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SU60KX
User Manual
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Tripp Lite SU60KX User Manual

SU-Series 3-Phase UPS Hardware:
Introduction and Troubleshooting
PRELIMINARY
1111 W. 35th Street, Chicago, IL 60609 USA
+1.773.869.1234 • www.tripplite.com
1
Table of Contents
1 Basic Operation 3
1.1 Technical Specifi cations 3 KX Models 3 K and KTV Models 4 SU80K Model 5
1.2 Features 6
1.3 Operating Principles 13
1.3.1 System Layout 13
1.3.2 Internal Battery Layout 13
1.5 Operating Modes 15
1.5.5 Online Mode (Parallel UPS) 16
1.5.6 Battery Backup Mode (Parallel UPS) 16
1.5.8 Manual Bypass Mode (Parallel UPS) 17
1.6.1 Control Panel and Breaker Diagrams 18
1.6.3 Standard Start-Up Procedure (Single UPS) 18
1.6.4 Battery Start-Up Procedure (Single UPS) 19
1.6.5 Manual Bypass Procedure (Single UPS) 20
1.6.7 Preliminary Checklist (Parallel UPS) 21
1.6.8 Start-Up Procedure (Parallel UPS) 21
1.6.10 Manual Bypass Procedure (Parallel UPS) 23
1.6.11 Switching from Manual Bypass to Normal Mode (Parallel UPS) 24
1.7.1.2 K Models 28
1.7.1.3 KTV Models 32
1.7.2 PCB Power Module 33
1.8.2 K Models 40
1.8.3 KTV Models 45
2 Theory of Operation 48
2.3 Auxiliary Power Failure Detection 51
2.9 Bypass SCR Driver 57
2.10 Watchdog for System MCU 58
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2.11 LCD Panel Control Circuit 59
2.12 Fan Control Circuit 60
2.14 Communication Circuit for RS232 61
2.17 Communication Circuit for Input Dry Contact and REPO 64
2.18 External Battery Cabinet Temperature Detection 65
2.19 Detection Circuit for Manual Bypass Switch 66
2.22 Transformer Over Temperature Detection 71
3 Communication 72
3.01 RS232 Port 72
3.5 Downloading the Event Log 90
4 Internal Battery 91
4.2 Battery Cabinet 95
5 Troubleshooting 98
5.2.1 “MAIN VOLT/FREQ NOK” 100
5.2.2 “MAIN SEQUENCE NOK” 101
5.2.4 “BYPASS SEQUENCE NOK” 103
5.2.5 “BYPASS STATIC SWITCH OVER TEMPERATURE” 103
5.2.6 “BYPASS STATIC SWITCH FAULT” 104
5.2.7 “BYPASS STATIC SWITCH OVERLOAD” 104
5.2.8 “UPS INTERNAL COMM ABNORMAL” 105
5.2.9 “BATTERY TEST FAIL” 106
5.2.10 “BATTERY OVER CHARGE” 106
5.2.13 “TRANSFORMER OVERHEAT” 109
5.2.15 “PS EXT PARALLEL COMM ABNORMAL” 111
5.2.16 “PARALLEL FAILURE” 112
5.2.17 “REDUNDANCY LOSS” 113
6 Power Module 114
2
1 Basic Operation
1.1 Technical Specifi cations
KX Models:
Model SU20KX SU40KX SU60KX SU80KX (Capacity) (20kVA/16kW) (40kVA/32kW) (60kVA/48kW) (80kVA/64kW)
Input Input Voltage 220/380V, 230/400V or 240/415V AC, 3O, 4-wire + ground, wye
Voltage Regulation -25% ~ +20%
Harmonic Distortion < 5% (Full Load)
PFC (Full Load) > 0.99
Frequency 50 / 60 Hz
Frequency Tolerance 45 ~ 65 Hz
Output Output Voltage 220/380V, 230/400V or 240/415V AC, 3O, 4-wire + ground, wye
Output Frequency 50 / 60 Hz
Total Harmonic (Linear Load) ≤3%
Voltage Regulation Static ±1%
Dynamic ±7% (10% ~ 90% Linear Load)
Frequency Regulation Interior Oscillator ±0.05 Hz
Synchronized ±5%
Overload ≤125% : 10 minutes; ≤150% : 1 minute
Audible Warning Battery Backup Intermittent
UPS Abnormal Continuous
Display LED UPS Status: Normal • Bypass • Backup • Fault
LCD Input/Output • Bypass • Inverter • Frequency • Loading • Battery Voltage UPS abnormal messages with intelligent self-diagnosis.
Interface Standard RS-232, Dry Contact
Optional SNMPWEBCARD
Others Parallel Redundancy Yes (1+1 for 2 UPS systems of the same type and capacity only.)
