nameplate requirements of loads previously discussed. Contact your OnLine Power dealer or the factory
directly if you have any questions about powering unusual loads from your Protector 3.

2.7 OPTIONS (See section 6 for details)

The following options are available with the Protector 3:

Normally ON output CB’s
Normally OFF output CB’s

Auxiliary Output Circuit Breaker
Various size, type, and quantity of output distribution breakers for emergency circuits
Input Circuit Breaker with High KAIC rating
High Temperature Alarm
Output Overload Alarm
Remote Meter Panel
AS400
LED Indicators
Extended Battery Run Times
GMS – Global Monitoring System

2-11

OnLine Power

SECTION 3 – INSTALLATION

3.1 SITE PLANNING AND PREPARATION

The Protector 3 is designed for installation indoors and meets NEMA specifications for operating

temperature, humidity, and utility voltage. These cabinets are rugged and corrosion resistant. The footprint
of the Protector 3 is less than 6 square feet. Listed below are the environmental specifications for the

Protector. Adequate clearance in the front of the equipment MUST

3.1.1 Operating Environment

• AMBIENT TEMPERATURE 0° to 40° C

• OPERATING ALTITUDE 1,829 M (6,000 FT) DERATE 10% FOR EACH ADDITIONAL

305 M (1,000 FT) UP TO 2,744 m (9,000 FT)

• RELATIVE HUMIDITY 0% to 95% (non-condensing)

Operating the Protector and batteries at either extreme of the temperature range may affect the long-term

reliability of the system. This is especially true of the sealed, maintenance-free batteries. Sealed,
maintenance-free batteries are designed to operate at normal room temperatures (72 to 77 °F).

3.1.2 Storage Environment

Provide a storage environment which meets the following conditions:

• AMBIENT TEMPERATURE -20°C to 68°C

• RELATIVE HUMIDITY 0% to 95% non-condensing

• NOTE System should be stored in its original packaging

be provided for service access.

3.1.3 Location Considerations (Illustration 3-1)

Site Planning Specifications: Refer to details in Table A-3

KVA INPUT - OUTPUT VOLTAGE MODEL NUMBER (0.8 Power Factor)

10 208Y/120 - 208Y/120 PT010B0500T3-VA 39 X 68 X 18 192

10

15 208Y/120 - 208Y/120 PT015B0500T3-VA 39 X 68 X 18 192

15

20 208Y/120 - 208Y/120 PT020B0500T3-VA 39 X 68 X 18 192

20

25 208Y/120 - 208Y/120 PT025B0500T3-VA 39 X 68 X 18 288

25

30 208Y/120 - 208Y/120 PT030B0500T3-VA 39 X 68 X 18 288

30

40 208Y/120 - 208Y/120 PT040B0500T3-VA 39 X 68 X 18 312

40

50 208Y/120 - 208Y/120 PT050B0500T3-VA 39 X 68 X 18 552

50

62.5 208Y/120 - 208Y/120 PT062B0500T3-VA 39 X 68 X 18 552

62.5

480Y/277 - 480Y/277 PT010H0900T3-VA 39 X 68 X 18 192

480Y/277 - 480Y/277 PT015H0900T3-VA 39 X 68 X 18 192

480Y/277 - 480Y/277 PT020H0900T3-VA 39 X 68 X 18 192

480Y/277 - 480Y/277 PT025H0900T3-VA 39 X 68 X 18 288

480Y/277 - 480Y/277 PT030H0900T3-VA 39 X 68 X 18 288

480Y/277 - 480Y/277 PT040H0900T3-VA 39 X 68 X 18 312

480Y/277 - 480Y/277 PT050H0900T3-VA 39 X 68 X 18 522

480Y/277 - 480Y/277 PT062H0900T3-VA 39x68x18 522

CABINET SIZE W” X

H” X D”

BATTERY
VOLTAGE

3-1

OnLine Power

3.1.4 Cable Access

Blocking vents may cause equipment malfunction and failure.

The Protector 3 Cabinet Installation Diagrams for 10~62 KVA models provide cable/conduit openings on the

top and sides of the cabinet. Refer to Illustration 3-2.

Caution

34.37"2.3"

5"

1.5"

31.87"

CABLE ENTRY

TOP VIEW

1.25"

CABLE ENTRY
3/4"/1" & 1.5"/2"

CONDUIT

11.00"

8.00"

4.50"

CABLE ENTRY
3/4"/1" & 1.5"/2"

CONDUIT

18"

3.25"

46"

68"

14"

39"

FRONT VIEW

Forklifting Slot

CABLE ENTRY
3/4"/1" & 1.5"/2"

CONDUIT

46" 3.25"

RIGHT SIDE VIEWLEFT SIDE VIEW

Floor Mounting Holes

2"

34.75"

BOTTOM VIEW

2.12"

ILLUSTRATION 3-1: CABLE ACCESS AND MOUNTING

3-2

OnLine Power

Caution

Each model of the Protector 3 is designed to supply a maximum load
which is determined by its kVA (1000’s of volt-amperes) and kW rating. It

is very important that the load is within the rating of this Protector to
ensure that the connected loads will be properly supported.
Each electrical device to be powered by the Protector 3 should have a
specification sheet attached to it, which specifies the amount of power it
requires. In addition, this information should be listed in the manual
supplied with each piece of equipment. The device’s nameplate should
also list the electrical requirements of the device.
The total load to be powered by the Protector 3 must not exceed its kVA
rating. If the total load is exceeded, the Protector monitoring will sense an
overload condition and a summary alarm will occur.

3.1.5 Pre-Installation

All customer connections are brought through knockouts located on the top or on the sides of the unit. The
Protector 3 consists of one electronics and one or more battery cabinets. Before unpacking the equipment,
inspect the exterior, the shipping container, and the equipment itself for damage that may have occurred
during transit. If the shipping container or equipment itself shows evidence of damage, note the damage on
the receiving document before signing for receipt of the equipment. Damage claims should be filed directly
with the carrier.

3.2 EQUIPMENT UNPACKING

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

Front

Forklift Forks

Danger!

Remove the equipment from the shipping
carton. Since the Protector is designed for
pad mounting installations, there are no
casters. It is suggested that a forklift be used
to remove the Protector from its shipping
pallet. See illustration 3-2 for the location of
forklift slot.

ILLUSTRATION 3-2: FORKLIFTING

3-3

OnLine Power

3.3 UNIT INSTALLATION

3.3.1 Mechanical Installation - Preparing to Install UPS Unit

1) Before placing the Protector onto the mounting bolts (where it will be installed), the conduit
knockouts need to be removed. The conduit knockouts are located on the sides and top of

the cabinet. (See illustration 3-2) NOTE: If site restrictions prevent routing of conduit to

the locations where conduit knockouts are located, do not drill holes in the cabinet
without first consulting OnLine Power at 800-PWR-SRVC (800-797-7782). The conduit
knockouts provided are positioned to prevent airflow disruptions that could cause the
unit to overheat. Our engineers will be happy in assisting you in locating the conduit to
maintain unit reliability.

2) Determine which knockouts will be used to bring cables into and out of the unit. Only remove
the conduit knockouts that are to be used.

3) Measure the locations for the conduits on the conduit knockouts.

4) Punch holes in the conduit knockouts for the conduits.

5) Anchor the Protector to the mounting pad at the four (4) mounting locations (Shwon on
illustration 3-1).

6) Anchor the conduits to the conduit knockouts

If equipment is not ready for normal operation, it must be protected from dust to prevent damage to
equipment. This concludes the mechanical installation.

3.3.2 Electrical Connection Arrangements B-9, B-10, and B-11

VERIFY THAT ALL CUSTOMER-SUPPLIED WIRING IS DE-ENERGIZED
BEFORE PERFORMING ANY ELECTRICAL WORK. FAILURE TO DO SO

COULD RESULT IN ELECTROCUTION, INJURY OR DAMAGE TO EQUIPMENT.

EVEN WHEN THE POWER WAVE IS OFF, THERE ARE POTENTIALLY
DANGEROUS VOLTAGES WITHIN THE POWER WAVE UNIT DUE TO THE
BATTERIES. EXTREME CARE MUST BE TAKEN WHEN WORKING WITHIN THE

Danger!

Danger!

POWER WAVE ENCLOSURE TO AVOID THE POSSIBILITY OF

ELECTROCUTION, INJURY OR DAMAGE TO THE EQUIPMENT.

Caution

VOLTAGES ON INPUT TERMINAL BLOCK TB10 MUST HAVE CORRECT PHASE
ROTATION (CLOCKWISE A, B, C)

3-4

OnLine Power

3.3.3 Customer Connections (Input and Output)

1) Verify that the main input circuit breaker, battery circuit breaker, and output circuit breaker(s),
if provided, are in the ”OFF” position. See illustration 2-2 for the location of the circuit
breakers.

2) Run the wire through the space between shelf and cabinet using provided knockouts.

3) Connect the input wires to the input terminal block, TB10. Five (5) wires total: Phase A, Phase
B, Phase C, neutral, and ground.

• Connect Phase A, B, C.

Phase A

From

Reserve

Power

Input Source

• Please refer to the functional diagram for Dual Input Power System Illustration 2-4

4) Connect the output wires to the output terminal block, TB12. Five (5) wires total: Phase A,
Phase B, Phase C, neutral, and ground.

5) Connect the battery wires from external battery cabinet (if provided) to battery terminal block,
TB6, three (3) wires total for (+), (-), and Ground.

This concludes the electrical connections.

1

Phase 2

2
3

Phase 3
Neutral or Ground for Delta connection

4

Caution

REFER TO BATTERY CONNECTION DIAGRAM

Input C/B

Battery C/B

Output C/B

Maintenance
Bypass Switch

5 Form “C”
Alarm Terminal

Do not apply power to the Protector 3 at this time.

Aux. Output
Circuit Breaker

ILLUSTRATION 3-3: Protector 3 Customer Connection

Ground TB

Input TB

Battery TB

Reserve Aux.
Input TB
(Optional)

Netural Bus

Output TB

3-5

OnLine Power

• CONNECT INPUT POWER TO INPUT POWER T/B.
Phase A, Phase B, Phase C, Neutral as shown above

• CONNECT BATTERY WIRES
Positive (+) to Battery C/B (Left side)
Negative (-) to Battery C/B (Right side)

Verify the polarity prior to connect. Refer to above.

• FOR MULTIPLE BATTERY CABS

Positive (+) to TB5-1
Negative (-) to TB5-2

• CONNECT OUTPUT POWER TO OUTPUT POWER T/B.
Phase A, Phase B, Phase C, Neutral as shown above

If there are no requirements for remote signaling, section 3.4 may be skipped.

3.4 REMOTE SIGNALING CONNECTIONS (OPTION)

The Protector 3 includes the feature of providing dry relay contacts for remote signaling capabilities.
Signals available for remote annunciation are:

“INPUT FAILURE” - N/O contact that closes upon loss of input power.
“LOW BATTERY” - N/O contact that closes when the unit is on battery operation and the batteries

approach inadmissible discharge status.

“BYPASS ON” - N/O contact that closes when the unit transfers the load to static by-pass.
”SUMMARY ALARM” - N/O contact that closes when the unit has any one of the following alarm

conditions. internal failure, system overheat, battery undervoltage.

3.4.1 Dry relay contacts for remote signaling are provided via connector (P2) on Control Board (A2), located on

the inside of the right door of the enclosure. See illustration 1-2 for location of Control PCB.

3.4.2 Dry relay contacts have the following maximum ratings:

125 volts (AC or DC) maximum

1.25 amperes maximum
30 watts / 50 VA maximum
It is important that contact ratings are observed to prevent damage to the relays and the Control Board.

3.4.3 Determine which signals will be used. Connect wires (customer-supplied) to the connector.

3.4.4 See illustration 1-2 for location of dry C contacts terminal.

This concludes the installation procedure. Please proceed to Section 4 - Start-Up.

3-6

OnLine Power

3.5 STORAGE

The Protector 3 can be placed in storage while not in use. Provide a protected environment which meets
the environmental parameters listed below.

• AMBIENT TEMPERATURE -4° to 140°F

-20° to 60°C

• RELATIVE HUMIDITY 0% to 95% non-condensing

If the Protector 3 will be stored for three months or longer, it should be serviced by charging the batteries
for 24 hours at regular, three-month intervals. While in storage, service the unit using the procedures in
this section.

3.5.1 Battery Maintenance

During long-term storage, the batteries are subject to aging and deterioration. After visual inspection, if the
batteries need to be replaced, contact your OnLine Power dealer or the OnLine Power factory directly to
purchase new batteries. Batteries matching sequence numbers used should be purchased to set-up a
string.

