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9305 HS Series

Powerware 9305 HS Series User And Installation Manual

User’s and Installation Manual 20 - 80 kVA parallel UPS systems
User’s and Installation Manual 20 - 80 kVA Parallel Systems
1018390 Revision C
Table of content:
1. Safety Instructions .................................................................................................................... 5
2. Introduction .............................................................................................................................. 7
2.1 Overview ............................................................................................................................... 7
2.2. Easy power protection .......................................................................................................... 7
3. System Description ................................................................................................................... 8
3.1 Overview ............................................................................................................................... 8
3.2 Theory of operation .............................................................................................................. 9
3.3 Sizing ................................................................................................................................... 10
3.4 Accessories........................................................................................................................... 10
4. Instructions and preventive maintenance .................................................................................. 11
4.1 General ................................................................................................................................ 11
4.2 Unpacking and incoming inspection .................................................................................... 11
4.3 Storage ................................................................................................................................. 12
4.4 Handling and lifting ............................................................................................................. 12
4.5 Moving ................................................................................................................................. 12
4.6. Initial start-up and upgrades ................................................................................................ 12
4.7 Maintenance......................................................................................................................... 13
5. Mechanical installation ............................................................................................................. 14
5.1 Overview .............................................................................................................................. 14
5.2 Placing UPS modules............................................................................................................ 15
5.3 Placing battery cabinets ....................................................................................................... 17
6. Electrical installation ............................................................................................................... 18
6.1 Overview .............................................................................................................................. 18
6.2 Location of terminals ........................................................................................................... 18
6.3 Input and output power cables ............................................................................................. 19
6.4 Parallel operation ................................................................................................................ 20
6.5 Battery cables ....................................................................................................................... 20
6.6 SPM tie cabinet options ........................................................................................................ 23
6.7 Input filter option ................................................................................................................ 33
6.8 Installation check list ........................................................................................................... 34
7. Communication interfaces ........................................................................................................ 34
7.1 Overview .............................................................................................................................. 34
7.2 Software ............................................................................................................................... 35
7.3 RS-232 serial communication .............................................................................................. 35
7.4 Potential free relay outputs .................................................................................................. 36
7.5 Signal inputs......................................................................................................................... 37
8. Start-up and operation .............................................................................................................. 38
8.1 Overview .............................................................................................................................. 38
8.2 Start-up procedure ............................................................................................................... 38
8.3 Operating system bypass switch ........................................................................................... 39
8.4 Shut-down procedure ........................................................................................................... 40
8.5 Control panel operation ....................................................................................................... 41
8.6 Control panel displays ......................................................................................................... 42
9. Troubleshooting ....................................................................................................................... 45
9.1 Overview .............................................................................................................................. 45
9.2 Alarms and reasons .............................................................................................................. 45
10. Warranty ................................................................................................................................46
11. Technical specifications .......................................................................................................... 47
Copyright 2003
The contents of this manual are the copyright of the publisher and may not be reproduced (even extracts) unless permission granted. Every care has been taken to ensure the accuracy of the information contained in this manual, but no liability can be accepted for any errors or omission. The right to make design modifications is reserved.
1. Safety Instructions
1.1 General
Warning!
The complete safety instructions (p/n: 1009917) must be followed when installing, operating and servicing the parallel UPS system. Study the complete safety instructions carefully.
Because of the high energy stored within the batteries, the UPS equipment must be handled with care. The UPS must always be kept in the position marked on the package and must not be dropped during storage or transportation. Moreover, do not place the parallel UPS system in an airtight room.
The instructions are important for electrical safety with all personnel involved in UPS handling. Any failure to recognise the electrical hazards could prove fatal or cause injury.
1.2 Installation and service
Switch off the supply to the distribution point to which the UPS unit is to be connected. Remove the fuses from the selected line for extra safety precaution. Make absolutely sure that there is no power connected to UPS modules.
Warning!
The parallel UPS system must be installed according to the instructions given on this manual. Qualified electricians should carry out all electrical installation and maintenance work on the parallel UPS system. Local safety legislation and regulations for electrical UPS installations must be followed.