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EPO Standard (Local and Remote)
SRAM Event Log 500 Records
Parameter Configuration Yes
Hot Standby Installation Optional
Battery Temperature Compensation Optional
Battery Cold-Start Standard
Overall Efficiency Normal 94%
ECO 97%
Transfer Time 0 ms
Temperature 32° F ~ 104° F (0° C ~ 40° C)
Humidity (non-condensing) 90%
Noise (1 m) 65 dBA 68 dBA 70 dBA 70 dBA
Dimensions (Power Module) Width 520 mm
Depth 850 mm
Height 1165 mm
Weight (Power Module) 267 kg* 412 kg* 210 kg 244 kg
3
1 Basic Operation (continued)
1.1 Technical Specifi cations (continued)
K and KTV Models:
Model SU40K SU60K SU60KTV SU80KTV (Capacity) (40kVA/32kW) (60kVA/48kW) (60kVA/48kW) (80kVA/64kW)
Input Input Voltage 120/208V AC, 3O, 277/480V AC, 3O, 4-wire + ground, wye 4-wire + ground, wye
Voltage Regulation -25% ~ +20%
Harmonic Distortion < 5% (Full Load)
PFC (Full Load) > 0.99
Frequency 50 / 60 Hz
Frequency Tolerance 45 ~ 65 Hz
Output Output Voltage 120/208V AC, 3O, 277/480V AC, 3O, 4-wire + ground, wye 4-wire + ground, wye
Output Frequency 50 / 60 Hz
Total Harmonic (Linear Load) ≤3%
Voltage Regulation Static ±1%
Frequency Regulation Dynamic ±7% (10% ~ 90% Linear Load)
Interior Oscillator ±0.05 Hz
Synchronized ±5%
Overload ≤125% : 10 minutes; ≤150% : 1 minute
Audible Warning Battery Backup Intermittent
UPS Abnormal Continuous
Display LED UPS Status: Normal • Bypass • Backup • Fault
LCD Input/Output • Bypass • Inverter • Frequency • Loading • Battery Voltage UPS abnormal messages with intelligent self-diagnosis.
Interface Standard RS-232, Dry Contact
Optional SNMPWEBCARD
Others Parallel Redundancy Yes (1+1 for 2 UPS systems of the same type and capacity only.)
EPO Standard (Local and Remote)
SRAM Event Log 500 Records
Parameter Configuration Yes
Hot Standby Installation Optional
Battery Temperature Compensation Optional
Battery Cold-Start Standard
Overall Efficiency Normal 92%
ECO 96%
Transfer Time 0 ms
Temperature 32° F ~ 104° F (0° C ~ 40° C)
Humidity (non-condensing) 90%
Noise (1 m) 65 dBA 68 dBA 70 dBA 70 dBA
Dimensions (Power Module) Width 520 mm
Depth 850 mm 950 mm 850 mm
Height 1696 mm
Weight (Power Module) 682 kg* 534 kg 534 kg 584 kg
* With internal batteries.
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4
1 Basic Operation (continued)
1.1 Technical Specifi cations (continued)
SU80K Model:
Model (Capacity) SU80K (80kVA/64kW)
Input Input Voltage 120/208V AC, 3Ø, 4-wire + ground, wye
Voltage Regulation -25% ~ +20%
Harmonic Distortion < 5% (Full Load)
PFC (Full Load) > 0.99
Frequency 50 / 60 Hz
Frequency Tolerance 45 ~ 65 Hz
Output Output Voltage 120/208V AC, 3Ø, 4-wire + ground, wye
Output Frequency 50 / 60 Hz
Total Harmonic (Linear Load) ≤3%
Voltage Regulation Static ±1%
Dynamic ±7% (10% ~ 90% Linear Load)
Frequency Regulation Interior Oscillator ±0.05 Hz
Synchronized ±5%
Overload ≤125% : 10 minutes; ≤150% : 1 minute
Audible Warning Battery Backup Intermittent
UPS Abnormal Continuous
Display LED UPS Status: Normal • Bypass • Backup • Fault
LCD Input/Output • Bypass • Inverter • Frequency • Loading • Battery Voltage UPS abnormal messages with intelligent self-diagnosis.
Interface Standard RS-232, Dry Contact
Optional SNMPWEBCARD
Others Parallel Redundancy Yes (1+1 for 2 UPS systems of the same type and capacity only.)
EPO Standard (Local and Remote)
SRAM Event Log 500 Records
PRELIMINARY
Parameter Configuration Yes
Hot Standby Installation Optional
Battery Temperature Compensation Optional
Battery Cold-Start Standard
Overall Efficiency Normal 92%
ECO 96%
Transfer Time 0 ms
Temperature 32° F ~ 104° F (0° C ~ 40° C)
Humidity (non-condensing) 90%
Noise (1 m) 70 dBA
Dimensions (Power Module) Width 520 mm
Depth 1026 mm
Height 1696 mm
Weight (Power Module) 655 kg
5
1 Basic Operation (continued)
1.2 Features
1.2.1 Advanced Features:
• True on-line double conversion with superior IGBT inverter technology
• Low input current THD allows 1:1 generator sizing for maximum effi ciency and cost savings
• Internal N+1 power module redundancy (except for SU20KX model)
• Built-in parallel redundancy (1+1) capability for increased capacity or fault-tolerance
• Up to 80kVA capacity in a compact footprint; up to 160kVA in parallel redundancy (1+1) confi guration
• High input power factor and high effi ciency with low thermal loss and low noise
• Simplifi ed, easy-to-repair, long-life, high-availability system design
• Redundant auxiliary power and control circuits
• Dual input design with separated rectifi er and bypass input (SU20K, SU40K, SU60K, SU80K only)
• All models support external battery cabinets for extended battery backup runtime
• High-resolution LCD status screen simplifi es operation and delivers detailed operational information, including system block diagrams
1.2.2 Control Panel Features
A E F G H I J KBCD
“NORMAL” LED:• This green light illuminates to indicate that the UPS system is in online (normal) mode. The primary AC input supply is
A
present and within standard operating parameters.
“BATTERY” LED:• This amber light illuminates when the UPS system is in battery backup mode, discharging the batteries to provide power
B
C
D
E
F
G
H
I
J
K
If the UPS system is in battery backup mode when the EPO button is activated:
If the UPS system is in online (normal) mode when the EPO button is activated:
PRELIMINARY
to connected equipment. An audible alarm will also sound.