If the UPS is stored in its original packaging, unpack UPS using unpacking procedures outlined in
Equipment Unpacking Section 3.2.

If the UPS is not connected to a source of power, first connect the UPS to an appropriate power source
using the procedures in Unit Installation Section 3.3.

Then recharge batteries as follows:

1) Unlock and open front doors.

2) Set AC input power source to ON.

3) Close input circuit breaker and wait for 1 minute,

4) Close battery circuit breaker, only when UPS Normal is displayed on screen.

5) The UPS automatically recharges batteries. The LCD panel will indicate the battery voltage
and charging current.

6) Allow UPS to run for 24 hours to fully charge batteries.

7) When batteries have reached partial charge, the battery charging current will be under 1 Amp
on LCD panel.

8) Open CB2 Battery Breaker

9) Turn OFF input power to the UPS.

10) Close and lock front door.

3-7

OnLine Power

SECTION 4 – OPERATION

4.1 START-UP PROCEDURES

Initial start-up must be performed by OnLine Power service personnel or an authorized representative. To
request start-up, fax a completed Request for Turn-On form to OnLine Power at 323-721-5017. The
Request for Turn On form is attached in this manual as Appendix E. The start-up procedure described in
this manual refers to a start up of the Protector 3 after a maintenance shutdown or rectified fault.

4.1.1 Verify that the main input circuit breaker, battery breaker, and output circuit breaker(s), are in the ”OFF” or

”down” positions. Refer to illustration 2-2 for the location of the circuit breakers.

4.1.2 Check all cable connections are firmly secured.

If during the start-up procedures anything unusual occurs, immediately

Caution

turn off the input circuit breaker, and contact OnLine Power at (800) 797­7782 for technical assistance. Also, use this number for any other

questions or additional information.

Caution

4.1.3 Apply input power to the Protector.

4.1.4 Turn on the main input circuit breaker.

4.1.5 After turning on the system, wait one (1) minute while the Protector runs through its internal
diagnostic routines.

The main input power and reserve input power should be available at the
same time when dual input power sources are used.

• Input Circuit Breaker remains open.

• Verify that the voltage measured on the input circuit breaker is 208V or 480 VAC and is the same

as nameplate voltage rating. If the voltage is not the same as on nameplate within +15% to -10%
tolerance, do not precede any further. Contact OnLine Power at [phone] for technical
assistance.

• Verify that there are no voltages measured on the output terminal block.

• Hear the sound of contactor closing.

• See the fan(s) running.

• See the LCD display screen showing UPS Normal message.

4-1

OnLine Power

K

Line 1
Line 2
Line 3
Line 4

• Verify that the LCD display panel indicates all correct parameters - see Appendix D for details.

• Verify that the output voltage is 120/208/277/480 VAC per the nameplate.

4.1.6 Close battery breaker in the UPS cabinet [and in battery cabinet(s)].

4.1.7 At this time, the Protector should be providing AC line power. If the Protector is not operating in the normal

mode, turn off the input circuit breaker. Contact OnLine Power at [phone] for technical assistance.

4.1.8 Recheck that the output voltage is 208Y/120 or 480Y/277 VAC.

• If the output voltage is approximately the same as the nameplate, turn on the loads.

4.1.9 Verify battery operation and the inverter test switch.

• To place the Protector in battery operation (simulate loss of input power), press and hold yellow
Inverter Test Push Button. With Push Button in the hold position, the Protector should be running
on its internal batteries.

• Verify that the LCD panel displays is as below, where “xx” is the kVA of this unit:

UPS NORMAL @ 15 kVA
INPUT OK @ CHRG ON
BATTERY OK @ DC O
ON INVERTER @ OUT O K

Line 1
Line 2
Line 3
Line 4

• Release the yellow Inverter Push Button and Verify that the LCD PANEL displays
“INPUT OK @ CHRGR OFF”.

Caution

UPS NORMAL @ xx kVA
INPUT BAD @ CHRGR ON
BATTERY OK @ DC OK
ON INVERTER @ OUT OK

Be sure to release the Push Button, after the test, so it will not deplete the
batteries.

4.1.10 The Protector is now fully functional - providing clean, sine wave power to the load with battery back-up in

case of an input power failure.

This concludes the start-up procedures.

4-2

OnLine Power

4.2 OPERATION

4.2.1 Turning On the Protector 3

1) Apply input power.

2) With input power available, turn on the main input circuit breaker.

3) Wait untill you hear the input contactor closing and fan running.

4) Close the battery circuit breaker, only after the LCD display is lit and displays screens per
Appendix D.

5) Verify that all parameters on the LCD display panel are correct. See Appendix D for display
details.

6) Close the output circuit breaker.

7) Turn On the auxilery output circuit breakers.

4.2.2 Turning Off the Protector 3

Turn off the Output Breaker(s), Battery Breaker, and Input Breaker.

4.3 FIELD REPLACEABLE UNITS (FRUS)

Refer to Table 4-1 for ordering the replacement parts from the factory. Supply the information from the
unit’s nameplate, including the serial number, model number, kVA, P.F., input/output battery voltages, and
date of manufacture, when ordering parts from factory. Call Toll Free (800) PWR-SRVC in North America.
Replacement parts must be replaced by qualified factory trained service personnel only.

Circuit boards and IGBTs contain ESDS (ElectroStatic
Discharge Susecptable) components. Handle and package
ESDS devices in accordance with JEDEC standard JESD625­A. Use a grounded ESD wrist strap when handling the devices
and circuit boards. Always package components and circuit
boards in static-dissipative plastic bags before transporting
even if a device has failed

. Failure to do so could result in

further damage, complicating repair and failure analysis.

4.3.1 Control Board

The Control Board is located on the inside right door at the top and mounted at 4 corners with screws and
washers. Verify that all connectors are matches with their designations and pins #1, 2, etc. Unplug P1
through P15. Install the new board. Reconnect all plugs and connections maintaining them with their
original orientations.

4.3.2 All Other Parts

Verify that the cables are marked before disconnecting. Replace the defective part with the new part.
Reconnect wiring the same way as it was disconnected.

4-3

OnLine Power

4.3.3 Heat Sink Assembly Replacement Procedure

1) Disconnect and isolate all sources of power.

2) The Heat Sink Assembly is located on the right side of the top electronic shelf, inside the UPS
cabinet (Illustration 4-1). Verify that all cables and connectors have labels and are identified
as shown. This is important for reinstalling the assembly.

3) Disconnect connectors P7, P6, P4, P1 from the PCB, A1, which is mounted horizontally on the
big black heat sink.

4) Disconnect 11 power cables at TB4-1 through TB4-7B using flat screw driver. Verify and
install label ID for each cable before disconnecting.

5) Loosen 3 Phillips head screws at front holding heat sink bracket. Pull the complete assembly
forward and up. Remove it from tray gently, making sure that no cables or wires are catching
(See illustration 4-1).

6) Install the new assembly in the reverse order. Note that the rear bracket attached to the heat
sink slides under the bracket secured on to the back panel. Slide the assembly back and
reinstall 3 Phillips screws.

7) Reinstall all the cables and connectors in the reverse order. Verify per illustration 4-1.

8) Verify connections prior to starting up the unit.

Phase C (Q3/Q4)

Phase A (Q1/Q2)

Phase B (Q5/Q6)

E2 (Q7/Q8)

E1/C2 (Q7/Q8)

TB5-1

TB4-7B

TB5-2

TB4-6B

TB4-2

TB4-5B

TB4-4

TB4-4B

TB4-2

TB4-3

TB4-1

1

J1

1

J7

1

1

J7

J6

P7

J7

P4

P6

J6

1 2 3 4

J4

1 2

ILLUSTRATION 4-1: HEAT SINK ASSEMBLY (FRU)

4-4

1 2

BLK
RED

P1

BLK
RED

OnLine Power

4.4 RENEWAL PARTS

ITEM QTY DESCRIPTION DESIGN

1 1 Bypass Static Switch PB1
2 1 Output Static Switch PB2
3 2 Input Choke L1A, B,C
4 1 Output Choke L2
5 1 DC Choke L4
6 1 The Frequency Noise Filter Capacitors for output Power C11, C12, C13
7 1 Control Board A2
8 1 LCD Display Board A5

9 1 Input Contactor K1
10 1 SCR Driver
11 1 Control Power Transformer T2
12 1 Control Transformer Fuse F4.5

13 1 Fan Fuse
14 1 Heat Sink Assembly HS1

15 1 Fan(s) B1~9
16 1 NL1 (NEON LIGHT) NL1
17 1 Input Breaker CB1
18 1 Output Breaker CB3

System Parts

F11-14

4-5

OnLine Power

SECTION 5 – MAINTENANCE

5.1 SAFETY PRECAUTIONS

Danger!

READ AND UNDERSTAND THIS SECTION THOROUGHLY BEFORE

PERFORMING ANY MAINTENANCE WORK ON OR AROUND THE UPS. 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 UPS IS

OPERATING WITH ALL CABINET DOORS CLOSED. HOWEVER, THE UPS

AND BATTERY CABINETS MUST BE KEPT FREE OF STANDING PUDDLES OF

WATER, EXCESS MOISTURE, OR DEBRIS. DEBRIS CAN CONSIST OF

EXCESSIVE DUST IN AND AROUND THE UNIT, AS THE COOLING FANS IN

Danger!

ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT

TO INSTALL OR REPAIR THE UPS 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 FAILURE.

SPECIAL SAFETY PRECAUTIONS AND LOCKOUT TAGOUT PROCEDURES

ARE REQUIRED FOR ALL OPERATIONS INVOLVING THE HANDLING,

INSTALLATION, OR MAINTENANCE OF THE UPS SYSTEM AND ANY

Danger!

ASSOCIATED BATTERY CABINETS. FAILURE TO FOLLOW SAFETY

PROCEDURES COULD RESULT IN DEATH, INJURY OR DAMAGE TO

EQUIPMENT.

5-1

OnLine Power

THIS EQUIPMENT CONTAINS CIRCUITS THAT ARE ENERGIZED WITH HIGH

Danger!

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!

OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION

OR SERVICE OF THE UPS 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 UPS.

FAILURE TO FOLLOW THOSE INSTRUCTIONS AND THE INSTRUCTION

LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN

EXPLOSION, FIRE, EQUIPMENT FAILURE, OR ELECTROCUTION.

Danger!

BE CONSTANTLY AWARE THAT THE UPS 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 FAILURES 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.

5-2

OnLine Power

5.2 WHEN TO CALL

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

1) Repeated start-up attempts are unsuccessful.

2) A UPS fault occurs which cannot be cleared.

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

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.

5.3 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.

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

Danger!

TO QUALIFIED PERSONNEL ONLY.

5.4 PREVENTATIVE MAINTENANCE

UPS Operator Maintenance consists of the basic tasks listed in this section. Other maintenance functions
require OnLine Power Service personnel.

5.4.1 Maintaining an Operator’s Log

Careful record keeping will ensure proper maintenance of the UPS Unit, and assist in the correction of any
abnormal conditions.

The operator’s log should contain the following information:

• Date of system start-up

• Dates that battery maintenance was performed

• Dates that input, output, and battery status readings were checked and the values displayed for

these readings.

• Dates and summaries of all communications with OnLine Power Service Personnel.

5-3

OnLine Power

5.4.2 Periodic Testing of UPS

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

5.4.3 Maintaining the Batteries

BATTERY CIRCUIT BREAKER OPERATES AT THE RATED BATTERY
VOLTAGES AT ALL TIMES. TRIPPED BATTERY CIRCUIT BREAKER
INDICATES A SERIOUS PROBLEM THAT MAY RESULT IN SERIOUS INJURY
OR DAMAGE TO THE EQUIPMENT IF CLOSE THE CIRCUIT BREAKER
WITHOUT KNOWING WHY IT FAILED. CHECK SHORT IN BATTERY OR CALL
ONLINE POWER CUSTOMER SERVICE AND SUPPORT FOR ASSISTANCE AT
1-800-PWR-SRVC.

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 BE
WASHED DOWN WITH A SUITABLE ACID NEUTRALIZING AGENT. ONE
COMMON PRACTICE IS TO USE A SOLUTION OF APPROXIMATELY ONE
POUND (500 GRAMS) OF BICARBONATE OF SODA TO APPROXIMATELY
ONE GALLON (4 LITERS) OF WATER. THE BICARBONATE OF SODA
SOLUTION SHOULD BE APPLIED TO THE SPILL UNTIL EVIDENCE OF
CHEMICAL REACTION (FOAMING) HAS CEASED. THE RESULTING LIQUID
SHOULD BE FLUSHED WITH WATER AND THE AREA DRIED.