Any installation work must be done with the power off, and power is not to be reconnected unless the installation work is complete. Ensure by measuring that the part of the cabinet you are working on is not live.
Warning!
UPS modules are not provided with automatic power feedback relay. A readily accessible disconnect device must be installed in the fixed input wiring. Note that dangerous voltages remain in battery terminals when disconnect device is opened.
Ensure that the output of an UPS module is disconnected from the other parallel modules. Thus, open the output service switch before any installation work or maintenance in a parallel connected UPS module.
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1.3 User operations
Warning!
Do not open the UPS cabinet! Some components inside the UPS cabinet carry high voltages. To touch them may prove fatal or cause injury. All operations inside the unit must be carried out only by service personnel from the manufacturer or from an agent authorised by the manufacturer.
Do not operate the equipment in the presence of flammable gases or fumes. Operation of the electrical equipment in such an environment constitutes a safety hazard.
The only user operations permitted are:
• Starting up and shutting down the UPS unit (not the initial start up).
• Using the maintenance bypass switch of the system bypass module
• Operating the user interface.
• Connecting data interface cables.
• Monitoring the UPS modules with LanSafe III and PowerVision software.
User operations must be performed according to the instructions given on this manual. During any of these operations, the user must take greatest care and perform only the prescribed operations. Any deviation from the instructions could be dangerous to the operator.
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2. Introduction
2.1 Overview
This manual gives you the necessary information about parallel UPS systems in redundancy or capacity configuration. The largest systems include maximum of four UPS modules in parallel configuration.
Instructions and procedures are covered in this manual: shipping; storing; handling; installation; user start-up and operation; troubleshooting; and preventive maintenance. The manual is intended for the chief operator/system supervisor, electrical consultants and installation electricians. It describes the specific functions and features of the parallel UPS system.
Figure 1. A parallel configuration constructed with four UPS modules.
Always remember that the parallel UPS system is connected to the AC mains power and contains internal high-current batteries for back up. Hence, prudence principle must be followed to prevent electrical hazards when operating the parallel UPS system.
2.2. Easy power protection
One can choose from a variety of power protection devices to shield critical data and equipment from power problems. However, by far the most sophisticated devices are Uninterruptible Power Systems (UPS).
An on-line, double conversion UPS is ideally suited for the most critical equipment. It provides clean AC power and protects the critical load against nine types of power problems:
1. Power outages
2. Power sags
3. Power surges
4. Undervoltages
5. Overvoltages
6. Switching transients
7. Line noise
8. Frequency variations
9. Harmonic distortion
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3. System Description
3.1 Overview
Parallel UPS configurations are recognised as either redundancy or capacity systems. The redundancy system is used to improve the system reliability with N+1 redundant UPS module. The capacity system for its part provides the maximum output power without focusing to the highest system reliability.
A parameter selection is used to switch between the redundancy and capacity modes. It is important to remember that the mode is affecting to the output power rating and overall system reliability.
UPS modules of the parallel system share equally the load with Hot Sync™ technology. The parallel outputs are combined in a System Parallel Module or cabinet. It is the system component containing the obligatory service switches. Customer’s low-voltage distribution panel can also be used instead of the System Parallel Module. In the redundancy system, service switches enable the maintenance or service on an UPS module. In the capacity system, one needs to have a common system bypass switch to do the maintenance or service without safety hazards.
Figure 2. Parallel configurations with UPS modules.
Field upgrading can be used to extend existing capacity/redundancy systems with UPS modules. The upgrading must be carried out by service personnel from the manufacturer or from an agent authorised by the manufacturer.
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3.2 Theory of operation
A double conversion on-line UPS conditions the raw mains and supplies continuous, clean three-phase power to the critical systems. It keeps the battery constantly charged while feeding the critical load. The UPS will continue to supply clean power without any interruption at the output even at mains failure. It will shut down in order to prevent a total discharge of the battery if the power failure outlasts the backup time of battery bank. The UPS will start up again automatically, providing power to the critical load and charging the battery bank, when the mains voltage is restored.
