OPTI-UPS MD120L User Manual

User’s Guide

MD Series

Modular UPS

200V / 208V

警告

危险

APPLICABLE STANDARDS

This product complies with CE 73/23 & 93/68 (low voltage safety) and 89/336 (EMC) , and EMC standards of Australia and New Zealand (C-Tick) , and the following UPS product standards: *IEC62040-1-1-General and safety requirements for use in operator access area *IEC/EN62040-2 EMC requirements CLASS C3 *IEC62040-3 Performance requirements and test methods

警告

危险

WARNING- High earth leakage current

Earth connection is critical before connecting the input supply (include both utility supply and battery). This equipment must be earthed in accordance with local electrical authority codes of practice. Earth leakage current exceeds 3.5 mA and is less than 1000 mA. Transient and steady-state earth leakage currents, which may occur when starting the equipment, should be taken into account when selecting instantaneous RCCB or RCD devices. Residual Current Circuit Breakers ( RCCBs) must be selected insensitive to DC unidirectional pulses ( class A ) and transient current pulses ( RCCBs). Note it that the earth leakage currents of the load will also flow across RCCB or RCD.

警告

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Components that can be maintained by user

All the equipment maintenance and servicing procedures involving internal access need special tools and should be carried out only by trained personnel. The components that can only be accessed by opening the protective cover with tools cannot be maintained by user. This UPS full complies with “IEC62040-1-1-General and safety requirements for use in operator access area. UPS dangerous voltages are present within the battery box. However, the risk of contact with these high voltages is minimized for non-service personnel. Since the component with dangerous voltage can only be touched by opening the protective cover with a tool, the possibility of touching high voltage component is minimized. No risk exists to any personnel when operating the equipment in the normal manner, following the recommended operating procedures in this manual.

警告

危险

Battery Voltage Higher Than 400Vdc

All the battery maintenance and servicing procedures involving internal access need special tools or keys and should be carried out only by trained personnel. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING WITH THE BATTERIES ASSOCIATED WITH THIS EQUIPMENT. WHEN CONNECTED TOGETHER, THE BATTERY TERMINAL VOLTAGE WILL EXCEED 400Vdc AND IS POTENTIALLY LETHAL. Battery manufacturers supply details of the necessary precautions to be observed when working on, or in the vicinity of, a large bank of battery cells. These precautions should be followed implicitly at all times. Particular attention should be paid to the recommendations concerning local environmental conditions and the provision of protective clothing, first aid and fire-fighting facilities.

Safety Precautions

This manual is about the installation and operation of MD Series modular UPS (Hereinafter referred

to as UPS).

Please carefully read this manual prior to installation.

The UPS must be debugged and maintained by the engineer commissioned by the manufacturer or the agent. Otherwise, human safety may be endangered and the damage of UPS shall not belong to the warranty scope.

Contents

Chapter 1 Installation .............................................................................................................................. 4

1.1 Introduction ................................................................................................................................. 4

1.2 Initial Checking ............................................................................................................................ 4

1.3 Positioning .................................................................................................................................. 5

1.3.1 Distribution Room ............................................................................................................ 5

1.3.2 Battery Room ................................................................................................................... 5

1.3.3 Storing ............................................................................................................................. 5

1.4 Disassembly, Initial Checking and Positioning ............................................................................ 5

1.4.1 System Packaging: .......................................................................................................... 5

1.4.2 Module Packaging: .......................................................................................................... 7

1.4.3 UPS Composition ............................................................................................................ 9

1.4.4 Operation Space ............................................................................................................ 10

1.4.5 Front and Back Access .................................................................................................. 10

1.4.6 Final Positioning ............................................................................................................ 10

1.4.7 Power Module Installation .............................................................................................. 10

1.4.8 Cable Entry .................................................................................................................... 11

1.5 Protective Devices .................................................................................................................... 12

1.5.1 Rectifier and Bypass Input Supply of the UPS ............................................................... 12

1.5.2 Battery ........................................................................................................................... 12

1.5.3 UPS Output.................................................................................................................... 13

1.6 Power Cables ............................................................................................................................ 13

1.6.1 Maximum stable state current and configuration of cable system .................................. 13

1.6.2 Cable Connection .......................................................................................................... 14

1.7 Control and Communication Cabling......................................................................................... 14

1.7.1 Dry Contact Interface of Battery and Environmental Temperature Detection ................ 15

1.7.2 Remote EPO Input Port ................................................................................................. 15

1.7.3 Generator Input Dry Contact .......................................................................................... 16

1.7.4 BCB Input Port ............................................................................................................... 17