Danger!

Danger!

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

Danger!

5-4

OnLine Power

Caution

Caution

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

● Power Battery PRC-12xxx is one battery manufacturer used by OnLine

Power, with xxx representing the amp-hour size of the battery.
Universal Battery UB12xxx is another battery manufacturer authorized

●

by OnLine Power, the xxx is the amp-hour size of battery.

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.

DO NOT GROUND BATTERY POSITIVE OR NEGATIVE.

Danger!

Caution

Caution

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 with the same number of batteries, and
same manufacturer, type, and model that was supplied with the unit. To
avoid system failure, replace all batteries if one or more batteries fail to

perform to specifications.

5-5

OnLine Power

5.4.4 Battery Cabinets

Although the individual batteries are sealed and require only minimal maintenance, the batteries should be
given a periodic inspection and electrical check. Checks should be performed annually to ensure years of
trouble-free service. Tightness of battery terminal connections should be tested to recommended torque
values. Battery Service Agreements are available through OnLine Power. Although the individual batteries
are sealed and require only minimal maintenance, the batteries should Customer Service and Support at 1­800-PWR-SRVC (800-797-7782)...

5.4.5 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 shall be initially torqued to 75 in/lbs. Subsequent re-torquing shall be

to 65 in/lbs.

5.4.6 Battery Terminals

• Check for discoloration, corrosion, and connection integrity. Clean and tighten as necessary. Note:
Initial Torque Values are greater than re-torque values.

• 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 you must clean and re-torque the
connection hardware.

OnLine Power Customer Service Personnel must approve non-Standard Batteries. Please call at 1-

•

800-PWR-SRVC (800-797-7782).

5.5 ONLINE POWER CUSTOMER SERVICE AND SUPPORT

Start-up, UPS Maintenance, battery maintenance, and preventative maintenance programs are available
through your OnLine Power sales representative or through OnLine Power Customer Service & Support.

5.5.1 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).

5.5.2 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-PWR­SRVC (800-797-7782).

5.5.3 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 UPS System or the batteries.

5-6

OnLine Power

SECTION 6 – SYSTEM OPTIONS

This section describes options available with the Protector 3 phase. The following options are available:

Part Number Options

3000-044 thru -048 and

-055 thru -057

9100-1363-02 Audio Alarms with Silence Switch

9100-1020-04 Remote UPS Status Display, 3 Phase Monitor

9100-1362-02 Form “C” N/O Contacts for Alarms

9100-1440-01 TVSS (Transient Voltage Surge Suppressor), 208V

9100-1440-011 TVSS (Transient Voltage Surge Suppressor), 480V

9100-1343-01 thru -16 Normally ON/OFF Output Aux. Circuit Breakers

9100-1439-01 thru -03 External Output Aux. Circuit Breakers in Panel Board

9100-1372-01-03 10% Input Current Harmonic Filter

9100-1373-01-04 5% Input Current Harmonic Filter

See page 6-9 Higher KAIC Norm .ON/OFF Output Circuit Breaker 3 Phase

Higher KAIC Norm. ON/OFF Output Circuit Breaker 1 Phase.

9100-1445-01 thru -05 EMI Filters

9100-1446-01 thru -03 Dual Input System WYE/WYE

9100-1446-04 thru -06 Dual Input System DELTA/WYE

See page 6-9 Dual Input System DELTA/DELTA

External Manual Bypass Switch

9100-1317-02 Seismic Mounting Bracket (Left and Right set per cabinet)

9100-1429 Rack Stack

9100-1493-02 Power Flow Mimic

GMS (Global Monitoring System)

9100-1466-02 Local On UPS -Event Log

9100-1453-01 Local On UPS - Aux. Output CB Trip Monitor w. Event Log

9800-03-25 thru -150 Local on PC - via RS232

9800-04-150 thru -1000 Local on PC - via RS485

9100-1468-02 Remote - Dial-Up

9100-1469-01 WEB/SNMP

6-1

OnLine Power

6.1 Optional External Maintenance Bypass Switch – P/N 3000-044 thru -056

ILLUSTRATION 6-1: EXTERNAL MAINTENANCE BYPASS SWITCH DIAGRAM

6.1.1 Installation

Allow front access to the MBS box at all times for maintenance and servicing. Electrical codes require that the MBS
box be installed with no less than 3 feet at the front of the cabinet. Side and rear panels do not require service
clearance, however side vents must not be blocked.

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 DEATH, INJURY, EXPLOSION, FIRE OR DAMAGE TO THE
EQUIPMENT. VERIFY THAT ALL INCOMING HIGH AND LOW VOLTAGE
POWER CIRCUITS ARE DE-ENERGIZED AND LOCKED OUT BEFORE
INSTALLING CABLES OR MAKING ANY ELECTRICAL CONNECTIONS.

Danger!

Refer to Section 3.1, Site Planning and Preparation

Verify the following connections have been made per wiring diagrams: 6001-032-11, 6001-032-12, and

specific application related sheets.

6-2

OnLine Power

Wiring Inspection:

1) Verify all power connections are tight.

2) Verify all control wire terminations are tight.

3) Verify all power wires and connections have proper spacing between exposed surfaces,
phase-to-phase and phase-to ground.

4) Verify that all control wires are run in individual, separate steel conduit.

6.1.2 Operation

The external maintenance bypass switch in mounted in a box which is field installed on the UPS cabinet.
This box includes a rotary switch to provide a single control for transferring to and from maintenance
bypass. For ratings, wiring diagram enclosure dimensions and installation refer to drawings # 6001-032-11
for 3-pole, and 6001-032-12 for 4-pole panels.

The operator control switch for external manual bypass switch can be accessed by opening the cabinet
front door.

The single control simplifies the operation of the external manual bypass

Caution

switch, however operating instructions must be carefully observed before
using the bypass switch. Using the improper sequence in operation of the

bypass switch SW-1 and toggle switch S-1 could result in unwanted
action.

ILLUSTRATION 6-2: MAINTENANCE BYPASS SWITCH

The two Manual Bypass Switch Positions are:

1) “MAN” – Connects power to the critical load through the external maintenance bypass line.

UPS needs to be de-energized for maintenance purposes.

2) “AUTO” – Connects the critical load to the output of the UPS and establishes normal

operation.

6-3

OnLine Power

6.1.3 Specification. Optional External Manual Bypass Switch

Part Number Description

3000-044 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK, 55AMP, 3

POLES / LINE ONLY, 14”(W) x 10.00(D) x 18.00 (H).

USE FOR: 10/15KVA, 208V/480V UNIT INPUT

20/25/30/40KVA – 480V UNIT INPUT

3000-045 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK, 110AMP, 3

POLES / LINE ONLY, 14”(W) x 11.00(D) x 18.00 (H).

USE FOR: 20/25VA, 208V UNIT INPUT
50/62.5KVA – 480V UNIT INPUT

3000-046 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK,

175AMP, 3 POLES / LINE ONLY, 16”(W) x 12.00(D) x 20.00 (H).

USE FOR: 30/40KVA, 208V UNIT INPUT

3000-047 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK,

240AMP, 3 POLES / LINE ONLY, 14”(W) x 10.00(D) x 18.00 (H).

USE FOR: 50/62.5KVA, 208V UNIT INPUT

3000-055 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK,

55AMP, 4 POLES / LINE / N ONLY, 14”(W) x 10.00(D) x 18.00 (H).

USE FOR: 10/15KVA, 208V/480V UNIT INPUT

20/25/30/40KVA – 480V UNIT INPUT

3000-056 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK,

110AMP, 4 POLES / LINE/N ONLY, 14”(W) x 11.00(D) x 18.00 (H).

USE FOR: 20/25KVA, 208V UNIT INPUT
50/62.5KVA, 480V UNIT INPUT

3000-057 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK,

175AMP, 4 POLES / LINE/N ONLY, 16”(W) x 12.00(D) x 20.00 (H).

USE FOR: 30/40KVA, 208V UNIT INPUT

3000-058 EXTERNAL MANUAL BYPASS SWITCH, MAKE BEFORE BREAK,

240AMP, 4 POLES / LINE/N ONLY, 20”(W) x 14.00(D) x 24.00 (H).

USE FOR: 50/62.5KVA, 208V UNIT INPUT

6-4

OnLine Power

6.2 OPTIONAL AUDIO ALARM WITH SILENCE SWITCH – P/N 9100-1363-02

6.3 OPTIONAL REMOTE UPS STATUS PANEL - P/N 9100-1020-04

6.3.1 Installation

The Remote UPS Status Panel is available in a console mount style box in black finish.
It can also be wall mounted and comes with a 10 foot long “DB” connector signal cable
or optional length cable that can be up to 1000 feet long.

6.3.2 Operation

The Remote Status Panel requires 120 VAC power, comes with 6 ft power cord, SILENCE, LED / HORN
test switches and includes following status LED’s.

• INPUT FAIL

• ON BYPASS

• INVERTER ON

• LOW BATTERY

• SUMMARY ALARM

6.3.3 Specifications

UPS Remote Status Panel Installation Drawing 9100-1020-10, revision A, attached at the end of System
Options Section.

6.4 OPTIONAL FORM “C” CONTACTS FOR ALARMS – P/N 9100-1362-02

6.4.1 Installation

Terminal strip TB is provided on the optional alarm relay board for user connection to the individual alarm
contacts.

6.4.2 Operation

The Remote Contact Board includes isolated Form C contacts for the following alarm signals:

TB-1 LOW BATTERY
TB-2 ON BYPASS
TB-3 SUMMARY ALARM
TB-4 NOT USED
TB-5 INPUT FAIL
TB-6 COMMON

6-5

OnLine Power

6.5 OPTIONAL TVSS P/N – 9100-1440-01

6.5.1 Operation

TVSS contains energy absorbing components designed for specific line configurations. The device has
two-stage protection. When protection components are damaged by absorbed transients, the device will
show a reserve flag indicating a need for replacement. At this time the device is still operational, due to
redundant circuits. After the second spike, the device will show and alarm condition indicating replacement
is mandatory. Remote indication contacts “TS” allows remote control of the protection status.

6.5.2 Specifications
Part Number Description

9100-1440-01 TVSS OPTION. 208V, 3PH, 40KVA 8/20US, THREE PHASE, REPLACEABLE

DIN RAIL, LED ALARM, AND INTERNAL DISCONNECTOR.
IEC61643-1 / EN61643-11
ANSI / IEEE C62.41 / UL1449, Second Edition –Feb.2007
CULUS / UL94-V2
3PHASE PLUS NEUTRAL

9100-1440-11 TVSS OPTION, 480V, 3PHASE, THREE PHASE, REPLACEABLE DIN RAIL,

LED ALARM, AND INTERNAL DISCONNECTOR.
IEC61643-1 / EN61643-11
ANSI / IEEE C62.41 / UL1449, Second Edition –Feb.2007
CULUS / UL94-V2
3PHASE PLUS NEUTRAL.

6.6 OPTIONAL NORMALLY ON/ NORMALLY OFF OUTPUT AUX. CIRCUIT BREAKERS – P/N

9100-1343-01 THRU -16

These circuit breakers are 1 pole, 20 A devices for protection of customer’s circuits.

Normally ON C.B. Option
Normally OFF C.B. Option
Normally OFF Delay C.B. Option

6.7 OPTIONAL EXTERNAL OUTPUT AUX. CIRCUIT BREAKERS IN PANEL BOARD – P/N 9100­1439-01 THRU -03

6.7.1 Description

A matching external panel board with 1P 20A, (QO-Square D) circuit breakers is provided for power
distribution from the UPS output to critical loads. The panel board accommodates up to 42 breakers. A
main circuit breaker is provided with each panel board. See drawing 6001-03-15 for panel mounting
arrangement.

6.7.2 Specification

Part Number Description

9100-1439-01 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD

1PH, CB. UP TO 24 (QO BREAKER) 125AMP.

9100-1439-02 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD

1PH, CB. UP TO 30 (QO BREAKER) 200AMP.

9100-1439-03 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD

1PH, CB. UP TO 42 (QO BREAKER) 225AMP.

2025-125 10KAIC @240V, 120/240V, APPLICATION

CB, 1PH, 20AMP QO BREAKER FOR 9100-1439-xx.

6-6

OnLine Power

6.8 OPTIONAL 10% INPUT CURRENT HARMONIC FILTER – P/N 9100-1372-01-03

Part Number Description

9100-1372-01 10% INPUT CURRENT HARMONICS FILTER USE FOR 10/15/25KVA
9100-1372-02 10% INPUT CURRENT HARMONICS FILTER USE FOR 25KVA

9100-1372-03 10% INPUT CURRENT HARMONICS FILTER USE FOR 30/40 KVA.