“BYPASS” LED:• This amber light illuminates when the UPS system is in bypass mode (auto bypass or manual bypass). Battery backup power will not be available to connected equipment while the UPS system is in bypass mode, but connected equipment loads will be supported by the bypass (reserve) power source.
“FAULT” LED:• This red light illuminates when any UPS system or input power fault occurs. Available diagnostic information will be displayed on the LCD screen.
LCD Status Screen:• This illuminated LCD status screen displays text and graphics to indicate a wide range of UPS system operating conditions and diagnostic data. Note: The LCD backlight will turn off after 10 minutes of inactivity. Turn on the backlight by momentarily
pressing the ON button or one of the scroll buttons.
“ESC” (Escape) Button:• Press this button to return to the previous page or menu.
Scroll Buttons (•
buttons are also used for data entry in several screens.
Enter Button (• ): Press this button to select a menu item or confirm a setting change.
ON Button:• Press and hold this button for 3 seconds to turn the UPS system’s inverter ON.
OFF Button:• Press and hold this button for 3 seconds to turn the UPS system’s inverter OFF. If the UPS system is in online (normal) mode,
it will switch to auto bypass mode. Note: If the UPS system remains off for an extended period of time, the batteries should be recharged periodically. The UPS system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.
“EPO” (Emergency Power Off) Button:• Press this button to turn the UPS system’s output OFF and also disable bypass output.
Main output and bypass output are turned off, the alarm sounds, fans shut down after approximately one minute, and control circuitry •
remains active.
Releasing the EPO button (by pressing it again) turns off the UPS system completely, including the alarm and control circuit. Press the •
ON button for 3 seconds to restart the UPS system.
Main output and bypass output are turned off, the alarm sounds, fans and control circuitry remain active.•
Releasing the EPO button (by pressing it again) turns off the alarm and places the UPS system in auto bypass mode. Press the ON button •
for 3 seconds to return the UPS system to online (normal) mode.
and ): Press these buttons to move the cursor up or down and navigate the control panel menus and screens. These
6
1 Basic Operation (continued)
1.2 Features (continued)
1.2.3 Front and Rear Panel Features
A
B
C
E F
D
G
H
I
Fig 1.2.3a SU40KX front
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
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Control Panel:• The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.)
A
Internal Power Modules:• 20kVA internal power modules can be replaced in the field without powering down connected equipment loads. The
B
number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy in SU40KX, SU60KX and SU80KX models.
Internal Battery Pack Compartment (SU20KX and SU40KX only; shown without batteries):• Internal batteries must be connected by a
C
qualified electrician. (See section 4 for more information.)
Output Circuit Breaker Switch (Q4):• Controls AC output power.
D
Manual Bypass Circuit Breaker Switch (Q3):• Controls AC input power to the UPS system during manual bypass operation.
E
Bypass Input Circuit Breaker Switch (Q2):• Controls AC input power to the UPS system during auto bypass operation.
F
Main Input Circuit Breaker Switch (Q1):• Controls AC input power to the UPS system during online (normal) operation.
G
Levelers:• The levelers provide long-term support for the UPS system.
H
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
I
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term support.
H
I
7
1 Basic Operation (continued)
1.2 Features (continued)
J
L
H
I I
Fig 1.2.3b SU40KX rear
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
Levelers:• The levelers provide long-term support for the UPS system.
H
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
I
J
K
L
M
N
O
P
PRELIMINARY
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term support.
Accessory Slot:• Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call +1 773 869 1234 for more information about the SNMPWEBCARD accessory.
RS-232 Serial Communications Port:• This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic shutdown during extended blackouts and monitoring of operating and power conditions.
Parallel Redundancy Port:• This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a parallel redundancy (1+1) configuration. (See sections 1.5 and 1.8 for more information.)
Input Dry Contact Interface:• This interface receives dry contact signals that allow the UPS system to receive commands and monitor external battery conditions.
Output Dry Contact Interface:• This interface allows the UPS system to send information via dry contact communications. (See section 3.3 for more information.)
Internal Battery Circuit Breaker Switch (SU20KX and SU40KX only):• Controls the input/output power of the UPS system’s internal batteries.
Terminal Block Cover:• Remove the terminal block cover to access the UPS system’s input, bypass input, external battery cabinet, output and grounding connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. (See section 1.8 for more information, including a detailed diagram of the terminal block.)
M
K
N
O
P
H
8
1 Basic Operation (continued)
1.2 Features (continued)
A
B
C
E
D
F
G
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H H
Fig 1.2.3c SU40K front
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
Control Panel:• The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.)
A
Internal Power Modules:• 20kVA internal power modules can be replaced in the field without powering down connected equipment loads. The
B
number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy.
Internal Battery Pack Compartment (SU40K only):• Internal batteries must be connected by a qualified electrician. (See section 4 for more
C
information.)
Output Circuit Breaker Switch (Q4):• Controls AC output power.
D
Manual Bypass Circuit Breaker Switch (Q3):• Controls AC input power to the UPS system during manual bypass operation.
E
Bypass Input Circuit Breaker Switch (Q2):• Controls AC input power to the UPS system during auto bypass operation.
F
Main Input Circuit Breaker Switch (Q1):• Controls AC input power to the UPS system during online (normal) operation.
G
Levelers:• The levelers provide long-term support for the UPS system.
H
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
I
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term support.