1.7.5 Battery Warning Output Dry Contact Interface............................................................... 17

1.7.6 Integrated Warning Output Dry Contact Interface .......................................................... 18

1.7.7 Mains Failure Warning Output Dry Contact Interface .................................................... 18

1.7.8 RS232 Port and SNMP Card Port .................................................................................. 19

1.7.9 LBS (Load Bus Synchronizer) Port ................................................................................ 19

1.8 Installation Drawing ................................................................................................................... 19

Chapter 2 Operations ............................................................................................................................ 24

2.1 Introduction ............................................................................................................................... 24

2.1.1 Principle ......................................................................................................................... 24

2.1.2 Bypass Module .............................................................................................................. 25

2.2 Operation Mode ........................................................................................................................ 25

2.2.1 Normal Mode ................................................................................................................. 26

2.2.2 Battery Mode ................................................................................................................. 26

2.2.3 Auto-Restart Mode ......................................................................................................... 26

2.2.4 Bypass Mode ................................................................................................................. 26

2.2.5 Maintenance Mode ........................................................................................................ 26

2.2.6 ECO Mode ..................................................................................................................... 27

2.2.7 Frequency Converters Mode ......................................................................................... 27

2.3 Battery Management ................................................................................................................. 27

2.3.1 Normal Function ............................................................................................................ 27

2.3.2 Advanced Functions (Battery Self-checking and Maintenance) ..................................... 27

2.4 Battery Protection...................................................................................................................... 28

Chapter 3 Operating Steps ................................................................................................................... 29

3.1 Power Switches ........................................................................................................................ 29

3.2 UPS Start-up ............................................................................................................................. 29

3.2.1 Normal Module Start ...................................................................................................... 30

3.3 Procedure for Switching between Operation Modes ................................................................. 33

3.3.1 Procedure for Switching the UPS into Battery mode from Normal Mode ....................... 33

3.3.2 Procedure for Switching the UPS into Bypass mode from Normal Mode ...................... 33

3.3.3 Procedure for Switching the UPS into Normal from Bypass Mode ................................ 33

3.3.4 Procedure for Switching the UPS into a Maintenance Bypass from Normal Mode ........ 33

3.3.5 Procedure for Switching the UPS into Normal from a Maintenance Bypass Mode ........ 33

3.4 Procedure for Completely Powering down a UPS ..................................................................... 34

3.5 EPO Procedure ......................................................................................................................... 34

3.6 Language Selection .................................................................................................................. 34

3.7 Control Password ...................................................................................................................... 34

Chapter 4 Operator Control and Display Panel .................................................................................. 35

4.1 Introduction ............................................................................................................................... 35

4.1.1 LED Indicator ................................................................................................................. 36

4.1.2 Audible Alarm (buzzer) .................................................................................................. 36

4.1.3 Functional Keys ............................................................................................................. 37

4.2 LCD Display Type ..................................................................................................................... 37

4.3 Detailed Description of Menu Items .......................................................................................... 39

4.4 Alarm List .................................................................................................................................. 41

Chapter 5 Installation of Parallel Operation System .......................................................................... 44

Chapter 6 Maintenance ......................................................................................................................... 46

6.1 Instruction to Power, Bypass, and Output Power Distribution Module ...................................... 46

6.1.1 Precautions .................................................................................................................... 46

6.1.2 Instruction to Power Module .......................................................................................... 46

6.1.3 Instruction to Bypass Module ......................................................................................... 46

6.2 Replacing Dust Screen (optional).............................................................................................. 47

Chapter 7 Product Specification .......................................................................................................... 48

7.1 Applicable Standards ................................................................................................................ 48

7.2 Environmental Characteristics .................................................................................................. 48

7.3 Mechanical Characteristics ....................................................................................................... 48

7.4 Electrical Characteristics (Input Rectifier) ................................................................................. 49

7.5 Electrical Characteristics (Intermediate DC Link) ...................................................................... 49

7.6 Electrical Characteristics (Inverter Output) ................................................................................ 50

7.7 Electrical Characteristics(Bypass Mains Input) ......................................................................... 51

7.8 Efficiency ................................................................................................................................... 51

Appendix A Guidebook to Ordering and Selection of MU System ........................................................ 52

Chapter 1 Installation

警告

危险

Warning-Installation can only be done by authorized engineers

1. Do not apply electrical power to the UPS equipment before the approval of commissioning engineer.

2. The UPS should be installed by a qualified engineer in accordance with the information contained in this chapter.

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Note: 3-Phase 4-Wire Input Power is required

The standard UPS can be connected to TN, TT and IT AC distribution system (IEC60364-3) of 3-phase 5-wire

警告

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WARNING: battery hazards

SPECIAL CARE SHOULD BE TAKEN WHEN WORKING WITH THE BATTERIES ASSOCIATED WITH THIS EQUIPMENT. When connecting the battery, the battery terminal voltage will exceed 400Vdc and is potentially lethal.