6.9 OPTIONAL 5% INPUT CURRENT HARMONICS FILTER P/N 9100-1373-01-04

Part Number Description
9100-1373-01 5% INPUT CURRENT HARMONICS FILTER USE FOR 10/15/20KVA
9100-1373-02 5% INPUT CURRENT HARMONICS FILTER USE FOR 25KVA
9100-1373-03 5% INPUT CURRENT HARMONICS FILTER USE FOR 30/40KVA
9100-1373-04 5% INPUT CURRENT HARMONICS FILTER USE FOR 50KVA

6.10 OPTIONAL EMI FILTER – P/N 9100-1445-1 THRU -05

EMI FILTER EN55022, 1998 CLASS “B” RADIATED EMISSION EN55022, 1998 CLASS “B”
CONDUCTED EMISSION
FCC PART 15 CLASS “B” RADIATED EMISSION
FCC PART 15 CLASS “B” CONDUCTED EMISSION

Part Number Description

9100-1445-01 EMI FILTER ASSY. 60AMP, 3PHASE, UPS

FOR 10KVA/15KVA/20KVA/25KVA/30KVA/480Y/277V.

9100-1445-02 EMI FILTER ASSY. 100AMP, 3PHASE, UPS

FOR 20KVA/25KVA-208Y/120V; 40KVA/50KVA/62.5KVA—480Y/277V.

9100-1445-03 EMI FILTER ASSY. 150AMP, 3PHASE, UPS

FOR 30KVA/40KVA-208Y/120V

9100-1445-04 EMI FILTER ASSY. 200AMP, 3PHASE, UPS

FOR 50KVA-208Y/120V

9100-1445-05 EMI FILTER ASSY. 200AMP, 3PHASE, UPS.

FOR 62.5KVA-208Y/120V

6.11 OPTIONAL HIGHER KAIC NORM ON/OFF OUTPUT CIRCUIT BREAKER

6.11.1 Specifications
HIGHER KAIC NORMALLY ON/NORMALLY OFF OUTPUT AUX CBs OPTION, 1-PHASE, 20AMP

Part Number Description

9100-1434-31~-56 42 KAIC @120/240V, Din Rail
9100-1434-61~-86 65 KAIC @120/240V ONLY. Din Rail
9100-1435-01~-26 14 KAIC @277V ONLY. Molded Case C.B.
9100-1435-61~-86 65 KAIC @277V ONLY. Molded Case C.B.
9100-1343-01~-26 22 KAIC @120/240V, 10 KAIC 277V
9100-1435-61~-86 30 KAIC @120/240V, 10 KAIC 277V

6-7

OnLine Power

6.12 OPTIONAL DUAL INPUT SYSTEM WYE/WYE – SAME INPUT/OUTPUT VOLTAGE

P/N Voltage

9100-1446-01 208V IN/OUT 10/15/20 kVA, 480V IN/OUT 10-50 kVA
9100-1446-02 208V IN/OUT 25/30/40 kVA

6.13 OPTIONAL DUAL INPUT SYSTEM DELTA/WYE – SAME INPUT/OUTPUT VOLTAGE

6.14 OPTIONAL DUAL INPUT SYSTEM DELTA/DELTA –DIFFERENT INPUT/OUTPUT VOLTAGE

6.14.1Delta Input System 208V IN / 480V OUT Wye-Wye

6.15 OPTIONAL SEISMIC MOUNTING BRACKET – P/N 9100-1317-02

9100-1446-03 208V IN/OUT 50 kVA

P/N Voltage

9100-1446-04 208V IN/OUT 10/15/20 kVA, 480V IN/OUT 10-50 kVA
9100-1446-05 208V IN/OUT 25/30/40 kVA
9100-1446-06 208V IN/OUT 50 kVA

Use 6.13 and 6.14 Dual Input System and separate Iso-Care Transformer to match the output voltages.

Consult factory for proper kVA and model number

P/N: 5088-025 Left / Right seismic floor mounting bracket

6.16 OPTIONAL STACKABLE RACK – P/N 9100-1429-xx

Drawings: 6001-032-07 Refer to illustration on page B-8. One rack only

6.17 OPTIONAL POWER FLOW MIMIC – P/N 9100-1493-02 (illustration 6-3)

6.17.1 Operation

Power Flow Mimic allows unit power status verification at-a-glance. It has 6 LED’s indicating the following
conditions: GREEN – Input OK, GREEN – Inverter On, YELLOW – On Battery, YELLOW – On
Bypass, RED – Low Battery, RED – Summary Alarm. The LED’s are located on the pictogram below for
quick status assessment.

ILLUSTRATION 6-3: MIMIC PAD

6-8

OnLine Power

6.17.2 Specification

Description: POWER FLOW MIMIC OPTION – 3 PHASE
Part Number: 9100-1493-02
Color: Blue with black lettering
Dimensions: 4.25” x 4”
Mounting: Self-adhesive Scotch pad
LED’s: Water clear lens, 20 mA, View Angle 140. Nicom.ZU55W-05,
Connectors: Nicomatic 8 Pin, Black

6.18 OPTIONAL GMS – GLOBAL MONITORING SYSTEM

6.18.1 Local On UPS - Event Log – P/N 9100-1466-02

6.18.1.1 Operation

Control and Monitoring PCB acquires event data and displays up to the 50 most recent Date and Time
stamped events. The default setting is a scroll of monitoring and alarm screens. When the log is full,
the first (oldest) events is erased from the register. System events are shown in Appendix B.
Key pad functions and resulting screens are presented below:

LOG – Press one time to activate the event log display. After approximately 5-seconds, the screen will

show the event log. All stored events will be continuously scrolled on the display. Press Log once
again to return to the main menu.

ILLUSTRATION 6-4: LOGGED EVENTS

FREEZE – Press one time. The display will freeze the next default monitoring and alarm screen. Press

the Freeze key again to return the display to the initial menu with scrolling operation.

ILLUSTRATION 6-5: STATUS SCREEN

6-9

OnLine Power

TEST – Press the key one time. System data appears on the screen after few seconds. Pressing the

key once again returns the display to the default screen.

ILLUSTRATION 6-6: SYSTEM INFO

RESET – Pressing the “Reset” and “Test” keys together clears the screen and deletes the event log.

6.18.1.2 Specification

Description: Local On UPS - Event Log
Part Number: 9100-1466-02
Components:
Monitoring PCBA: P/N 1625-344-01
Power Supply: P/N 1625-339, 5, 12 VDC, 25W
Com Cable: P/N 7060-1187-01
Keypad Overlay: P/N 1250-064

6.18.2 Local On UPS - Aux CB’s Trip Monitor – P/N 9100-1453-01

6.18.2.1 Operation

Trip signals coming from the breakers are displayed on the circuit breaker trip screen. The circuit
breaker is a part of default monitoring and alarm display, that scrolls continuously when the unit is in
operation. Below is an illustration of a typical circuit breaker trip screen.

6.18.2.2 Specification

Description: Local On UPS – Aux. CB’S Trip Monitor With Event Log
Part Number: 9100-1453-01
Components:
Event Log Option – P/N 9100-1466-02
Trip monitoring modules: ABB S2C-S/H 6R, DIN rail mount
Monitored CBs: only ABB MCB serie

ILLUSTRATION 6-7: AUXILLIARY CB TRIP

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6.18.3 Local On PC - Via RS 232 - P/N 9800-03 – 25 THRU 150 (25-150ft)

6.18.3.1 Description

This option requires a PC and LabView monitoring software. The software is provided on a disc that is
easily installed on any Windows platform. An attached cable of a specified length plugs into a PC serial
port and connector J6 on the Control PCB 1625-296.
LabView software must be selected for COM port 1.

6.18.3.2 Operation

LabView software translates data protocol coming to COM port 1 from an active unit via the
RS232/RS485 interface and displays the parameters and active alarms on a PC monitor in the
appropriate form. Below is a sample of a PC screen with measured parameters and actual unit status.

ILLUSTRATION 6-8: SAMPLE PC SCREEN

6.18.3.3 Specification

Description: Local On PC – Via RS 232
Part Number: 9800-03-25 thru 150
PC system requirements: 98 and higher Windows OS, serial port.
Viewing software: LabView, included
RS232 cable: 25 thru 150ft, as specified, included

6.18.4 Local On PC - Via RS 485 - P/N 9800-04-150 thru 1000 (150-1000 ft)

Installation, Operation, Specification as above (except RS 485 cable)

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6.18.5 GMS- Remote Dial UP Monitor 2000: p/n 9100-1468-02

Remote Dial Up: Data, Voice, Fax, Pager, PC, E-mail, Event Log, Stats.
For details of all fuctions and operation refer to User's Manual, 6002-1770.

6.18.5.1 Description

Monitor 2000 requires a phone line for remote operation. It comes with an interface PCB, that
provides monitor inputs with isolated signals from the unit. The option comes wired and fully
functional. For local PC communication, you must connect your computer serial port to the 2000
RS232 data communication port.

ILLUSTRATION 6-9: MONITOR 2000 FRONT VIEW

The Manager 2000 Windows setup program makes installation quick and easy. Picture below is an
actual Manager 2000 screen.

ILLUSTRATION 6-10: MANAGER 2000 SCREEN

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6.18.5.2 OPERATION

The dial-up Monitor 2000 measures and monitors the following set of parometers
and status contacts.

1. Input Volts

2. Output Volts

3. Output AMPS

4. Battery run

5. Low battery

6. Cabinet temperature (ºF)

7. On by-pass

8. Summary alarm

User can monitor all inputs in real time graphical form and can access real time input monitoring
from the
tool bar button labeled monitors.
The details are given in GMS 2000 Manual, refer to the 6002-1770.( GMS 2000 user's manual)

6.18.5.3 ALARMS

When an alarm occurs, the unit will dial out and send a message to all programmed
destination.

GMS 2000 will call up to 32 telephone numbers or email addresses (both referred to as
destinations) to report alarm conditions or send reports. Destinations can be voice calls, fax
machine, computers with dodems running GMS 2000 software, email addresses, numeric pagers,
or alphanumeric papers. You must be online with the unit to program the Destination parameters.
Once you are online, choose Program from the main menu, then select Destinations. You can
also access the Destination programming from the toolbar button labeled Destinations.

The Dialout Destinations form allows you to program information for up to 32 destinations. The
parameters and their options are listed below.

Dialout Destinations Form

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Name:

This field allows you to program a description (16 characters max) for each destination. The
name will appear an faxes and e-mail transmissions whenever an alarm or report is send to
destination. If you are entering a fax destination be sure to use the name of person who you

Destination:

Numeric Pagers:

Alphanumeric Pagers:

E-mail:

Dial Type:

This is used specify the type of call GMS 2000 will make to a particular destination. The available

Fax – This instructs GMS 2000 to send a fax transmission to either a fax machine or a PC with

Email – This instructs GMS 200 to deliver a message to the E-mail address programmed in the

intend to receive the fax.

The actual telephone number or e-mail address GMS 200 dials to deliver its report or alarm
message.
The destination field can be up to 64 characters long for e-mail addresses and 32 digits for all
other Dial
Types and may consist of numbers, letters, and special dialing codes.

The GMS 2000 can send alarm messages to numeric pagers. It will automatically send its
telephone number and the alarm input number when dialing to a numeric pager. All you have to
do is enter the telephone number of your pager.

Example: [phone]

The GMS 200 can dial alphanumeric pagers to send alarm messages. The MGS 2000 will send
the unit description, tele-phone number, input name and input value. To program an
alphanumeric pager destinatio, enter the phone followed by the letter A and then the pager ID.

Example: 1-610-555-4593 A 0504099

The GMS 2000 can send alarm messages and reports via email. For this to work, you must
designate an email host. you can use your own computer as an email host.

dialout types are: Fax, Voice, E-mail, Pager, alpha Pager, and Modem.

the ability to receive a fax directly.

destination field.

Numeric Pager – This instructs GMS 2000 to dial a numeric pager and leave the unit's ID

Alpha Pager – This instructs GMS 2000 to deliver a text message to an alphanumeric pager.

Note: If your pager service is answered by a voice-promted message you will need to
enter additional pro-gramming . See the special Dialing codes section below.

Note: For "E-mail" Dial Types, only e-mail addresses may be programmed in the

destination field, NOT telephone numbers. GMS 2000 will contact an e-mail host as
designated on the System screen.

number and alarm input numbers on the display. This will happen automatically just by
entering the pager's telephone in the destination field. If you want to change the
information that is dent to your pager or you are having trouble receiving the page, you
may use the special dialing codes to customize the dialout to your pager.