I
9
1 Basic Operation (continued)
1.2 Features (continued)
L
J
M
K
N
O
P
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H
Fig 1.2.3d SU40K rear
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
H
Levelers:• The levelers provide long-term support for the UPS system.
I
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term support.
J
Accessory Slot:• Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call (773) 869-1234 for more information about the SNMPWEBCARD accessory.
K
RS-232 Serial Communications Port:• This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic shutdown during extended blackouts and monitoring of operating and power conditions.
L
Parallel Redundancy Port:• This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a parallel redundancy (1+1) configuration. (See sections 1.5 and 1.8 for more information.)
M
Input Dry Contact Interface:• This interface receives dry contact signals that allow the UPS system to receive commands and monitor external battery conditions.
N
Output Dry Contact Interface:• This interface allows the UPS system to send information via dry contact communications. (See section 3.3 for more information.)
O
Internal Battery Circuit Breaker Switch (SU40K only):• Controls the input/output power of the UPS system’s internal batteries.
Terminal Block Cover:• Remove the terminal block cover to access the UPS system’s input, external battery cabinet, output and grounding
P
connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. (See section 1.8 for more information, including a detailed diagram of the terminal block.)
I
H
10
1 Basic Operation (continued)
1.2 Features (continued)
A
B
C
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D
E
Fig 1.2.3e SU80K front
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
Control Panel:• The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.)
A
Internal Power Modules:• 20kVA internal power modules can be replaced in the field without powering down connected equipment loads. The
B
number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy.
Main Input Circuit Breaker Switch (Q1):• Controls AC input power to the UPS system during online (normal) operation.
C
D
Levelers:• The levelers provide long-term support for the UPS system.
E
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term support.
D
11
1 Basic Operation (continued)
1.2 Features (continued)
H
F
I
G J
L
M N
K
PRELIMINARY
D
Fig 1.2.3f SU80K rear
Note: Individual models may vary from diagrams. Unit shown with breaker guard removed.
D
Levelers:• The levelers provide long-term support for the UPS system.
E
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term support.
F
Accessory Slot:• Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call (773) 869-1234 for more information about the SNMPWEBCARD accessory.
G
RS-232 Serial Communications Port:• This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic shutdown during extended blackouts and monitoring of operating and power conditions.
H
Parallel Redundancy Port:• This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a parallel redundancy (1+1) configuration. (See sections 1.5 and 1.8 for more information.)
I
Input Dry Contact Interface:• This interface receives dry contact signals that allow the UPS system to receive commands and monitor external battery conditions.
J
Output Dry Contact Interface:• This interface allows the UPS system to send information via dry contact communications. (See section 3.3 for more information.)
K
Terminal Block Cover:• Remove the terminal block cover to access the UPS system’s input, external battery cabinet, output and grounding connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. The UPS system includes alternate circular knockouts in the bottom panel. (See section 1.8 for more information, including a detailed diagram of the terminal block.)
L
Bypass Input Circuit Breaker Switch (Q2):• Controls AC input power to the UPS system during auto bypass operation.
M
Manual Bypass Circuit Breaker Switch (Q3):• Controls AC input power to the UPS system during manual bypass operation.
N
Output Circuit Breaker Switch (Q4):• Controls AC output power.
E
12
D
1 Basic Operation (continued)
1.3 Operating Principles
1.3.1 System Layout
MAIN
BATTERY
Q3
Manual Bypass Circuit Breaker
Q2
Bypass Input
Circuit Breaker
Q1 LOAD
Main Input
Circuit Breaker
Main
Manual Input
Bypass Input
20kVA/3U POWER MODULE
20kVA/3U POWER MODULE
20kVA/3U POWER MODULE
20kVA/3U POWER MODULE
STS
Output
Circuit Breaker
Fig 1.3.1a System Block Diagram for KX models
Q3
Manual Bypass Circuit Breaker
Manual Input
Bypass Input
Q4
STS
Q4
Output
LOAD
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MAIN
BATTERY
Bypass Input
Circuit Breaker
XFMR XFMR
Q2
Q1
Main Input
Circuit Breaker
Fig 1.3.1b System Block Diagram for K and KTV models
20kVA/3U POWER MODULE
20kVA/3U POWER MODULE
20kVA/3U POWER MODULE
20kVA/3U POWER MODULE
Circuit Breaker
The SU-Series 3-Phase UPS is confi gured with 3-phase 20kVA power modules that can be paralleled for redundancy or capacity upgrades. Each KX- (Figure 1.3.1a), K- , and KTV-series (Figure 1.3.1b) UPS includes three key functions:
1) A central bypass static switch, which causes a critical load to automatically bypass any overload or fault conditions that occur.
2) A maintenance bypass switch, which eliminates UPS faults by supplying a critical load.
3) A matched transformer, which increases and decreases the input/output voltage
1.3.2 Internal Battery Layout
B+ N B-
12Vdc, 20pcs 12Vdc, 20pcs
Fig 1.3.2a Battery Strings
An internal battery pack (number of packs vary by model) supplies the UPS system with battery backup power. Each internal battery pack consists of 40 12Vdc VRLA batteries arranged in two strings: one string of 20 positive batteries (black cable) and one string of 20 negative batteries (red cable). The two strings are connected by a neutral (N) point (Figure 1.3.2a).
13
1 Basic Operation (continued)
1.3 Operating Principles (continued)
1.3.3 Power Module Layout
The SU-Series 3-Phase UPS double-conversion power modules consist of three components (Figure 1.3.3a):
1) An AC/DC converter
2) An AC/DC inverter
3) A charger
The power module’s 3-phase, 4-wire input runs A/C current through the AC/DC converter to generate regulative dual DC bus (±370Vdc). During backup mode, this current is provided by battery power.