Figure 3a. Block diagram of UPS module
A double conversion UPS provides the best protection for computer systems and other intelligent devices such as measurement instruments and industrial automation applications. UPS modules incorporate digital signal processing technology to monitor and control its own operation. They protect different types of sensitive electrical devices such as computers, workstations, banking systems, sales terminals, critical instrumentation, telecommunications systems, process control systems, hospital equipment, etc.
Figure 3b. Functional components of UPS module
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The mains is rectified and boosted to DC power in the rectifier part. The rectifier provides power to the battery charger and the inverter load. The battery charger keeps the battery in recharged condition with ABM™ technology. The DC Link connects the rectifier output with the inverter input. It is the means for transferring power between these system components.
The output of the inverter is constantly maintained in phase synchronism with the bypass supply voltage provided that it is within the voltage and frequency tolerances specified for the load transfer condition. The inverter is changing the output operation to internal set frequency if the bypass supply exceeds these tolerances.
In the event of a mains power interruption, the battery is supplying the inverter load. The rectifier starts again to supply the inverter load when the AC mains power returns. The battery charger is recharging the battery after the mains return, too.
The static switch is initiating uninterrupted transfer of the load to the bypass line when the inverter is overloaded or the inverter is not able to feed the load. The output is protected with a tripping circuit breaker to separate the faulty UPS module from the parallel load bus.
The parallel load sharing is implemented individually in UPS modules with Hot Sync™ technology. The critical load is supported even in the unlikely situation of the redundant bus communication failure.
3.3 Sizing
The output power rating of the parallel UPS configuration should be specified according to the total power demand of the protected load. Some margin should be allowed for potential expansion, and for possible inaccuracy in calculating or measuring the actual power requirement.
The battery should be sized according to the desired backup time. Note that the backup time is longer if the load is less than the nominal power rating of the parallel UPS system.
3.4 Accessories
The following external options are available:
• System Parallel Module (SPM):
– SPM9305 cabinet : 2-4 x 80 kVA – SPM9305 cabinet : 2-4 x 20-60 kVA – SPM9305/9340 cabinet : 2 x 80-130 kVA – SPM9305 module : 2 x 40-60 kVA – SPM9305 module : 2 x 20-30 kVA
• Battery cabinets:
– BAT D, BAT E, and BAT F
• Input filter:
– THDi 10%
• ViewUPS:
– Remote status/control panel
• LanQuattro:
– 4 x RS-232 data manager
• ConnectUPS:
– SNMP adapter
• Others:
– Engineered solutions upon request
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4. Instructions and preventive maintenance
4.1 General
Proper provision must be made for transportation and handling because of heavy weight and high energy stored within batteries. See technical specifications for dimensions and weights of the UPS modules.
4.2 Unpacking and incoming inspection
Unpack the equipment and remove the shipping and packing materials. The shipping and packing materials should be stored for further investigation if damage has occurred during the transportation.
The equipment must be inspected for shipping damage. A claim must be filed immediately if visible damages can be noticed. Proceed as follows to file the claim for a shipment damage:
• Inform the carrier about the damage within 7 days of receipt of the equipment.
• Check and verify that the shipment is complete against the packing list.
The installation may proceed if there are no damages or discrepancies. UPS system is also thoroughly inspected and tested at the factory.
Figure 4. Removing the UPS module from the shipping pallet.
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4.3 Storage
UPS modules must be stored in the original packing and shipping pallet. They should be handled with care. Make sure that you do not stack the pallets when the equipment is placed to local warehouse for storage.
If the UPS is not immediately installed the following must be remembered:
• Electrical equipment must always be protected from moisture and weather.
• The recommended storage temperature is between +15°C and +25°C
• UPS batteries should be charged regularly for at least 8 hours every 6 months to
maintain the battery condition.
4.4 Handling and lifting
UPS modules are shipped on specifically designed packing and pallets. It is easy to move and lift them with a forklift. Hence, equipment should be lifted in the original and packed condition.
Crane lifting can be used if a suitable lifting net is used. There exist no lifting eyeholes for crane lifting. Note that equipment must be kept in an upright position and must not be dropped.