 Eye protection should be worn to prevent injury from accidental electrical arcs.  Remove rings, watches and all metal objects.  Only use tools with insulated handles.  Wear rubber gloves.  If a battery leaks electrolyte, or is otherwise physically damaged, it must be replaced, stored in a

container resistant to sulfuric acid and disposed of in accordance with local regulations.  If electrolyte comes into contact with the skin, the affected area should be washed immediately with water.

Chapter 1 Installation

This chapter introduces the installation of MD series UPS (hereby referred to as UPS), including

initial checking, sitting, positioning, cabling and installation drawings.

1.1 Introduction

This chapter introduces the relevant requirements for positioning and cabling of the UPS.

As each site has its requirements, this chapter provides step-by-step installation instructions, which acts as a guide to the general procedures and practices that should be observed by the installing engineer.

1.2 Initial Checking

Perform the following checking operations prior to the UPS installation.

1. Visually examine if there is any damage inside and outside the UPS rack and battery equipment

due to the transportation. Report any such damage to the shipper immediately.

2. Verify the product label and confirm the correctness of the equipment. The equipment label is

attached on the back of front door. The UPS model, capacity and main parameters are marked on

the label.

Chapter 1 Installation

1.3 Positioning

1.3.1 Distribution Room

The UPS is designed for indoor installation, which shall be located in a clean environment with adequate ventilation to keep the environmental temperature within the required specification. The UPS uses forced convection cooling by internal fans. Cooling air enters the module through ventilation grills located at the front part of the cabinet and exhausted through grills located in the rear part of the cabinet. Please do not block the ventilation holes.

If necessary, a system of extractor fans should be installed to aid cooling-air flow. An air filter should be used when the UPS is to operate in a dirty environment and should be regularly cleaned to maintain airflow.

Note: The UPS should be installed on a cement surface or other surface that is not combustible.

1.3.2 Battery Room

The battery will generate some amount of hydrogen and oxygen at the end of charging, so the fresh air volume of the battery installation environment must meet EN50272-2001 requirements. The ambient temperature of the battery must be stable. Ambient temperature is a major factor in determining the battery capacity and life. The nominal operating temperature of battery is 20°C. Operating above this temperature will reduce the battery life, and operation below this temperature will reduce the battery capacity. If the average operating temperature of battery is increased from 20ºC to 30ºC, then the service life of the battery will be reduced by 50%. If the operating temperature of the battery is above 40ºC, then the battery service life will be decreased in exponent rate. In a normal installation, the battery temperature is maintained between 15°C and 25°C. Keep batteries away from heat sources or air outlets.

If external batteries are to be used, a battery protection device (a DC circuit breaker) must be

mounted as close as possible to the batteries, and the connecting cables should be as short as possible.

1.3.3 Storing

If the equipment is not installed immediately, it must be stored in a room so as to protect it against excessive humidity and heat sources. The battery needs to be stored in dry and cool place with good ventilation. The most suitable storage temperature is 20 ºC to 25ºC.

1.4 Disassembly, Initial Checking and Positioning

Check the packaging first upon the arrival of product to see if there is any damage; open the packaging to check the equipment; report any such damage to the shipper immediately.

1.4.1 System Packaging:

Open the wooden case first, the open method is shown in fig 1-1:

Chapter 1 Installation

Fig 1-1 Open method

Firstly, open the top plate of the steel-edged wooden case with slotted awl and plier, followed by

sideboards. Be careful not to scratch the product. See fig 1-2.

Fig 1-2 Disassemble the case

Take out the foam after disassembling the sideboards of the case as shown in fig 1-3.

Chapter 1 Installation

Fig 1-3 Complete the disassembly

Tip: Dismantle the bolt that connects the cabinet and wooden pallet after disassembly, then lift the

cabinet to installation position. The dismantlement should be careful so as not to scratch the body.

Verify the product label and confirm the correctness of the equipment. The equipment label is attached on the back of front door. The UPS model, capacity and main parameters are marked on the label.

1.4.2 Module Packaging:

The open method is shown in fig 1-4:

The packing case should be placed horizontal and stable;

Fig 1-4 Open method

Cut the plastic packing belt and scotch tape to open the carton, see fig 1-5:

Chapter 1 Installation

Carton

Foamed package

Carton Equipment

Top cover of foamed package

Foamed package

Fig 1-5 Open the carton

Open the foamed cover, the equipment with plastic package can be see as shown in fig 1-6:

At last, take out the equipment with plastic package, and dismantle the packaging materials.