The dual DC bus then runs through the AC/DC inverter to generate a pure sine wave of AC power (3-phase, 4-wire). The DC bus also charges the dual battery strings by running current through the charger. Each power module has a maximum charge current of 5 A.
R
S
INPUT OUTPUT
T
N
BATTERY
Fig 1.3.3a Power Module Block Diagram
Charger
U
V
W
N
1.4 Opening and Closing the Unit
[PENDING]
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14
1 Basic Operation (continued)
1.5 Operating Modes
This section provides a basic description of the UPS system’s operating modes. For more information about switching between operating modes, refer to Section 1.6 – Start-Up, Shutdown and Bypass.
1.5.1 Online (Normal) Mode (Single UPS)
In online (normal) mode, the UPS system’s rectifier converts incoming AC utility power to DC power that charges the batteries and supplies the inverter. The inverter transforms the DC power to precision-regulated, pure sine wave AC power that supports the operation of connected equipment. This dual conversion technology isolates connected equipment from all power problems and ensures that connected equipment receives ideal power at all times.
1.5.2 Battery Backup Mode (Single UPS)
When a blackout or other extreme power event occurs, the UPS system automatically switches from normal mode to battery backup mode. The UPS system’s batteries (internal and/or external) provide emergency DC power to the inverter. The inverter transforms the DC power to precision­regulated, pure sine wave AC power that supports the operation of connected equipment.
1.5.3 Auto Bypass Mode (Single UPS)
If the inverter malfunctions due to excessive temperature, overload, output short circuit, abnormal voltage or battery problems, the inverter will shut down. If the UPS system detects a bypass (reserve) power source that conforms to normal parameters, then the UPS system automatically switches to auto bypass mode to continue supplying power
PRELIMINARY
to connected equipment. When all problems are eliminated, the UPS system switches back to online (normal) mode automatically.
1.5.4 Manual Bypass Mode (Single UPS)
If UPS system maintenance or repair is required, you can bypass the UPS system and enable bypass (reserve) power manually. After confirming that bypass (reserve) power is present, switch the UPS system into manual bypass mode. This allows service technicians to perform maintenance or repair jobs without interrupting the flow of AC power to connected equipment. Warning: The UPS system must be
de-energized completely before performing maintenance or repair by shutting it down completely after switching it to manual bypass mode.
15
1 Basic Operation (continued)
1.5 Operating Modes (continued)
1.5.5 Online Mode (Parallel UPS)
Parallel redundancy (1+1) provides UPS system redundancy or increased total capacity. Under parallel redundancy, the total load is shared by two UPS systems. If one of the UPS systems malfunctions, the total connected equipment load is supported by the remaining UPS system. If the total load exceeds the capacity of the remaining UPS system, it will switch to auto bypass mode.
1.5.6 Battery Backup Mode (Parallel UPS)
Similar to on battery backup mode for a single UPS system (Section
1.5.2), except the total connected equipment load is shared by the parallel
(1+1) UPS systems.
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1.5.7 Auto Bypass Mode (Parallel UPS)
Similar to auto bypass mode for a single UPS system (Section 1.5.3), except with parallel (1+1) UPS systems.
16
1 Basic Operation (continued)
1.5 Operating Modes (continued)
1.5.8 Manual Bypass Mode (Parallel UPS)
Similar to manual bypass mode for a single UPS system (Section 1.5.4), except with parallel (1+1) UPS systems. Note: Both UPS systems must
be switched into manual bypass mode.
1.5.9 Hot Standby Mode (Parallel UPS)
For added fault-tolerance, the redundant UPS system acts as the bypass (reserve) power source for the main UPS system.
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17
1 Basic Operation (continued)
1.6 Start-Up, Shutdown and Bypass
Warning: The UPS system’s output voltage is set at 220/380V by default. If you require output voltage of 230/400V or 240/415V, you must change the UPS system’s output voltage by accessing the output setup menu described in Section 10-9 of the owner’s manual. You must place the UPS system in bypass mode before changing the output voltage. Do not connect your equipment to the UPS system’s output until you have set the proper parameters.
1.6.1 Control Panel and Breaker Diagrams
“NORMAL” LED•
A
“BATTERY” LED•
B
C
“BYPASS” LED•
“FAULT” LED•
D
LCD Status Screen•
E
F
“ESC” (Escape) Button•
Scroll Buttons (•
G
H
Enter Button (• )
I
ON Button•
OFF Button•
J
K
“EPO” (Emergency Power Off) Button•
Output Circuit Breaker Switch•
L
M
Manual Bypass Circuit Breaker Switch•
N
Bypass Input Circuit Breaker Switch•
Main Input Circuit Breaker Switch•
O
and )
A
B
C
D
1
L
Output
2
Circuit Breaker Switches (UPS System Front Panel)
E
Control Panel
M
Manual Bypass
G
N
Bypass
Input
F
I
J
H
O
Main Input
K
1.6.2 Preliminary Checklist (Single UPS)
• All circuit breaker switches should be off, including the breaker of the external battery cabinet (if present).
PRELIMINARY
• Confi rm that no voltage potential exists between Neutral and Ground.
• Confi rm that the input power source matches the rating (voltage, frequency and phase) of the UPS system.
Note: After start-up, the UPS system will perform a brief self-test and display the results on the LCD screen. After a successful self-test, the UPS system will provide AC power to the connected equipment load.