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Modem –This instructs GMS 2000 to call a modem attached to a computer running Manager

Important: the unit Description on your computer must match the Unit Description stored

Intercall Delay:

The intercall delay is the amount of time MGS 2000 will wait after completing a call before calling

the next destination . The delay is in seconds, with a default of 30.

Alarm Call Mode:

The three selections for destination Alarm Call Mode are Disabled, Until A Acknowledged, and

Disabled: Destinations programmed with Alarm Call Mode Disabled will never be called. This is

Until Acknowledged: Destinations programmed with Alarm Call Mode " Until Acknowledged"

Inform.

simply a way to disable dialing to this destination if necessary.

will continue to be called until one of them acknowledges the alarm. Once acknowledged, the
remaining destinations will not be called.

Inform: Destinations programmed with Alarm Call Mode "Inform" will be called until the alarm

2000 software. The sofhware must be in Answer Mode. When the Manager 2000
software receives the alarm call, it will download the unit's Event log, execute an alarm
query, and display the result on the screen. You may also have the computer print a copy
of the alarm event as well as play a recorded message when an alarm is received.

in your GMS 2000 for Alarm and Report call-in features to work properly.

Note: A 30-second delay is too short to allow a call back if a pager is being called.

Increase the delay time enough to accommodate your pager.

NOTE: Fax,E-mail and Modem destinations cannot be programmed as "Until

Acknowledged" call modes.

message has been successfully delivered one time, regardless of acknowledgment. If a
transmission to an " Inform" destination was successful, that destination will not be
contacted again. GMS 2000 will only make additional attempts to contact an Alarm Call
Mode " Inform" destination if that destination hasn't successfully received its transmission
(for example, due to a "no answer," busy signal," "no carrier" response). If a transmission
fails to reach a destination after the last calling round is completed, the failure is recorded
in Event Log. Calls to priority "Inform" destinations are useful for providing records of
alarm events.

Important: Destinations programmed as Alarm Call Mode " Inform" cannot

acknowledge alarms.

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6.18.5.4 GRAPH:

Once the Data Log records have been displayed, they may be viewed in graph form by clicking
the "Graph" button. The graph will show all inputs selected in the query. If too many samples
are selected for graphing, the software gives you the option to average values. Oherwise, you will
have to perform a smaller query to avoid averaging. The graph has many features that allow to
display the data graphically, including line graphs, bar charts and three dimensional views.
Experimentation is the best way to larn about all of the available options. A sample graph follows.

PRINT:

Once the Data Log records have been display, they may be printed by clicking this button.

EXPORT:

Once the Data Log records have been displayed, the displayed information may be saved as a
comma-delimited file. This file can then be used in a spreadsheet such programs as Lotus 123 or
Microsoft Excel.

Send Report:

GMS 2000 can be programmed to automatically send reports to selected destinations. Check this
box to include this destination when sending reports.

Sample Graph

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Note: Reports may only be send to fax, E-mail, or Modem destinations.

6.18.5.5 DATALOGGING

GMS 2000's built-in data Logger can log and store information an all 8 universal inputs, AC
power and backup battery voltage. You must be on-line with the unit to program the Data logging
Logging. You can also access the Data Log programming from the Toolbar button labeled Data
Log.

Note that whenever you change any parameters on the Data log form the datalogger in the GMS
2000 will be reset. If you need to make changes to your programming, be sure to "Retrieve Data"
first.

Viewing the Data Logger (on-line):

Once the Data Logger has been downloaded, it can be view the Data Logger, click the "View
Database" button on the Data Log Programming form. The following form will appear.

Viewing the Data Logger (off-line):

To view a unit's downloaded Data Logger off-line, follow the instructions for "Offline
Communication". Below is a list of programming parameters for viewing the Data Logger.

Data Log Viewer

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GMS 2000 Eve

ogger

6.18.5.6 EVENT LOGGER

GMS 2000 keeps track of important system events with its built-in Event Logger. Each GMS
2000 unit stored the last 500 system events. System events include alarms, incoming and outgoing
phone calls, and alarm acknowledgments. Once the Event Log is full, the oldest record is
overwritten by the newest.

Downloading the Event Logger:

To view GMS 2000's Event Log, the unit's Event Logger must first be downloading to your PC.

You must be online with the unit to download the Event Log. Once you are online, choose "
Functions" from the main menu, and then select "View Events." You can also access the Event
Logger from the Toolbar button labeled Events.

The following event log form will appear:

Viewing the Event Logger:

Once the Event Logger has been downloaded, it can be viewed on the form called
" Event Viewer".
Below is a list of programming parameters for viewing the Event Logger:

nt L

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6.18.6 GMS WEB/SNMP (GWS) , STATUS, ALARM, EVENT LOG, E-MAIL 9100-1469-01

6.18.6.1 Description

The GWS option card is a web enabled monitoring device for a UPS with Internet access.

RJ45 on the front of the card marked " Network" is the connecting point for the Ethernet cable. The unique
IP Internet address is pre-assigned and can be change to fit customer network settings.

6.18.6.2 Operation

The GWS card can monitor the UPS on the network through a web browser or a Network Management
System. The alarm Viewer utility program provides monitoring of multiple units through a single console
application. Entering IP address assigned to the Web card into the browser brings up the Log-In screen with
password protecting the actual web site. The main, UPS Status screen has links to subsequent Web pages as
depicted below.

For detail operation, refer to the user's manual number , 6002-1988 This manual comes with this option,

9100-1469-01

6.18.6.3 Networking with GWS

The GWS gives the user two options when it comes to network connection. The user may choose to

manage and control the various serial devices over Internet using windows Virtual COM poet functions
(refer to fig.1) In this configuration, a GWS is connected to a serial device. The user can then manage and
control each GWS these serial devices over LAN.

GWS

UPS

PCBD

( J8 )

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Any Further dtails of GWS, refer to user's manual,

6.18.6.4 PACKAGING CONTENTS.

Section 4. GWS Description

6002-1988 for GWS option (9100-1469-01)

One GWS module

Fig. 3 GWS Front View

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(RJ45)

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6.18.6.5 GWS DB-9 Pin Assignment

6.18.6.6 LED Indicators

GWS LED STATUS INDICATORS

GWS DB-9 PIN Assignment

DB-9 Pin No. RS-232

1

2 RxD

3 TxD

4

5 GND

6

7

8

9

Fig.5 GWS DB-9 PIN assignment

Orange Logon state

Yellow Data activity

Color Signal Difinition Condition / Indicators

Green Power state On: Normal power

Red Error Condition On: Error condition accurred

On: When there is Master or Drive
logon and receive the image.
Flash when there is data transmission /
receive by DB-9.

Fig.6 GWS Status LED Indicator

GWS LAN Port LED Light indicators

Color Condition / Description

Green

On: Internet correspond speed is 100M
Flash: Data transmitting / receiving

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Yellow

6.18.6.7 Installation Procedure

Before you start using GWS , you will need to set-up both the hardware and software. The following is a
flow chart on the installation procedure:

On: Internet correspond speed is 10M
Flash: Data transmitting / receiving

Connect the designated serial device, power
adaptor and Ethernet cable to GWS.

Install Netility supplied in the Utility CD.
Use Netility to set up the IP (for Static IP)

Connect the designated serial device, power
adaptor and Ethernet cable to GWS.

Fig.7 GWS LAN LED Indicator

Set-up completed

Fig.8 GWS installation flowchart

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6.18.6.8 HARDWARE INSTALLATION

The following details the installation procedure.

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6.18.6.8 MENU SELECTON:

The following menu selection options are avalable and the typical samples are shown in next pages.

A. INFORMATION:

SYSTEM STATUS - Show system information and network settings values shown here are by users.

BASIC INFORMATION- Show about U.P.S manufacturer/ UPS firmware revision / UPS model.

CURRENT STATUS- Show the UPS current status. Users can choose an internal. They are input,

output, and battery status.

REMOTE CONTROL- Provide remote UPS test fuctions, presently not provided.

METER / CHART- Displays temperature, capacity, load, voltage of the UPS by a chart and by

appearing with meters diagram, input voltage, output voltage, temperature,

B. CONFIGURATION :

UPS CONFIGURATION-Set the UPS configuration such as NO. of batteries, charge voltage, date of last

UPS ON/OFF SCHEDULE-Schedule on/off time for the UPS & set the time to turn on/off the UPS on

NETWORK:

• Set IP address, net agent subnet mask, net agent gateway and obtain an IP address.

• Sert primary DNS server IP, secondary DNS server IP.

• Set comunication speed fet ween net agent and network.

• Set stop UPS communication when net agent disconnects with athernet.

• Allow the user to alias a dymanic IP address.

• Register a domain name, login name, login password.

• Allow Net Agent to connect the internet directly using your XDSL modem with

SNMP-

• Set net agent SNMP settings so it can be used by a NMS.

• Give system name, a name to administrator, net agent location.

frequency, load , and capacity.

battery replacement, UPS data log, UPS test schedule, length of UPS
testing,critical loading (%), temperature (C), and critical capacity (%).

particular days, weekly, and send a warning massege before a schedule
shutdown and wake On-LAN to wake the PC within the network.

login name and login password.

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E-MAIL -

SMS – Allows short message signals are sending and received using a GSM modem.

WEB/Telnet – Set up the user account in Net Agent such as

• Set the IP address.

• Set a community name for NMS.

• Set authorities of administrators.

• Set E-mails details

• Set net agent E-mail server

• Set whether the E-mail server requires authemtication

• Set an E-mail account name

• Set a password

• Set E-mail addresses to receive warning E-mail

• Select events to send warning E-mail

• Set E-mail addresses to receive daily report

• Set a particular time to send daily report every day

• Select YES to send a warning E-mail stating Event Log has reached 500

• Select YES to send a warning E-mail stating Data Log has reached 500

Operating information such as

• SMS settings

• Account name, password

• Send SMS when event accurs

• Receiver cellular number for events log

• Warning message through SMS when events accurs

• Reciprents mobile number

• User account number

• Password

Set user's authorizations of read or read/write

•

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SYSTEM TIME – Set Netagent system time such as

LANGUAGE – Set the language for web pages

(C) LOG INFORMATION:

Event Log - A UPS event log with date/time and description.

SMS Log - Short message signal log with date/time

Data log - A UPS data log, record date/time, Input/output volt,freq (HZ), load as %, capacity (UPS

Save Data Log- Save RS232 UPS'S voltage, frequency, load, capacity, temperature., ect as another file.

Sytem Information

Hardware Version HDP520 UPS Last Self Test -­Firmware Version 2.40.DP520 UPS Next Self Test -­Serial Number 3925949185 UPS Critical Load 110%
System Name Wave Rider UPS 1PH UPS Critical Temperature 70.0 C
System Contact Jose Zamora UPS Critical Capacity 10%
Location Show Room
System Time 2001/01/01 00:06:27
Uptime 00:06:28

Warning will be initiated 10 minute(s) before Scheduled Shutdown Event
Send Email for Daily Report

Network Status

• Set a particular IP address

• Set on interval for time syncluonization

• Choose the nearest time server to your location

• Set a difference time zone for different countries

• Set time normally

• Set to auto restart the system at a predetermined interval

• Restart normally the system

battery capacity) as %, and temperature in C.

System Status Display ( Sample - TYP )

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MAC Address 00:03:EA:01:3B:01 Primary DNS Server 168.95.1.1
Connection Type 100Mbps Full-Duplez Secondary DNS Server
IP Address 192.168.1.98 Time Server time.nist.gov
Subnet Mask 255.255.255.0 PPPoE IP
Gateway
Email Server mail.onlinepower.com

Current Status ( Sample - TYP )

UPS Status

Input Status

AC Status On Battery

Input Line Voltage 0.0 V

Input Max. Line Voltage 121.0 V

Input Min. Line Voltage 0.0 V

Input Frequency 60.0 HZ

Output Status

Output Voltage 122.0 V

Output Status On Battery

UPS load 0 %

Battery Status

Temperature 19.0 C (66.2 F)

Battery Status Baterry Normal

Battery Capacity 0 %

Battery Voltage 26.9 V

Time on Battery 00:00:14

UPS Normal

Basic Information ( Sample - TYP )

UPS Information

UPS Manufacturer

UPS Firmware Version

UPS Model

Battery Information

Date of last battery replacement 2008/12/15

Number of Batteries 8

Battery Charge Voltage 108.0 V

Rating Information

Voltage Rating 120.1 V

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60

p

)

?