Warm Tips: Please dispose the wasted materials in accordance with environmental protection requirements after disassembly.

To prolong the service life, the place chosen for the UPS must guarantee:

 Easy wiring  Sufficient space for operation

Fig 1-6 Open the foamed cover

Chapter 1 Installation

功率模块

旁路模块

开关单元

配电单元

Bypass module

Power module

Distribution unit

Switch unit

 Air sufficient enough to dispel heat produced by UPS  Against ambient corrosive gases  Against excessive humidity and heat sources  Against dust  With the current fire prevention requirements  The operating environment temperature is within 20℃～25℃. The batteries are at maximum

efficiency in this temperature range (for information about the battery storage and transportation as well as the environment, please refer to table 6-2).

1.4.3 UPS Composition

UPS composition shall refer to fig 1-7; UPS configuration shall refer to table 1-1.

2m cabinet (front view) 2m cabinet (back view)

Chapter 1 Installation

开关单元

旁路模块

功率模块

配电单元

Involved part name

Quantity (Piece)

Note

Cabinet

Switch PDU

Standard configuration

Monitoring + bypass

module

Standard configuration

Power module

1～6 or 1～10

Field installation is

required

switch unit

Switch unit

Bypass module

Power module

Distribution unit

1.6m cabinet (front view) 1.6m cabinet (back view)

Fig 1-7 UPS Composition Diagram Table 1-1 UPS Configuration Table

1.4.4 Operation Space

As UPS has no ventilation grills at either sides, no clearances are required for the sides.

To enable routine tightening of power terminations within the cabinet, it is recommended that clearance around the front and back of the equipment should be sufficient to enable free passage of personnel with the doors fully opened.

1.4.5 Front and Back Access

The component layout of the UPS supports front and back access for servicing, diagnosing and

repairing the UPS, thus reducing the space requirement for side access.

1.4.6 Final Positioning

When the equipment has been finally positioned, ensure the adjustable feet are set so that the UPS

will remain stationary and stable.

1.4.7 Power Module Installation

The installation position of power module and output distribution module are shown in fig 1-8. the installation principle of these modules is to installed from bottom to top to prevent inclination of the cabinet due to high center of gravity .

As is shown in fig 1-8, the installation procedure of power module is as follows:

Chapter 1 Installation

固定孔

A处放大

固定孔

A处放大

进线通道

Power module

Fixing hole

Amplification of A

Cable entrance

1. Each module shall be installed from bottom to top, the default setting of the system is module No. 1,

2, 3, 4, 5, 6, 7, 8, 9, and 10.

2. Insert the module into installation position, and push in the cabinet. The wiring terminals in between

shall be tight, and excessive force shall be prevented against the damage to inserted pins of the terminals.

3. Fix the module to the cabinet though the mounting holes on two sides of the front plate of the

module.

Fig 1-8 Power Module Installation Diagram

1.4.8 Cable Entry

Cables can enter the UPS from top and below as shown in fig 1-9. Both the top and bottom of the UPS have cable entrance.

The recommended installation practice is to install power cables in the entrance channel

at both sides of the cabinet back door, so as not to affect the ventilation.

Fig 1-9 Cable Entry Diagram

Chapter 1 Installation

警告

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Note

For IT power network system, 4-pole protective device must be installed on the external input distribution of the UPS.

20 batteries connected in series

1.5 Protective Devices

For safety concerns, it is recommended to install external circuit breakers or other protective devices for the input AC supply of the UPS system. This section provides generic practical information for qualified installation engineers. The installation engineers should have the knowledge of the regulatory wiring standards, and of the equipment to be installed.

1.5.1 Rectifier and Bypass Input Supply of the UPS

Install suitable protective devices in the distribution unit of the incoming mains supply, considering the power cable current-carrying capacity and overload capacity of the system. Generally, the magnetic circuit breaker with IEC60947-2 tripping curve C (normal) at the 125% of the current listed in table 1-2 is recommended.

If protection against earth faults (RCD devices) is required for the upstream of the input supply, the installed device should:

 Sensitive to DC unidirectional pulses (class A) in the network

 Insensitive to transient current pulses

 Have an average sensitivity that is adjustable between 0.3A～1A

The RCCB must be sensitive to DC unidirectional pulses (class A) in the network, while insensitive to transient current pulses, as shown in fig 1-10 respectively.