1.6.3 Standard Start-Up Procedure (Single UPS)
1
If there is an external battery cabinet connected, switch on the • circuit breaker
Confirm that the manual bypass circuit breaker switch •
2
A
of the external battery cabinet.
A
is off.
A
1
18
A
Output
2
Manual Bypass
Bypass
Input
Main Input
1 Basic Operation (continued)
1.6 Start-Up, Shutdown and Bypass (continued)
1.6.3 Standard Start-Up Procedure (Single UPS) (continued)
3
Switch on the output circuit breaker switch • circuit breaker switch B. After a brief initialization process, the LCD screen will show “ON AUTO BYPASS”, the “BYPASS” LED will illuminate and UPS system output will be supplied by the bypass (reserve) power source.
A
and bypass input
A B
Output Manual
3
Switch on the main input circuit breaker switch •
4
A
. If the AC input
Bypass
Bypass
Input
Main Input
power source is normal, the UPS system is ready for start-up.
A
5
Press the ON button •
A
for 3 seconds (until you hear a beep), then
release the button. The inverter will activate and synchronize with
Output Manual
4
Bypass
Bypass
Input
A
Main Input
the bypass source, then automatically switch from auto bypass (reserve) mode to online (normal) mode. The “BYPASS” LED will darken and the “NORMAL” LED will illuminate.
5
PRELIMINARY
1.6.4 Battery Start-Up Procedure (Single UPS)
Note: The battery must be at least partially charged for this operation to succeed.
If there is an external battery cabinet connected, switch on the •
1
A
circuit breaker
of the external battery cabinet.
2
Confirm that the manual bypass circuit breaker switch •
3
Press the ON button •
A
for 3 seconds (until you hear a beep), then release the button. The inverter will activate and use stored DC battery power to supply AC power to connected equipment. The “BATTERY” LED will illuminate.
A
is off.
19
A
1
A
Output Manual
2
3
Bypass
Bypass
Input
Input
A
Main
1 Basic Operation (continued)
1.6 Start-Up, Shutdown and Bypass (continued)
1.6.5 Manual Bypass Procedure (Single UPS)
Warning: Placing the UPS system in manual bypass will disable the inverter and power all loads from the manual bypass (reserve) source, but the UPS system will still be energized. Before performing maintenance or repair on the UPS system, shut down and de-energize the UPS system completely by following the steps in Section 1.6.6. Although connected equipment loads will be powered by the bypass (reserve) power source, they will not receive battery backup in the event of a utility power failure.
1
When the UPS system is in online (normal) mode, press the ON •
A
button
for 3 seconds (until you hear a beep), then release the button. The inverter will automatically switch to bypass mode and the “BYPASS” LED will illuminate.
Switch on the manual bypass circuit breaker switch •
2
off the output circuit breaker switch
B
.
A
, then switch
1
AB
A
Output Manual
2
Bypass
Bypass
Input
Main Input
1.6.6 Shutdown Procedure (Single UPS)
Warning: The UPS system shutdown procedure will eliminate the AC power output for all loads. Before shutdown, confirm that all loads are turned off or place the UPS system in manual bypass mode to keep loads powered by the reserve (bypass) power source.
Press the OFF button •
1
release the button. If the UPS system is in online (normal) mode, it
PRELIMINARY
A
for 3 seconds (until you hear a beep), then
will switch to bypass mode. If the UPS system is in battery backup mode, the inverter will shut down and AC output power will be interrupted.
1
2
Switch off the main input circuit breaker switch •
3
Switch off the bypass input circuit breaker switch •
A
.
Output
2
A
.
Manual Bypass
Bypass
Input
A
A
Main Input
20
A
3
Output
Manual Bypass
Bypass
Input
Main Input
1 Basic Operation (continued)
1.6 Start-Up, Shutdown and Bypass (continued)
1.6.6 Shutdown Procedure (Single UPS) (continued)
4
Confirm that the UPS system is off and that all main output circuits • are off. If the UPS system is connected to an external battery cabinet, turn off the external battery cabinet circuit breaker switch
A
.
A
4
5
Switch off the output circuit breaker switch • power source is normal, the UPS system is ready for start-up.
Note: If the UPS system remains off for an extended period of time, it should be turned on periodically to allow the batteries to recharge. The UPS system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.
1.6.7 Preliminary Checklist (Parallel UPS)
Warning: Parallel redundancy requires exactly two UPS systems (1+1 redundancy ). Do not attempt to link more than two UPS systems via parallel redundancy. The UPS systems must have the same rating and capacity for parallel redundancy installation. Attempting to link dissimilar UPS systems will damage the UPS systems and create a serious risk of personal injury and property damage.
All circuit breaker switches should be off, including the breakers of the external battery cabinets.•
Confirm that no voltage potential exists between Neutral and Ground.•
Confirm that the input power source matches the rating (voltage, frequency and phase) of the UPS systems.•
You must use the control panel to set the parallel ID numbers of the UPS systems to be 1 and 2. See section 10-11 of the owner’s •
manual for information about setting the parallel ID numbers.
PRELIMINARY
Note: After start-up, the UPS systems will perform a brief self-test and display the results on the LCD screen. After a successful self-test, the UPS systems will provide AC power to the connected equipment load.
1.6.8 Start-Up Procedure (Parallel UPS)
Connect the parallel redundancy cable •
1
redundancy port B of each UPS system.