Frequency Rating 60.0 HZ

Battery Voltage Rating 120.0 V

Remote Control ( Sample - Display )

UPS Testing

10- Second Test

Deep Battery Test for minute(s)

Test Until Battery Low

Cancel Test

Miscellaneous

Turn off UPS when AC power Fails

Put UPS in Sleep mode for minute(s)

Wake up UPS

Reboot UPS

UPS Buzzer On/Off

Click once on " Meter/Chart" , then screen shows below.

Install On Demand (Other

To display this page corectly, you need to download and install the fallowing
components:

Java virtual machine

Never dowload any of these components.

Meter Display

(Sample – Typ)

10

Apply Reset Hel

X

Download Cancel

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8

08.0

80.0

008/12/15

None

UPS Properties

UPS Communication Type

Chart Display (Sample – Typ)

UPS Configuration (Sample Display – Typ)

RS232 [Mega Tec]

Number of Batteries

Battery Full Charge Voltage (V)

Battery Exhausted Charge Voltage (V)

Date of last battery replacement

1

2

(yyyy/mm/dd)

UPS Record

UPS Data Log

Minute

1

Test UPS

Test UPS every

Test UPS on Weekday

Monday

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30 seconds

0

70.010

y

p

es

Start Time of UPS Test (hh:mm)

Warning Threshold Value

Time out after loss of connection

Critical Load (%)

11

Critical Temperature (C)

Critical Capacity(%)

Appl

Reset Hel

UPS ON/OFF Schedule (Sample )

Weekly Schedule

Sunday

Monday

Tuesday

Wednesday

Thursday

Friday

Sarturday

Date Schedule

Date (yyyy/mm/dd) Turn ON (hh:mm) Turn OFF (hh:mm)

Warning will be initiated before Schedule Shutdown Event

10 Minut

Wake On Lan

Host 1
Host 2 IP: MAC:

Turn ON (hh:mm) Turn OFF (hh:mm)

IP:

MAC:

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p

68.1.98

55.255.255.0

68.95.1.

None

67.153.

.67

sabled

Host 3 IP: MAC:

Host 4 IP: MAC:

Host 5 IP: MAC:

Host 6 IP: MAC:

Host 7 IP: MAC:

Host 8 IP: MAC:

IP Address

IP Address

Subnet Mask

Gateway

Obtain an IP Server IP

DNS Server IP

Primary DNS Server IP

Secondary DNS Server IP

Ethernet

Connection Type *

Stop UPS communication when Ethernet disconnected

Dynamic DNS

Services Provider

Domain Name

Login Name

Login Password

Use external STUN server to get Public IP to register

Primary STUN Server IP

Secondary STUN Server IP

PPPoE

When Connection Should be made

Network (Sample Display )

192.1

2

1

Apply Reset Hel

Using DHCP

1

Auto Sense

Yes

Yes

142

Di

6-32

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p

Wave

Jose Zamora

Show Room

t

t

t

t

t

t

t

t

Login Name

Login Password

System will reboot when these items have been Applied.

SNMP (Sample Display )

MIB System

System Name System Contact System Location

Access Control

Rider UPS 1PH

Apply Reset Hel

Manager IP Address Community Permission Description

**** Public Read/Write

**** No access

**** No access

**** No access

**** No access

Public

Public

Public

Public

Trap Notification

Destination IP Address Community Severity Accept Description Events

**** Public

****

****

****

****

****

****

****

Public

Public

Public

Public

Public

Public

Public

Information

Information

Information

Information

Information

Information

Information

Information

No

No

No

No

No

No

No

No

Selec

Selec

Selec

Selec

Selec

Selec

Selec

Selec

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0

0

0

0

p

epower.com

Jose Zamora

NO jzamora@o

epower.com

bcortez@o

epower.com

Select

Select

m

Select

Select

j

m

Select Select

Select Select

Device Connected

Email Setting

Email Server

Sender's Email address

Email Server Requires Authentication

Account Name

Password

Send Email When Event Occurs

Recipients Email address (for Event Log)

Account 1

Account 2

Account 3

Account 4

Account 5

Account 6

Account 7

Account 8

Recipient's Email Address (for Daily Report)

Account 1

Account 2

Device Rating (%) Connected

NO

NO

NO

NO

Apply Reset Hel

EMAIL (Sample Display )

mail.onlin

nlin

YES

[e-mail]

[e-mail]

nlin

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p

68.0.

80

j

m

Select

Select

Select

Select Select

Select Select Select

p

Account 3

Account 4

Send Email for Daily Report (hh:mm)

Send Email when Event Log overflows (100 records)

Send Email when Data Log overflows (500 records)

SMS Settings

SMS Server

SMS Server Port

Account Name

Password

Send SMS When Event Occurs

Receiver Cellular Number ( for event log) EVENTS

Cellular Phone Number 1

Cellular Phone Number 2

Cellular Phone Number 3

Cellular Phone Number 4

Cellular Phone Number 5

Cellular Phone Number 6

Cellular Phone Number 7

Cellular Phone Number 8

User Account

SMS (Sample Display )

6263547671

WEB/TELNET (Sample Display )

No

zamora@onlinepower,co

at

No

No

Apply Reset Hel

192.1

1

YES

Apply Reset Hel

User Name Password Permission IP Filter

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p

y

t

y

00:14:

p

e(S)

y

y

Read/Write

No Access

**** No Access

****

**** No Access

**** No Access

**** No Access

System Time

Time Between Automatic Updates

Time Server

Time Zone (Relative to GMT)

System Time (yyyy/mm/dd hh:mm:ss)

Auto Restart

Auto Restart System for Every (0: Disable)

Manual Restart System After 30 Seconds

Interface Language

English
Chinese (Traditional)
Chinese (Simplified)
Korean

No Access

SYSTEM TIME (Sample Display )

LANGUAGE (Sample Display )

****

****

Apply Reset Hel

12 Hours

time.nist.gov

GMT+8:00

Apply Reset Hel

2001/01/01

0

Appl

Appl

Appl

Edi

42

Minut

Reset

Reset

Appl

6-36

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p

r

p

Japanese
German
Portuguese
Spanish
France
Italian

(Note: Setting preferences will not work if you have disabled cookies in your browser.)

Email Preferences

Use below interface language in Email and SMS notification

English

LOG INFORMATION (Sample Display )

Date/Time Event

2001/01/01 00:15:53 Failed to send mail
2001/01/01 00:14:38 UPS has switched to battery power
2001/01/01 00:11:28 Fail to send mail
2001/01/01 00:10:13
2001/01/01 00:08:58
2001/01/01 00:07:43
2001/01/01 00:07:43 Utility power has been restored
2001/01/01 00:07:15 UPS has switched to battery power
2001/01/01 00:06:28 Fail to send mail
2001/01/01 00:06:26 Utility power has been restored
2001/01/01 00:05:37 UPS has switched to battery power
2001/01/01 00:05:13 Fail to send mail
2001/01/01 00:04:19 Utility power has been restored
2001/01/01 00:03:58 UPS has switched to battery power
2001/01/01 00:01:21 Fail to send mail
2001/01/01 00:00:06 UPS Capacity Underrun

Fail to send mail
Fail to send mail
Fail to send mail

DATA LOG (Sample Display )

Date/Time Input volt Output volt Freq.(Hz) Load Capacity Temp.

0

2001/01/01 00:15:56 0.0 122.0 60.0

60.0 0 0

2001/01/01 00:14:52 0.0
2001/01/01 00:13:49 121.0
2001/01/01 00:12:46 121.0

122.0

60.0 0 0

122.0

60.0 0 0

122.0

0

Apply Reset Hel

Clea

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

20.0C 68.0F

Hel

6-37

OnLine Power

r

p

122.0

2001/01/01 00:11:42 121.0

121.0

2001/01/01 00:10:39
2001/01/01 00:09:36
2001/01/01 00:08:33
2001/01/01 00:07:29
2001/01/01 00:06:26
2001/01/01 00:05:23
2001/01/01 00:04:19
2001/01/01 00:03:16
2001/01/01 00:02:13
2001/01/01 00:01:10

124.0 60.0 0 0

121.0

122.0 60.0 0 0

122.0 60.0 0 0

121.0

0.0

122.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

124.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

SAVE DATA LOG (Sample Display )

Click once ON ,OPEN or SAVE
Click once ON , OPEN , then screen will show details as below (TYP)

Date/Time Input volt Output volt Freq.(Hz) Load Capacity Temp.

2001/01/01 0.0 122.0 60.0
2001/01/01 0.0
2001/01/01 121.0
2001/01/01 121.0
2001/01/01 121.0
2001/01/01
2001/01/01

File Download

Some files can harm your computer. If the file information

?

below looks suspicious, you do not fully trust the source, do
not open or save this file.

File name: upsdata.csv

File type: Microsoft Excel Comma Separated Values File

From: 192.168.1.98

Would you like to open the file or save it to your computer?

Open Save Cancel More Info

Always ask before opening this type of file

122.0

122.0

122.0

122.0

124.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

60.0 0 0

122.0 60.0 0 0

X

0

0

60.0 0 0

60.0 0 0

60.0 0 0

60.0 0 0

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

20.0C 68.0F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

Clea

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

20.0C 68.0F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

Hel

6-38

OnLine Power

2001/01/01
2001/01/01
2001/01/01
2001/01/01
2001/01/01
2001/01/01
2001/01/01
2001/01/01

121.0

122.0 60.0 0 0

0.0

122.0 60.0 0 0

121.0

122.0 60.0 0 0

122.0 60.0 0 0

121.0

124.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

122.0 60.0 0 0

121.0

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

20.0C 68.0F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

19.0C 66.2F

6-39

OnLine Power

6.19 OPTIONAL ECC - EMERGENCY CIRCUIT CONVERTER – P/N 9100-1501

6.19.1 Installation

Indoor use only. Simple and fast installation in ceiling or wall mounted standard single gang E-box . Installation

must be performed by a qualified electrician per Installation, Operation and Maintenance Instructions, provided
with the ECC.

6.19.2 Operation

When used with an inverter system, the ECC is designed to allow you the ability to turn off ALL of the lighting in a
given area via the local switch, and still provide emergency lighting during a power failure. The device will provide
single phase power from the emergency source to the designated emergency fixtures regardless of their current
status (on or off), thereby insuring safe egress from the facility at all times. The automatic Diagnostic feature will
confirm the emergency system is ready to provide back up power.

6.19.3 Specification

Description: ECC - EMERGENCY CIRCUIT CONVERTER OPTION

Part Number: 9100-1501-01 - 120 VAC

9100-1501-01- 277 VAC

Rating: 120 VAC - 20 A Ballast load, 1000 W Tungsten Lamp load, 20 A, 1 HP

277 VAC – 20 A Ballast load, 1800 W Tungsten Lamp load, 20 A, 1.5 HP

Operating Temperature: 20 to 150 F

Flame rating: UL 94V-O

Size: 2.75”W x 4.75”H x 1.75”D (overall)

Low profile – recessed portion is only 1.5” deep

Color: White

Weight: 8 oz.

EMERGENCY

POWER

TEST SWITCH

UTILITY
POWER

ILLUSTRATION 6-12: ECC EMERGENCY CIRCUIT CONVERTER

6-40

OnLine Power

6.20 OPTIONAL ECM - EMERGENCY CONTROL MODULE – P/N 9100-1502

6.20.1 Installation

Indoor use only. ECM is a universal mount unit. Simple and fast installation in ceiling or wall mounted standard

single gang E-box, recommended box size 4”. Installation must be performed by a qualified electrician per

Installation, Operation and Maintenance Instructions provided with the EMC.

6.20.2 Operation

The emergency power is provided from a central lighting inverter that is automatically switched over to 24 hour
emergency power distribution panel. The room switch turns on and off both regular and emergency lights
simultaneously. This is accomplished by having the room switch leg power activate the Emergency Control Module.
Wire input#1 is connected internally to a sensing circuit. During a power interruption, this circuit causes contact X
to drop into a N.C. position. Please review wiring schematics.

6.20.3 Specification

Description: ECM - EMERGENCY CONTROL MODULE
Part Number: 9100-1502-01 - 120 VAC

9100-1502-02 - 277 VAC

Rating: Maximum Ballast load 1500 W, 120 and 277 VAC

20 A N.C. UL contact rating
High Voltage surge protectors

Approvals: UL 924, NFPA 1104-2.4.1, OSHA

NEC 700 thru 700-26, 701-717,702-709, 705-750,
Operating Temperature: 210 to 150 F
Size: 2.75”W x 1.5”H x 1.25”D (overall)
Color: Black
Weight: 8 oz.