Fig 1-10 RCCB sign

1.5.2 Battery

A battery unit is composed of 40 batteries connected in series, a centreline is drawn from in between (the joint part between the 20th and 21st battery), plus the line drawn from the front and back, there are altogether 3 lines connected with UPS line contact bank. The battery line must push through a DC circuit breaker before connecting to corresponding UPS line contact bank. The detailed wiring please refer to fig 1-11 below:

Chapter 1 Installation

警告

危险

Warning

Prior to cabling the UPS, confirm the status and positions of the switches of the UPS rectifier input power supply / bypass power supply and mains power distribution board. Ensure that these switches are opened and attached with WARNING label so as to prevent unauthorized operation to these switches.

System Name

MD36/6

MD72/12

MD60/6

MD120/12

Capacity

System

capacity

36kVA

72kVA

60Kva

120kVA

Module

capacity

6kVA

12kVA

6kVA

12kVA

Cabinet

dimension

600*900*1600(W*D*H mm)

600*900*2000(W*D*H mm)

Main Input

Rated

current A

180

150

300

Cable mm2

Output

Rated

current A

180

150

300

Cable mm2

Battery

Rated

current A

133

267

223

445

Cable mm2

120

Cable mm2

警告

危险

Warning

FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES CAN RESULT IN EMI, ELECTRIC SHOCK HAZARD OR RISK OF FIRE.

Fig 1-11 Diagram of batteries connected in series

1.5.3 UPS Output

A main output switch has been installed in UPS, the user shall install the over current protective

device on the bypass of each output of the external distribution cabinet.

1.6 Power Cables

Design the cables according to the descriptions in this section and local regulatory wiring standards,

and the environmental conditions should be taken into consideration. Refer to IEC60950-1 Table 3B.

1.6.1 Maximum stable state current and configuration of cable system

Maximum stable state current and configuration of cable system, please refer to table 1-2.

Table 1-2 Maximum stable state current and configuration of cable system

Chapter 1 Installation

警告

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Note

The operations described in this section must be performed by authorized electricians or qualified technical personnel. If you have any difficulties, do not hesitate to contact our Customer Service & Support department .

警告

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Warning-Hazardous battery terminal voltage of 400Vdc

Ensure the correct polarity connection between the battery terminals and the UPS terminals: Positive terminal to positive terminal, negative terminal to negative terminal, and disconnect one or more than one cable between every two layers of batteries. Do not connect the cables and close the battery circuit breakers before getting the approval from the commissioning engineer.

干接点接口

SNMP卡接口

RS485接口

RS232接口

LBS接口

Dry contact interface

SNMP card port

LBS port

RS232 port

RS485 port

1.6.2 Cable Connection

After the equipment has been finally positioned and secured, connect the power cables as

described in the following procedures:

1. Verify that all the external input distribution switches of the UPS are completely opened and the

UPS internal maintenance bypass switch is opened. Attach necessary warning signs to these

switches to prevent unauthorized operation.

2. Open the back door of the cabinet, remove the cover and then the input and output terminal,

battery terminal and earth terminal are visible.

3. Connect the input earth wire to input earth terminal. Please note: the earth wire shall be connected

in accordance with related local or state regulation

4. For common bypass and rectifier inputs, connect the AC input supply cables to the UPS input

terminals (Main input A-B-C-N), and connect the output loaded cable to the UPS output terminals

(Output A-B-C-N) and tighten the connections to 13 Nm (M8 Bolt). ENSURE CORRECT PHASE

ROTATION.

5. Connect the battery cables between the UPS battery terminals and battery switch. ENSURE

CORRECT PHASE ROTATION.

6. Re-install all the protective covers.

1.7 Control and Communication Cabling

As shown in fig 1-12, the front panel of the bypass module will provide dry contact interface

(J2~J10), communication interface (RS232, 485 and SNMP card interface), as well as LBS interface.

Fig 1-12 Dry contact interface and communication interface

Chapter 1 Installation

J2 J3

TEMP_BAT

TEMP_ENV

Position

Name

Purpose

J2.1

TEMP_BAT

Battery temperature detection

J2.2

GND

Power ground

J3.1

TEMP_ENV

Environment temperature detection

J3.2

GND

Power ground

Note: Specified temperature sensor is required for temperature detection (R25=5Ohm, B25/50=3275), please confirm with the manufacturer, or contact local maintenance engineers when placing an order.

The UPS accepts external signal from zero-voltage (dry) contacts connected through external dry contact terminals produced and phoenix terminals that are in bypass module. Through software programming, these signals become active when these contacts connect to +24V to ground).The cables connected to DRY terminal must be separated from power cables. Moreover, these cables should be double insulated with a typical 0.5 to 1.5 mm between 25 and 50 meters.

cross-section area for a maximum connection length

1.7.1 Dry Contact Interface of Battery and Environmental Temperature Detection

The input dry contact J2 and J3 can detect the temperature of batteries and environment respectively, which can be used in environment monitoring and battery temperature compensation 1.