A
. If the AC input
A
to the DB9 parallel
A
Output Manual
5
Bypass
Bypass
Input
Main Input
B
2
If the UPS systems have external battery cabinets connected, switch • on the external battery cabinet circuit breaker switch battery pack.
A
of each
21
B
1
A
2
A
1 Basic Operation (continued)
1.6 Start-Up, Shutdown and Bypass (continued)
1.6.8 Start-Up Procedure (Parallel UPS) (continued)
Switch on the bypass input circuit breaker switch •
3
UPS system. After a brief initialization process, the LCD screen will show “ON AUTO BYPASS” and the “BYPASS” LED will illuminate.
A
of each
A
4
Switch on the main input circuit breaker switch •
A
of each UPS
system.
5
Press the ON button •
A
of one of the UPS systems for 3 seconds (until you hear a beep), then release the button. The inverter will activate and synchronize with the bypass source. Press the ON button for the other UPS system for 3 seconds (until you hear a beep), then release the button. When the inverter of each UPS system is operating normally, they will automatically switch from auto bypass (reserve) mode to online (normal) mode at the same time. The “BYPASS” LED will darken and the “NORMAL” LED will illuminate.
6
Check the output voltage of each UPS system. The phase deviation •
PRELIMINARY
between each UPS system should be less than 5V. If the phase deviation is within the acceptable range, switch on the output circuit breaker switch
A
of each UPS system. Note: For more information on checking the output voltage of each UPS system, see section 10-6 of the owner’s manual.
Output Manual
3
Output Manual
4
5
A
Bypass
Bypass
Bypass
Input
Bypass
Input
Main
Input
Main
Input
A
A
Output Manual
6
Bypass
Bypass
Input
Main
Input
1.6.9 Shutdown Procedure (Parallel UPS)
Warning: The UPS system shutdown procedure will eliminate the AC power output for all loads. Before shutdown, confirm that all loads are turned off or place the UPS systems in manual bypass mode to keep loads powered by the bypass (reserve) power source.
1
For the UPS system you wish to shut down, press the OFF button •
A
for 3 seconds (until you hear a beep), then release the button. If the other UPS system can support the connected equipment loads alone, the UPS system that was turned off will shut down its inverter and its LCD screen will read “LOAD NOT POWERED”. The other UPS system’s LCD screen will read “ONLINE MODE”. If the total connected equipment load is too large to be handled by a single UPS system, both UPS systems will shut down their inverters and switch to bypass mode, and their LCD screens will
1
A
read “ON AUTO BYPASS.”
2
For the UPS system you wish to shut down, switch off the main • input circuit breaker switch
B
breaker switch
.
A
, then switch off the output circuit
22
AB
Output Manual
2
Bypass
Bypass
Input
Main
Input
1 Basic Operation (continued)
1.6 Start-Up, Shutdown and Bypass (continued)
1.6.9 Shutdown Procedure (Parallel UPS) (continued)
3
For the UPS system you wish to shut down, switch off the bypass • input circuit breaker switch A.
A
Output Manual
4
When the UPS system is completely shut down, the LCD screen •
3
Bypass
Bypass
Input
Main
Input
will be completely off. If the UPS systems have external battery cabinets connected, switch off the external battery cabinet circuit breaker switch
A
of each battery pack.
A
Note: If the UPS system remains off for an extended period of time, it should be turned on periodically to allow the batteries to recharge. The UPS system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.
4
1.6.10 Manual Bypass Procedure (Parallel UPS)
Warning: When the UPS system is in manual bypass, the inverter shuts down. Connected equipment loads are powered by the bypass (reserve) power source and will not receive battery backup during a utility power failure.
For the first UPS system you wish to shut down, press the OFF •
1
A
button
for 3 seconds (until you hear a beep), then release the button. If the other UPS system can support the connected equipment loads alone, the UPS system that was turned off will shut down its inverter and its LCD screen will read “LOAD NOT POWERED”. The other UPS system’s LCD screen will read
PRELIMINARY
“ONLINE MODE”. If the total connected equipment load is too large to be handled by a single UPS system, both UPS systems will shut down their inverters and switch to bypass mode, and their
1
A
LCD screens will read “ON AUTO BYPASS”. Repeat step 1 for the second UPS system you wish to shut down.
2
Switch off the main input circuit breaker switch • system.
A
of each UPS
A
3
Confirm that both UPS systems are shut down, then switch on the • manual bypass input circuit breaker switch
A
of each UPS system. The bypass (reserve) power source will power the loads and the LCD screen will read “ON MANUAL BYPASS.”
4
Switch off the bypass input circuit breaker switch • circuit breaker switch
B
of each UPS system. The LCD screen
A
and the output
will turn off completely.
23
Output
2
Output
3
Output
4
Manual Bypass
A
Manual Bypass
Manual Bypass
Bypass
Input
Bypass
Input
AB
Bypass
Input
Main
Input
Main
Input
Main
Input
1 Basic Operation (continued)
1.6 Start-Up, Shutdown and Bypass (continued)
1.6.10 Manual Bypass Procedure (Parallel UPS) (continued)
5
If the UPS systems have external battery cabinets connected, switch • off the external battery cabinet circuit breaker switch battery pack.
6
In this mode, only the output circuit breaker switch • terminal block B contain hazardous voltage, allowing qualified service personnel to perform maintenance or repair. Note:
Qualified service personnel may prefer to de-energize the UPS systems completely, depending on local codes and the nature of the maintenance or repair.
1.6.11 Switching from Manual Bypass to Normal Mode (Parallel UPS)
1
If the UPS systems have external battery cabinets connected, switch • off the external battery cabinet circuit breaker switch battery pack.