4.5 Moving
UPS can be simply pushed into place after unpacking. They are equipped with castors for easy movement but be careful not to tilt it. Please verify that the surface material, on which the UPS modules are moved, is strong enough for the heavy weight.
4.6. Initial start-up and upgrades
The authorised field service person shall perform the following procedure and tests during the start- up the new parallel UPS system:
1. Visual inspection
• Make a visual inspection of the equipment for signs of damage or foreign material.
Observe the type of ventilation system, the cleanliness of the room, the use of safety signs, and other environmental factors affecting the functionality or personnel safety.
2. Mechanical and electrical inspection
• Check the power connections, control wiring terminations, and plugs for tightness or
proper seating. Verify that the alarms log is clear and in the ’green’ condition.
• Check the parallel UPS system for possible ground leakage, proper input and bypass
voltages, and correct phase rotation. Check the proper battery float voltage.
3. Operating inspection
• Energise the parallel UPS system and verify the proper DC and AC output voltages.
Check the final DC link voltage and output wave form of the inverter output.
4. Operational training
• Before leaving the site, the field service engineer shall familiarise responsible personnel
with the operation of the UPS system. The UPS equipment shall be available for demonstration of the modes of operation.
Normally, the complete parallel UPS system is calibrated at the factory and no output calibration is needed in the field. However, UPS module upgrades to the existing parallel UPS system require always the service visit due to the field adjustment of calibration settings. Special calibration software and tools are required to make the parallel system function properly with the new, purchased UPS module.
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20 - 80 kVA parallel UPS system
User’s and Installation Manual
1018390
Revision C
4.7 Maintenance
Warning!
Maintenance work must be performed only by a service person with the service training completed.
One should sign a service and maintenance contract with an authorised local service centre. The maintenance work for parallel UPS system can be done with the system bypass switch.
The good condition of the batteries is crucial to correct operation of the parallel UPS system. Therefore, a battery discharge test is recommended once or twice per year in the preventive maintenance procedure.
The UPS units are provided with the automatic battery test ABM™, which continuously controls the condition of the battery bank. “Battery failure” alarm is activated when the capacity of the battery bank has decreased remarkable from the default value.
Scrapping
Before scrapping UPS or its battery cabinet, battery bank and the lithium battery on the logic board must be removed. Due to high energy and high voltage, removal of batteries is allowed only for authorised service personnel. Local requirements must be followed in battery recycling or discard.
WARNING!
HAZARDOUS MATERIALS. Batteries may contain HIGH VOLTAGES, and CAUSTIC, TOXIC and FLAMMABLE substances. Batteries can injure or kill people and damage equipment if used improperly. DO NOT DISCARD unwanted batteries or battery material in the public waste disposal system. Follow ALL applicable, local regulations for storage, handling and disposal of batteries and battery materials.
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20 - 80 kVA parallel UPS systems
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5. Mechanical installation
5.1 Overview
Environmental requirements and restrictions described in the technical specification shall be met to guarantee the proper function and safety of the equipment.
Figure 5. Dimensions of the parallel UPS system components.
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The installation surface must be smooth and steady to carry the point and distributed loading of the whole parallel UPS system.
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seirettab).scp84x2(htiwSPUAVk03-020942,70551
seirettabo/wSPUAVk06-040620,4536
seirettabo/wSPUAVk080823,4086
4-06-5039MPS0121,3025
4-08-5039MPS0821,4596
2-031-0439/5039MPS0821,4596
2-06-5039MPS057,0521
2-03-5039MPS057,0521
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Table 1. The floor loading of the parallel UPS system components.
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Maintain 1000-mm clearance at front of the UPS modules for service, user operations, and fire escape safety. Make also sure that free space requirements around UPS modules are met for the cooling air.
Figure 6a. Ventilation and space requirements for 20 - 30 kVA UPS.
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Figure 6b. Ventilation and space requirements for 40 - 80 kVA UPS.
Power cables shall be routed from the bottom or rear side of the UPS modules. The cables shall be protected with a casing tube. The size and location of the cable entries is shown in the drawing.
Figure 7. Cable entries of UPS modules.
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20 - 80 kVA parallel UPS system
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