J2 and J3 interfaces diagram are shown in fig 1-13, the description of interface is in table 1-3.

Fig 1-13 Diagram of J2 and J3 dry contact for temperature detecting

Table 1-3 Description of input dry contact interface J2 and J3

1.7.2 Remote EPO Input Port

The UPS has an Emergency Power OFF (EPO) function. This function can be activated by pressing a button on the control panel of the UPS or through a remote contact provided by the user. The EPO pushbutton is protected by a hinged plastic cover.

J4 is the input port for remote EPO. It requires shorting NC and +24v during normal operation, and the EPO is triggered when opening NC and +24v, or shorting NO and +24v. The port diagram is shown in fig 1-14, and port description is shown in table 1-4.

Chapter 1 Installation

EPO_NC

+24V

EPO_NO

+24V

Position

Name

Purpose

J4.1

EPO_NC

EPO is activated when disconnecting fromJ4.2

J4.2

＋

24V

+24V, connect the common terminal of NC and NO

J4.3

EPO_NO

EPO is activated when shorting with J4.2

警告

危险

Note

1. The emergency stop action within the UPS will shut down the rectifier, inverter and static bypass. However, it does not internally disconnect the mains input power supply. To disconnect ALL power to the UPS, open the upstream input circuit breaker(s) when the EPO is activated.

2. Pin 1 and 2 of J4 have been shorted before the UPS is delivered.

Fig 1-14 Diagram of input port for remote EPO

Table 1-4 Description of input port for remote EPO

The EPO is triggered when shorting pin 2 and 3 or opening pin 2 and 1 of J4.

If an external emergency stop facility is required, it is connected via the reserved terminals of J4. The external emergency stop facility needs to use shielded cables to connect to the normally open/closed remote stop switch between these two pins. If this facility is not used, then pin 3 and pin 4 of J4 must be open, or pin 1 and pin 2 of J4 must be shorted.

1.7.3 Generator Input Dry Contact

J5 is status interface for generator connection. Connect pin 2 of J5 with + 24V power supply, it indicates that the generator has been connected with the system. The interface diagram is shown in fig 1-15, and interface description is shown in table 1-5.

Chapter 1 Installation

GEN

+24V

AUX-N.O. AUX-N.O.

发电机

Position

Name

Purpose

J5.1

+24V

+24V power supply

J5.2

GEN

Connection status of generator

J5.3

GND

Power ground

BCB_DRV

BCB_CONT

BCB_ONL

+24V

Position

Name

Description

J6.1

BCB_DRV

BCB actuating signal, provide the actuating signal of +18V, 20mA

J6.2

BCB_CONT

BCB contact status, connect with the normally open signal of BCB

J7.1

GND

Power ground

J7.2

BCB_ONL

BCB on-line–input (normally open) , BCB is on-line when the signal is connecting with GND

Generator

Fig 1-15 Diagram of status interface and connection of generator

Table 1-5 Description of maintenance bypass switch and output switch status interface

1.7.4 BCB Input Port

J6 and J7 are the ports of BCB. The port diagram is shown in fig 1-16, and description is shown in

table 1-6.

Fig 1-16 BCB Port

Table 1-6 Description of BCB port

1.7.5 Battery Warning Output Dry Contact Interface

J8 is the output dry contact interface, which outputs the battery warnings of low or excessive voltage, when the battery voltage is lower than set value, an auxiliary dry contact signal will be provided via the isolation of a relay. The interface diagram is shown in fig 1-17, and description is shown in table 1-7.

Chapter 1 Installation

BAT_LOW_NC

BAT_LOW_NO

GND

Position

Name

Purpose

J8.1

BAT_LOW_NC

Battery warning relay (normally closed) will be open during warning

J8.2

BAT_LOW_NO

Battery warning relay (normally open) will be closed during warning

J8.3

GND

Center of battery warning relay

ALARM_NC

ALARM_NO

GND

Position

Name

Purpose

J9.1

ALARM_NC

Integrated warning relay (normally closed) will be open during warning

J9.2

ALARM_NO

Integrated warning relay (normally open) will be closed during warning

J9.3

GND

Centre of integrated warning relay

Fig 1-17 Battery warning dry contact interface diagram

Table 1-7 Battery warning dry contact interface description

1.7.6 Integrated Warning Output Dry Contact Interface

J9 is the integrated warning output dry contact interface, when one or more than one present warning is triggered, the system will send an integrated warning information, and provide an auxiliary dry contact signal via the isolation of a relay. The interface diagram is shown in fig 1-18, and description is shown in table 1-8.