A
of each
A
and the
A
of each
5
6
A
B
A
A
PRELIMINARY
2
Switch on the bypass input circuit breaker switch • circuit breaker switch B of each UPS system.
3
Confirm that both UPS systems are shut down, then switch off the • manual bypass input circuit breaker switch The LCD screen will read “ON AUTO BYPASS.”
4
Switch on the main input circuit breaker switch • system.
5
Press the ON button •
A
of the first UPS systems for 3 seconds (until you hear a beep), then release the button. Press the ON button for the second UPS system for 3 seconds (until you hear a beep), then release the button. When the inverter of each UPS system is operating normally, they will switch to online (normal) mode at the same time.
A
and the output
A
of each UPS system.
A
of each UPS
A
1
AB
Output Manual
2
Output
3
Bypass
A
Manual Bypass
Bypass
Input
Bypass
Input
Main
Input
Main Input
A
Output
4
Manual Bypass
Bypass
Input
Main Input
5
24
1 Basic Operation (continued)
1.7 Printed Circuit Boards (PCB)
Table 1.7a lists the printed circuit boards present in each UPS system:
SU80KX SU80K SU80KTV
V (2pcs) V (2pcs) NH-SYS-F1(BYP) 16-5505001371 Input EMI Filter for Bypass
V (2pcs) V (2pcs) NH-SYS-F1(MAIN) 16-5505001371 Input EMI Filter for Main
PRELIMINARY
SU60KX SU60K
V V V V NH-SYS-LCD 16-5505001323 Circuit for LCM, Circuit for LED and Function Key
V V V V NH-SYS-R 16-5505001327 Circuit for RS232, Output Dry Contact, Parallel Port,
V V V V NH-SYS-X 16-5505001319 Circuit for REPO, Input Dry Contact and Circuit for sense
V V V V NH-SYS-M 16-5505001321 System MCU and Control Circuit
V V V V NH-SYS-P 16-5505001325 Auxiliary Power for System, Detect Circuit for Voltage and
V V V V NH-SYS-B 16-5505001317 EMI Filter for Battery Input
V V V V NH-SYS-LA 16-5505001322 Input EMI Filter for each Power Module
V V V NH-SYS-LB 16-5505001353 Input EMI Filter for each Power Module
V V NH-SYS-LC 16-5505001354 Input EMI Filter for each Power Module
V NH-SYS-LD 16-5505001355 Input EMI Filter for each Power Module
V V NH-SYS-S 16-5505001326 Driver Circuit for Bypass SCR
V V V V NH-SYS-FC 16-5505001349 Output EMI Filter
V V NH-SYS-F2(MAIN) 16-5505001373 Input EMI Filter for Bypass
V V NH-SYS-F2(BYP) 16-5505001374 Input EMI Filter for Main
V V NH-SYS-F3 16-5505001372 Circuit for Surge suppress
V V V V NH-SYS-FB 16-5505001346 Circuit for Bypass Back-feed Detect
SU40KX SU40K SU20KX PCB name P/N Description
TOP
Connector to connect with each Power Module, Circuit for 2 Slots
External Battery Cabinet Temperature
Current
BOTTOM
V V NH-SYS-SA 16-5505001370 Driver Circuit for Bypass SCR
V (2pcs) V (2pcs) NH-SYS-FA 16-5505001347 Input EMI Filter
Table 1.7a
25
1 Basic Operation (continued)
1.7 Printed Circuit Boards (PCB) (continued)
1.7.1 PCB Location (System)
1.7.1.1 KX Models
SU20KX and SU40KX:
FA (BYP)
FB
X LA and LB
R
M
P
B
PRELIMINARY
O/P CT FCBYPASS SCR
FA (MAIN)
SA
LCD
26
1 Basic Operation (continued)
1.7 Printed Circuit Boards (PCB) (continued)
1.7.1 PCB Location (System) (continued)
1.7.1.1 KX Models (continued)
SU60KX and SU80KX:
F1 (BYP)
XBLA, LB, LC, LD
R
F3 FB
M
P
PRELIMINARY
LCDF1 (MAIN) F2 (BYP) F2 (MAIN)
O/P CT S
27
PC
1 Basic Operation (continued)
1.7 Printed Circuit Boards (PCB) (continued)
1.7.1 PCB Location (System) (continued)
1.7.1.2 K Models
SU40K:
X LA, LB
R
M
FA (BYP) FA (MAIN)
O/P
PRELIMINARY
Transfer
I/P
Transfer
SA
Bypas SCR FC
FB
B
P
LCD
O/P CT
28
1 Basic Operation (continued)
1.7 Printed Circuit Boards (PCB) (continued)
1.7.1 PCB Location (System) (continued)
1.7.1.2 K Models (continued)
SU60K:
X LA, LB, LC
R
M
P
F1 (BYP)
PRELIMINARY
I/P Tx
F1 (MAIN)
O/P Tx
Bypas SCR S
F3
F2 (BYP)
FB
F2 (MAIN)
BLCD
O/P CT FC
29
1 Basic Operation (continued)
1.7 Printed Circuit Boards (PCB) (continued)
1.7.1 PCB Location (System) (continued)
1.7.1.2 K Models (continued)
SU80K:
LA, LB, LC, LD
X
R
M
FBF2F1(BYP)
P
B
O/P Tx
PRELIMINARY
I/P Tx
F1(MAIN)
O/P CT FC
F2(BYP) F2(MAIN)
Bypass SCR S
LCD
30
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