ILLUSTRATION 6-13: ECM EMERGENCY CONTROL MODULE

6-41

OnLine Power

6.21 EVENT LOG ( 1625-344-01 PCBD ASSY.)

6.21.1 START-UP SCREEN:

When input power is applied for the unit, LCD panel lights up and display as
shown.

If LCD display panel is not lit, the unit has problem. Contact the Factory Service at
1-800-PWR-SRVC (1-800-797-9782)

6.21.2 SCREEN A: First default screen appears as below.

STATUS SCREEN

SYSTEM MEASUREMENT SCREEN

.

MULTI OUTPUTS

UPS START @ 3KVA
INPUT BAD @ CHRG OFF
BATT LOW @ DC OK
ON BYPASS @ OUT BAD

K1 contactor is closed, UPS start nornal operation.

OUTPUT: 000V @ 0000W
INPUT:118V @ 00A
DCBUS: 166V @ NA A
BATT: 014V @+000A

OUTPUT VOLT: 126V
OUTPUT VOLT: 217V
OUTPUT VOLT: 252V
OUTPUT VOLT: 289V

This screen shows that UPS is started.

This screen shows the input contactor is closed and
check Input AC and DC bus voltage.

This screen shows the Output voltages for
multi-output unit.

6-42

OnLine Power

6.21.3 This Screen will display from (1), (2), (3), and (1) continuously with 3 seconds period.

STATUS SCREEN

(1)

SYSTEM MEASUREMENT SCREEN

(2)

MULTI OUTPUTS

(3)

LED INPUT OK AC Input voltage is within an acceptable voltage range.

LED INVERTER ON: Inverter is on.

LED ON BATTERY: Battery/Charger voltage within an acceptable range.

LED ON BYPASS: By-pass (Solid State) switch is on.

LED LOW BATTERY: Battery voltage is low.

UPS NORMAL @ 3KVA
INPUT OK @ CHRG OFF
BATT OK @ DC OK
ON INVERT @ OUT OK

LOG FREEZE TEST

OUTPUT: 122V @ 01923W
INPUT:118V @ 19A
DCBUS: 166V @ NA A
BATT: 013V @+000A

OUTPUT VOLT: 122V
OUTPUT VOLT: 211V
OUTPUT VOLT: 244V
OUTPUT VOLT: 280V

(Display area)

6-43

OnLine Power

@

(2)

t

LED SUM ALARM: UPS is failed by critical alarm condition.

6.21.4

Push " LOG" switch, then screen will show all events with date and name following screen is a sample.

Event log

Push "LOG" switch again, then screen will go to (1), and continuously keep rolling from (1), (2), and (3).

STATUS SCREEN SYSTEM MEASUREMENT SCREEN MULTI OUTPUTS

(1) (2) (3)

UPS NORMAL @ 3KVA
INPUT OK @ CHRG OFF
BATT OK @ DC OK
ON INVERT @ OUT OK

(1) (2) (3)

2/24/08, 11 INP UV
2/24/08, 11 INP BAD
2/24/08, 11 INP BAD
2/24/08, 11 INP TEST

OUTPUT: 122V @ 01923W
INPUT:118V @ 19A
DCBUS: 166V @ NA A
BATT: 013V @+000A

OUTPUT VOLT: 122V
OUTPUT VOLT: 211V
OUTPUT VOLT: 244V
OUTPUT VOLT: 280V

Push "FREEZE" switch, then previous screen before
freeze will show and display continuously without
rolling (see sample below)

OUTPUT: 122V @ 01923W
INPUT:118V @ 19A
DCBUS: 166V @ NA A
BATT: 113V

log

freeze tes

If want to freeze (1) , (2) or (3) screen display, push "FREEZE"
switch at

for (1), at (3) for 2 and at (1) for 3 display

+000A

6-44

OnLine Power

6.21.5 To UN-FREEZE Display, push "FREEZE" switch again, then screen will go to normal rolling state from
(1), (2),(3) & (1) continuously.

STATUS SCREEN SYSTEM MEASUREMENT SCREEN MULTI OUTPUTS

(1) (2) (3)

UPS NORMAL @ 3KVA
INPUT OK @ CHRG OFF
BATT OK @ DC OK
ON INVERT @ OUT OK

OUTPUT: 122V @ 01923W
INPUT:118V @ 19A
DCBUS: 166V @ NA A
BATT: 013V @+000A

OUTPUT VOLT: 122V
OUTPUT VOLT: 211V
OUTPUT VOLT: 244V
OUTPUT VOLT: 280V

Push "TEST" switch once, then system history screen will show below as a sample.

SYSTEM HISTORY SCREEN

MINUTE ON BATT : 00135
SYSTEMS DAYS : 00000
BATT, EVENT : 00035
TEMPERATURE : 21 C

Push "TEST" Switch again, then screen will display as normal display mode continuously as below.

STATUS SCREEN SYSTEM MEASUREMENT SCREEN MULTI OUTPUTS

UPS NORMAL @ 3KVA
INPUT OK @ CHRG On
BATT OK @ DC OK
ON INVERT @ OUT OK

OUTPUT: 122V @ 01923W
INPUT:118V @ 19A
DCBUS: 166V @ NA A
BATT: 013V @+000A

OUTPUT VOLT: 122V
OUTPUT VOLT: 211V
OUTPUT VOLT: 244V
OUTPUT VOLT: 280V

(1) (2) (3)

6-45

OnLine Power

6.21.6 UPS alert mode:

When UPS in on alert mode by over temperature, the screen display will be as below , and continuously display
from )1), (2), and (3).

STATUS SCREEN SYSTEM MEASUREMENT SCREEN DIAGNOSTICS SCREEN

(1) (2) (3)

(1) (2) (3)

UPS ALERT @ 3KVA
INPUT OK @ CHRG ON
BATT OK @ DC OK
ON BYPASS @ OUT BAD

OUTPUT: 000V @ 01923W
INPUT:123V @ 000 A
DCBUS: 173V @ NA A
BATT: 108 V @ +000A

OVER TEMPERATURE
CALL FOR SERVICE
800- PWR-SRVC
800- 797-77827

Push "LOG" Switch , then screen dispalys date/month/year with alarm names as shown below as a sample.

2/24/08, 12 INP overtemp
2/24/08, 12 INP BAD
2/24/08, 12 INP BAD
2/24/08, 12 NP UV

Push "LOG" switch again, then screen display as alert mode and continuously display from (1), (2),, and (3).

STATUS SCREEN SYSTEM MEASUREMENT SCREEN DIAGNOSTICS
SCREEN

UPS ALERT @ 3KVA
INPUT OK @ CHRG ON
BATT OK @ DC OK
ON BYPASS @ OUT BAD

OUTPUT: 000V @ 00000W
INPUT:123V @ 000 A
DCBUS: 173V @ NA A
BATT: 108 V @ +000A

OVER TEMPERATURE
CALL FOR SERVICE
800- PWR-SRVC
800- 797-77827

Re-start system after repairs. Screen display will start from (1) beginning of
start-up mode.

6-46

OnLine Power

6.21.6 (Continue)

Event Logger will log any event from the list below and attached a time stamp that include date and hour at the
event occurred (see sample screen below).
The local display on front of the Inverter will display the list of event logged when the LOG button is pressed for
approximately 2 seconds. The event logger to log up 50 events and display them 4 (four) at a time on the local
display.

Sample Screen

Event Logger

2/24/08, 11 INP UV
2/24/08, 11 INP BAD

5) DC BUSS-
UNDER VOLTAGE
OVER VOLTAGE

6) OVER TEMPERATURE

7) BATTERY TEST _

8) AUX. OUTPUT CIRCUIT BREAKER
AUX. C.B. TRIP

2/24/08, 11 INP BAD
2/24/08, 11 INP TEST

List of Events:

1) OUTPUT –
UNDER VOLTAGE
OVER VOLTAGE

2) OUTPUT LOAD­ OVER LOAD

3) INPUT –
UNDER VOLTAGE
OVER VOLTAGE
INPUT BAD

4) BATTERY ­ UNDER VOLTAGE
OVER VOLTAGE
CHARGER OFF

RECORDS AUTOMATIC TEST MONTHLY FOR 10 MINUTES
AND YEARLY FOR 90 MINUTES.

6-47

OnLine Power

APPENDIX A - SPECIFICATIONS

Specifications for KVA, 0.8pf Units

POWER RATING (KVA/KW) 10/8 15/12 20/16 25/20 30/24 40/32 50/40
INPUT and OUTPUT

INPUT VOLTAGE (VAC) Three Phase, 4-Wire plus Ground, 208Y/120 or 480Y/277 VAC (-20% to +15%)

OUTPUT VOLTAGE (VAC) Three Phase, 4-Wire plus Ground, 208Y/120 or 480Y/277 VAC

OUTPUT FREQUENCY (Hz) 60 Hz +0.5 Hz

VOLTAGE REGULATION +/-3%, Regulated within CBEMA curve

OUTPUT WAVE FORM Sine-Wave <5% THD.

EFFICIENCY Minimum 90%

CREST FACTOR 3 to 1 Typical

SURGE PROTECTION The UPS will protect itself and the load against surges as defined in ANSI/IEEE C62.41 Categories A and B.

ISOLATION Complete from line. Output neutral bonded to ground

NOISE ISOLATION -120 dB Common-Mode; -60 kB Transverse-Mode

BATTERY Sealed maintenance-free (AGM) battery

RECHARGE CURRENT Conforms to UL Standards

EXTERNAL BATTERY Provisions for hardwire connection of optional external battery cabinets or DC source.

BATTERY

BATTERY RUN TIME Consult OnLine Power

BATTERY TYPE Sealed, Maintenance-Free, AGM, VRLA type

NOMINAL BATTERY VOLTAGE 192 VDC 192 VDC 192 VDC 288 VDC 288 VDC 312 VDC 552 VDC 552 VDC

OVERCURRENT PROTECTION Circuit Breaker

PACKAGING Batteries not housed in Same Enclosure as electronic (See Table 2-2)

62.5/50

A-1

OnLine Power

Specifications for KVA, 0.8pf Units (Continued)

MONITORING AND COMMUNICATIONS

INDICATORS LCD Display Panel

RELAY INTERFACE Dry Contacts for:

CONTACT RATING 125 Volts (AC or DC) Maximum; 1.25 Amperes Maximum; 30 Watts / 50 VA Maximum

INTERFACE CONNECTION Hard Wired (Terminal Block)

ENVIRONMENTAL

SURGE WITHSTANDABILITY ANSI C62.41-1980 Categories A & B

OPERATING TEMPERATURE Meets NEMA Requirements

OPERATING RELATIVE HUMIDITY 0 to 95% Non-Condensing

ALTITUDE Up to 6,000 Feet (1,829 Meters) with No De-Rating

COOLING Air Cooled-Forced Fan

PHYSICAL (KVA/KW) 10/8 15/12 20/16 25/20 30/24 40/32 50/40

SIZE HxWxD in. (cm) 70 x 39 x 20 (177.8 x 99.1 x 50.8)

WEIGHT lbs (kg) with batteries 1655 1655 1998 2092 2186 2566 TBD TBD

CONSTRUCTION Painted Steel Enclosure with 3 Point Double Locking Front Door; and Full-length Door Hinge.

ENCLOSURE Designed for Inside Installations

COLOR Black

ACCESSIBILITY Front - All Servicing is Through the Front; No Side or Rear Access is Required.

CABLE ENTRY Top or sides

MOUNTING Four (4) Holes Provided to Anchor Enclosure to Pedestal (Supplied by Others)

Sum Alarm (N.C.); Bypass On (N.O.); Loss of Input Power (N.O.); Low Battery (N.O.)

62.5/50

A-2

OnLine Power

A

Recommended Input/Output Protective Device Ratings, BTU/Hr, and Floor Loading

MAX.

UPS RATING
KVA/KW

10KVA / 8KW 208Y/120 208Y/120 31/38 48 28/35 44 192 56 3032 1083 222

15KVA / 12KW

20KVA / 16KW 208Y/120 208Y/120 62/78 97 56/70 88 192 112 6066 1679 344

25KVA / 20KW 208Y/120 208Y/120 77/76 120 69/86 108 288 85 7582 1679 344

INPUT

VOLT.

3PHASE 3PHASE NORM/MAX NORM/MAX UPS CAB

480Y/277 480Y/277 14/18 23 12/15 18 192 56 3032 1083 222

480Y/277

208Y/120 208Y/120 47/59 74 42/53 66 192 84 4549 1446 297

480Y/277 480Y/277 21/26 33 18/23 29 192 84 4549 1446 297
480Y/277 208Y/120 21/26 33 42/53 66 192 84 4549 1446 297

480Y/277 480Y/277 27/34 42 24/30 38 192 112 6066 1679 344
480Y/277 208Y/120 27/34 42 56/30 38 192 112 6066 1679 344

480Y/277 480Y/277 35/44 55 30/38 48 288 85 7582 1679 344
480Y/277 208Y/120 35/44 55 69/86 108 288 85 7582 1679 344

OUTPUT

VOLT.