Fig 1-18 Integrated warning dry contact interface diagram

Table 1-8 Integrated warning dry contact interface description

1.7.7 Mains Failure Warning Output Dry Contact Interface

J10 is the output dry contact interface for mains failure warning, when the mains fails, the system will send a mains failure warning information, and provide an auxiliary dry contact signal via the isolation of a relay. The interface diagram is shown in fig 1-19, and description is shown in table 1-9.

Chapter 1 Installation

J10

UTI_FAIL_NC

UTI_FAIL_NO

GND

Position

Name

Purpose

J9.1

UTI_FAIL_NC

Mains failure warning relay(normally closed) will be open during warning

J9.2

UTI_FAIL_NO

Mains failure warning relay (normally open) will be closed during warning

J9.3

GND

Centre of mains failure warning relay

UPS 1

LBS

监控旁路模块 UPS 2

LBS

监控旁路模块

UPS 1 monitoring bypass module

UPS 2 monitoring bypass module

Fig 1-19 Mains failure warning dry contact interface diagram

Table 1-9 Mains failure warning dry contact interface description

1.7.8 RS232 Port and SNMP Card Port

RS232 and RS485 Port: provide serial data which can be used for commissioning and maintenance by authorized engineers or maintainers, or can be used for networking or integrated monitoring system in the service room.

SNMP Card Port: used for field installation of the communication option card(SNMP card).

1.7.9 LBS (Load Bus Synchronizer) Port

The dual bus system (DBS) consists of two independent UPS rack module systems, as shown in fig 1-20. The dual bus system is configured for high availability and is suitable for powering the load with dual inputs. If the load is single-input load, the static transfer switch and LBS control is recommended to maintain both UPS outputs synchronized for uninterrupted transfers. Please install the system according to the installation descriptions for different system configurations.

The dual bus system is supported by UPS, it requires connecting the LBS signal cables of two UPS

when constructing the dual bus system; please refer to relevant chapter for detailed configuration and installation, and the system software shall be configured as required.

1.8 Installation Drawing

Please refer to fig 1-21, fig 1-22, fig 1-23 and fig 1-24:

Fig 1-20 LBS Connection Diagram

Chapter 1 Installation

Fig 1-21 Installation Diagram

Chapter 1 Installation

顶视图

Top view

2m cabinet front view

1.6 m cabinet (front view)

Fig 1-22 UPS front view (Unit: mm)

Chapter 1 Installation

2m cabinet

1.6m cabinet

Fig 1-23 UPS back view

Chapter 1 Installation

A处放大

Amplification of A

Fig 1-24 UPS front view

24 Chapter 2 Operations

警告

危险

Warning: Hazardous mains voltage and/or battery voltage present(s)behind the protective cover

The components that can only be accessed by opening the protective cover with tools can not be operated by user. Only qualified service personnel are authorized to remove such covers.

Chapter 2 Operations

This chapter introduces the basic knowledge of UPS operations, including working principle, operation mode, battery management and protection.

2.1 Introduction

UPS provides the critical load (such as communication and data processing equipment) with high quality uninterruptible AC power. The power from UPS is free from voltage and frequency variations and disturbances (interruption and spike) experienced at the Mains AC input supply.

This is achieved through high frequency double conversion power pulse width modulation (PWM) associated with full digital signal processing control (DSP), which features high reliability and convenience for use.

2.1.1 Principle

As shown in fig 2-1, the AC input mains source is supplied at UPS input and converted into a DC source. This DC source feeds the inverter that converts the DC source into a clean and input independent AC source. The battery powers the load through the inverter in case of an AC input mains power failure. The utility source can also power the load through the static bypass.

When the UPS needs maintenance or repair, the load can be transferred to maintenance bypass without interruption and the power module and bypass module can be removed for maintenance.

Chapter 2 Operations 25

警告

危险

Note

When the UPS is operating in bypass mode or on maintenance bypass, the connected equipment is not protected from power failures or surges and sags.

Fig 2-1 System principle framework

2.1.2 Bypass Module

The circuit blocks labeled “bypass module” in fig 2-1 contain electronically controlled switching circuits that enable the critical load to be connected to either the inverter output or to a bypass power source via the static bypass line. During normal system operation the load is connected to the inverter; but in the event of a UPS overload or inverter failure, the load is automatically transferred to the static bypass line.

To provide a clean (no-break) load transfer between the inverter output and static bypass line, the inverter output and bypass supply must be fully synchronized during normal operating conditions. This is achieved through the inverter control electronics, which makes the inverter frequency track that of the static bypass supply, provided that the bypass remains within an acceptable frequency window.

A manually controlled maintenance bypass supply is incorporated into the UPS design. It enables the critical load to be powered from the utility (bypass) supply while the UPS is shut down for routine maintenance.

2.2 Operation Mode

The MD UPS is an on-line, double-conversion, reverse-transfer UPS that permits operation in these modes:

 Normal mode

26 Chapter 2 Operations

警告

危险

Warning: Hazard may occur after transferring to maintenance bypass

After UPS being transferred to maintenance bypass, power module and bypass module do not work, no display on LCD, and input and output terminals as well as N bus are electrically connected.

 Battery mode

 Auto-Restart mode

 Bypass mode

 Maintenance mode (manual bypass)

 ECO mode

 Frequency converters mode

2.2.1 Normal Mode

The UPS inverter power modules continuously supply the critical AC load. The rectifier/charger derives power from the AC mains input source and supplies DC power to the inverter while simultaneously FLOAT or BOOST charging its associated backup battery.

2.2.2 Battery Mode

Upon failure of the AC mains input power; the inverter power modules, which obtains power from the battery, supplies the critical AC load. There is no interruption in power to the critical load upon failure.

After restoration of the AC mains input power, the “Normal Mode” operation will continue automatically

without the necessity of user intervention.

Note: UPS can also be started through battery (charged) mode via battery cold start function upon failure of the AC mains. Therefore, the battery power can be used independently to improve the utilization rate of UPS.

2.2.3 Auto-Restart Mode

The battery may become exhausted following an extended AC mains failure. The inverter shuts down when the battery reaches the End of Discharge voltage (EOD). The UPS may be programmed to “Auto Recovery after EOD” after a delay time if the AC mains recovers. This mode and any delay time are programmed by the commissioning engineer.

During the process of delay time, the battery will be charged by UPS to prevent any risks to load equipment from future mains failure.

2.2.4 Bypass Mode

If the inverter overload capacity is exceeded under normal mode, or if the inverter becomes unavailable for any reason, the static transfer switch will perform a transfer of the load from the inverter to the bypass source, with no interruption in power to the critical AC load.

2.2.5 Maintenance Mode

A manual bypass switch is available to ensure continuity of supply to the critical load when the UPS

becomes unavailable e.g. during a maintenance procedure.

Note: This manual bypass switch is fitted in all UPS modules. Transfer UPS system to bypass mode

for power supply first, then close maintenance bypass switch Q2, followed by Q1 and Q3.

Chapter 2 Operations 27

2.2.6 ECO Mode

If economical (ECO) mode is selected, the double-conversion UPS will stop to work so as to save energy. During the operation of ECO mode, the load power will be supplied by bypass preferentially. When bypass power is within the range of normal frequency and voltage, load power will be supplied by bypass, or the system will transfer to inverter output, followed by load power interruption which extends within 3/4 of the utility period. E.g. when the frequency is 50Hz, the interruption time will be less than 15ms; when the frequency is 60Hz, the time will be less than 12.5ms.

2.2.7 Frequency Converters Mode

If the frequency converter configuration is used by UPS, it will provide 50Hz or 60Hz stable output frequency. The range of output frequency is 40Hz～70Hz. Under this mode, static bypass is unavailable, but battery can be selected according to the actual requirements of battery mode.

2.3 Battery Management

2.3.1 Normal Function

The following functions should be fitted by commissioning engineers with specified software.

1. Constant current boost charging

Current can be set up.

2. Constant voltage boost charging

Voltage of boost charging can be set as required by the type of battery. For Valve Regulated Lead Acid (VRLA) batteries, maximum boost charge voltage should not

exceed 2.4V / cell.

3. Float charge

Voltage of float charging can be set as required by the type of battery. For VRLA, float charge voltage should be between 2.2V to 2.3V.

4. Float charge temperature compensation (optional)

A coefficient of temperature compensation can be set as required by the type of battery.

5. End of discharge (EOD) protection

If the battery voltage is lower than the EOD, the battery converter will shut down and the battery is isolated to avoid further battery discharge. EOD is adjustable from 1.6V to 1.75V per cell (VRLA) or 0.9 to 1.1 V per cell

6. Battery low warning time

It is adjustable between 3 and 60 minutes. The default is 5 minutes.

2.3.2 Advanced Functions (Battery Self-checking and Maintenance)

At periodic intervals, 20% of the rated capacity of the battery will be discharged automatically, and the actual load must exceed 20% of the rated UPS (KVA) capacity. If the load is less than 20%, auto-discharge cannot be executed. The periodic interval can be set from 30 to 360 days. The battery self-test can be disabled.

Conditions—Battery at float charge for at least 5 hours, load equal to 20~100% of rated UPS capacity Trigger—Manually through the command of “Battery Maintenance Test” in LCD panel or automatically Battery Self-Test Interval—30-360 days (default setting is battery self-test disabled).

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