INPUT

CURRENT

RECOM.

*OCPD

OUTPUT

CURRENT

RECOM.

*OCPD

BATT.

VOLT.

BATT.

DISCH.

208Y/120 14/18 23 28/35 44 192 56 3032 1083 222

MP

FULL

LOAD

BTU/HR

MAX.

TOTAL

UNIT

WEIGHT

FLOOR

LOADING

LBS/SQFT

30KVA / 24KW 208Y/120 208Y/120 93/16 145 83/104 130 288 102 9098 1719 353

480Y/277 480Y/277 41/51 64 36/45 56 288 102 9098 1719 353

208Y/120 41/51 64 83/104 130 288 102 9098 1719 353

480Y/277

40KVA / 32KW 208Y/120 208Y/120 123/154 192 111/139 174 312 169 12131 2066 424

480Y/277

480Y/277 54/68 84 48/60 75 312 169 12131 2066 424
208Y/120 123/54 192 111/139 174 312 169 12131 2066 424

480Y/277

50KVA / 40KW 208Y/120 208Y/120 155/194 242 139/174 217 552 120 15164 2463 505

480Y/277

480Y/277 67/84 105 60/75 94 552 120 15164 2463 505

480Y/277 208Y/120 155/194 242 139/174 217 552 120 15164 2463 505

62.5KVA / 50KW

208Y/120 208Y/120 194/243 303 174/218 272 552 150 18000 2565 526

480Y/277

480Y/277 84/105 131 75/94 117 552 150 18000 2565 526
208Y/120 194/243 303 174/218 272 552 150 18000 2565 526

480Y/277

Note: Battery run time is very, consult factor for the battery Qty and cabinet arrangement for a certain battery run time.

A-3

OnLine Power

APPENDIX B - BATTERY CONNECTIONS

For the actual battery connection diagram for your system, refer to the

Caution

The following diagrams show various battery connection configurations in the battery cabinets that are shipped

with the UPS. Refer to

diagram on each unit. The drawings below are shown for electrical
connection only and do not necessarily match the actual battery layout in

your unit. The arrangement may be different from drawings.

Table A-1 for nominal battery voltage information.

B-1

OnLine Power

192 Volt Nominal

Typical 1 String of 16 Battery system.

BATT. C/B

#16

#14 #13 #12 #11

#15

#7 #8 #9 #10

#6

#4 #3 #2 #1

#5

192 VDC
BUSS

2 STRING

Maximum 4 Strings of 16 Battery system are
available in maximum 4 Cabinets depend
upon Battery Run Time requirement.
Consult Factory for detail.

UPS CABINET

1

2

1

2

192 VDC

3 STRING

4 STRING

ILLUSTRATION B-1

B-2

OnLine Power

288 Volt Nominal

Typical 1 String of 24 Battery system.

#24 #23 #22 #21

BATT. C/B

Maximum 4 Strings of 24 Battery system are
available in maximum 4 Cabinets depend
upon Battery Run Time requirement.
Consult Factory for detail.

#16

#15

#6

#5

#17 #18 #19 #20

#14 #13 #12 #11

#7 #8 #9 #10

#4 #3 #2 #1

2 STRING

288 VDC
BUSS

UPS CABINET

1

2

1

2

288 VDC

3 STRING

4 STRING

ILLUSTRATION B-2

B-3

OnLine Power

312 Volts Nominal

Typical 1 String of 26 Battery system.

BATT. C/B

#26

#22 #23 #24 #25

#21

#20

#15

#6

#19 #18 #17 #16

#14 #13 #12 #11

#7 #8 #9 #10

BATT. C/B

Maximum 5 Strings of 26 Battery system
are available in maximum 7 Cabinets
depend upon Battery Run Time
requirement.

Consult Factory

UPS CABINET

1

2

1

2

312 VDC

#5

#4 #3 #2 #1

2 STRING

3 STRING

4 STRING

5 STRING

ILLUSTRATION B-3

B-4

OnLine Power

552 Volts Nominal

Typical 1 String of 46 Battery system.

#23 #22 #21

BATT. C/B

#17 #18 #19 #20

#16

Maximum 4 Strings of 46 Battery
system are available in maximum
8 Cabinets depend upon Battery
Run Time requirement.

Consult Factory for details.

#15

#6

#5

#16

#15

#6

#14 #13 #12 #11

#7 #8 #9 #10

#4 #3 #2 #1

#23 #22 #21

#17 #18 #19 #20

#14 #13 #12 #11

#7 #8 #9 #10

BATT. C/B

UPS CABINET

1

2

1

552 VDC

2

#4 #3 #2 #1

#5

2 STRING

3 STRING

4 STRING

ILLUSTRATION B-4

B-5

OnLine Power

@

APPENDIX C - LCD DISPLAY MENU AND TROUBLESHOOTING GUIDE

Two screens (A, B) are updated continuously for units without the optional output transformer.

Three screens (A, B, C) are updated continuously for units with the optional output transformer.

Start-up Screen

When input power is applied for the unit, LCD panel lights up and displays

If LCD display panel is not lit, the unit has problem. Contact the factory service at 1-800-PWR-SRVC (800­797-7782) at OnLine Power.

Screen A: The first default screen appears as below

OnLine Power

UPS

UPS NORMAL @ XX KVA
INPUT OK @ CHRG ON
BATTERY OK @ DC OK
ON INVERTER

OUT OK

The display may say:

Line 1: UPS NORMAL @ 15 KVA

15 KVA indicates the KVA rating, STAND BY or NORMAL indicating normal operating modes. STAND BY
ALARM FAILURE indicates UPS alarm condition and FAILURE indicates UPS failed or had persistent
alarm condition. This will require system reset by cycling power. Shut if off and wait till LCD is dark.
Restart the unit.

Line 2: INPUT OK @ CHG ON

INPUT OK: Input within an acceptable range.

INPUT BAD: Input out of range.

CHRG ON: Charger on.

CHRG OFF: The charger is off. This will happen if the input capacitor is open or the system

is in a failure mode. - UPS ALARM

Line 3: BATTERY OK @ DC OK

BATTERY OK: Battery voltage within an acceptable range.

BATTERY OV: Battery voltage high. This is normal when the battery is charging.

BATTERY LOW: Battery voltage low. Recharge battery.

DC OK: DC bus voltage within an acceptable range.

DC OV: DC bus voltage too high. - UPS ALARM

DC UV: DC bus voltage too low. - UPS ALARM

C-1

OnLine Power

NOTE: The typical DC buss voltage should be higher than the battery voltage.

SCREEN B: The second default screen appears as below

Line 1: Indicates output voltage and power in watts, when an output transformer is not used. It indicates

Line 2: Indicates input volts and Amps.

Line 3: Indicates internal DC bus condition for factory use.

Line 4: Indicates battery voltage. The (+) current in Amps indicates charging Amps, while (-) indicates

OUTPUT:_____V @ ______ W
INPUT: _____V @ ______ A
DC BUS: _____V @ NA A
BATT: _______V @ + _____ W

primary voltage of the output transformer (T1) (208 VAC, typically) when T1 is used.

discharging Amps.

SCREEN C: When an optional output transformer is installed, the multiple output voltages are

displayed as follows:

OUTPUT: 120 V @
OUTPUT: 208 V @
OUTPUT: 277 V @
OUTPUT: 480 V @

Line 1: Indicates L-N output voltage 1

Line 2: Indicates L-N output voltage 2

Line 3: Indicates L-N output voltage 3

Line 4: Indicates L-N output voltage 4

C-2

OnLine Power

APPENDIX D - Input and Output Ampacity for Various Models

Input and Output Ampacity for Various Models

SIZE

KVA/KW

10KVA/8KW

15KVA/

12KW

20KVA/

16KW

25KVA/

20KW

30KVA/

24KW

40KVA/

32KW

50KVA/

40KW

62.5KVA/
50KW

Note: * I TOTAL: Total Amps, I R: Total Amp (Resistive load)

INPUT

208Y/120 208Y/120 27.8 22 31 192 56

480Y/277 480Y/277 12 10 14 192 56
480Y/277 208Y/120 28 22 14 192 56

208Y/120 208Y/120 42 33 47 192 84

480Y/277 480Y/277 18 15 21 192 84
480Y/277 208Y/120 42 33 21 192 84

208Y/120 208Y/120 56 45 62 192 112

480Y/277 480Y/277 24 19 27 192 112
480Y/277 208Y/120 56 45 27 192 112

208Y/120 208Y/120 69 56 77 288 85

480Y/277 480Y/277 30 24 35 288 85
480Y/277 208Y/120 69 56 35 288 85

208Y/120 208Y/120 83 67 93 288 102

480Y/277 480Y/277 36 29 41 288 102
480Y/277 208Y/120 83 67 41 288 102

208Y/120 208Y/120 111 89 123 312 169

480Y/277 480Y/277 48 39 54 312 169
480Y/277 208Y/120 111 89 54 312 169

208Y/120 208Y/120 139 111 155 552 120

480Y/277 480Y/277 60 48 67 552 120
480Y/277 208Y/120 139 111 67 552 120

208Y/120 208Y/120 174 139 194 552 -

480Y/277 480Y/277 75 60 84 552 ­480Y/277 208Y/120 174 139 194 552 -

OUTPUT OUTPUT

I TOTAL I R VOLT AMP

INPUT

AMPS

DC

D-1

OnLine Power

APPENDIX E – Drawings (All drawings are downloadable from Website: www.onlinepower.com

1. Three Phase UPS Installation - Installation Dwg. – 6001-032-03 Rev.C

2. UPS & Battery Cabinet Installations (Battery Cabinet Layout) – Dwg. 6001-032-05 Rev. D

3. UPS & Battery Cabinet Installations (Battery Cabinet Layout) – Dwg. 6001-032-06 Rev. D

4. UPS & Battery Cabinet Installations with Stackable Rack – Dwg. 6001-032-07 Rev. D

5. 3 Phase UPS Functional Block Diagram – Single Line Diagram, Single Input Dwg. 6001-032-11-Rev. A

6. 3 Phase UPS Functional Block Diagram – Single Line Diagram, Dual Input Wye-Wye) – Dwg. 6001-032-04-Rev. C

7. 3 Phase UPS Functional Block Diagram – Single Line Diagram Dual Input Delta-Delta) – Dwg. 6001-032-10-Rev. C

8. UPS & Battery Cabinet Seismic Certification Drawing – Dwg. 04-0959A

9. 3 Ph. External Wrap Around 3 Pole By-Pass Panel, 55 A – 350 A, Dwg. 6001-032-11 Rev. X1, Sheet 1 & 2.

10. 3 Ph. External Wrap Around 3 Pole By-Pass Panel, 55 A – 350 A,Dwg. 6001-032-11B Rev. X1, sheet 1 & 2.

11. 3 Ph. External Wrap Around 3 Pole By-Pass Panel, 55 A – 350 A for Different Input / Output, Dwg.6001-032-11-X, rev

X1, Sheet 1 & 2.

12. 3 Ph. External Wrap Around 3 Pole By-Pass Panel,55 A – 350 A with Optional Circuit Breaker, Dwg. 6001-032-11-B-X

Rev X1, Sheet 1 & 2.

13. 3 Ph. External Wrap Around 4 Pole By-Pass Panel, 55 A – 350 A, Dwg. 6001-032-12 Rev. X1, Sheet 1 & 2.

14. 3 Ph. External Wrap Around 4 Pole By-Pass Panel,55 A – 350 A with Optional Circuit Breaker, Dwg. 6001-032-12B

Rev. X1, Sheet 1 & 2.

15. 3 Ph. External Wrap Around 4 Pole By-Pass Panel, 55 A – 350 A for Different Input / Output, Dwg.6001-032-12-X, rev

X1, Sheet 1 & 2.

16. 3 Ph. External Wrap Around 4 Pole By-Pass Panel,55 A – 350 A with Optional Circuit Breaker, Dwg. 6001-032-12B-X

Rev. X1, Sheet 1 & 2.

TABLES

1. Allowable Ampacities of Insulated Conductors Rated 0-2000 V, 60 to 90 deg. C, (140 – 194 deg. F). Table 310-16
of National Electrical Code.

2. Connection Type / Wire Size Range

3. Torque Specifications (Unless Otherwise Labeled)

4. UPS Installation Data

5. Specifications

E-1