Download PYRAMID PLUS

SERVICE MANUAL
PYRAMID PLUS
10-200kVA
Uninterruptible Power Systems
CONTENTS
1.
SAFETY........................................................................................................................2
2.
HANDLING ...................................................................................................................4
3.
INSTALLATION ...........................................................................................................5
3.1
3.2
3.3
3.4
4.
Introduction................................ ................................ ................................ ..............5
Unpacking ...............................................................................................................5
Equipment Positioning................................ ................................ ..............................5
Connections of Power Cables ...................................................................................6
3.4.1 Safety Earth ...................................................................................................7
3.4.2 Cable Connections .........................................................................................7
3.4.3 Battery Installation ..........................................................................................12
3.4.4 Communication (UPS-Server)..........................................................................15
FRONT PANEL ............................................................................................................16
4.1 4.1 Introduction .......................................................................................................16
4.2 Alarms and Troubleshooting .....................................................................................17
4.3 Menu Description .....................................................................................................20
4.4 MAIN Menu .............................................................................................................22
4.5 MEASURES MENU Items.........................................................................................22
4.6 ALARMS Menu Items...............................................................................................22
4.7 INFORMATION Menu Items....................................................................................23
4.8 SETTINGS Menu Items ............................................................................................23
4.9 COMMAND Menu Items ...........................................................................................24
4.10 TIME Menu Items..................................................................................................25
4.11 PASSWORD Menu Items ................................ ................................ ......................25
5.
OPERATING INSTRUCTIONS ...................................................................................26
5.1 UPS Switch on Procedures 10 to 30kVA ....................................................................26
5.2 UPS Switch on Procedures 40 to 200kVA ..................................................................26
5.3 Transfer to Maintenance By Pass 10 to 30kVA...........................................................27
5.4 Transfer to Maintenance By Pass Mode 40 to 200kVA................................................28
5.5 Transfer from Maintenance By Pass to Inverter Mode 10 to 30kVA .............................28
5.6 Transfer from Maintenance By Pass to Inverter Mode 40 to 200kVA ...........................29
5.7 Transfer from Static By Pass to Inverter Mode ...........................................................29
5.8 UPS Shutdown Procedures 10 to 30kVA ...................................................................29
5.9 UPS Shutdown Procedures 40 to 200kVA..................................................................30
5.10 Utility Interruption...................................................................................................30
6.
SYSTEM AND BOARD LEVEL INFORMATION........................................................31
6.1 Information About Boards .........................................................................................31
6.1.1 Information About DC Bus And Rectifier Controller Board..................................31
6.1.2 Information About Main Controller Board (P3MC) .............................................31
6.1.3 Information About Interface Board (ITF3).........................................................31
6.1.4 Information About Voltage Sense Board (3PVS2) ............................................32
6.1.5 Information About IGBT Driver Board (IGD3P).................................................32
6.1.6 Information About SCR Driver Board (SDR03) .................................................32
6.1.7 Information About 3 Phase Transformer Board (PTR3P) ..................................32
6.1.8 Information About Communication Board (RS330) ...........................................32
6.1.9 Information About LCD Panel Board (P3PANEL) ............................................32
6.2 BOARD LEVEL MAINTENANCE...............................................................................33
6.2.1 P3MC Main Controller Board...........................................................................33
6.2.2 IGD3P IGBT Driver Board ................................ ................................ ..............36
6.2.3 REC3P Rectifier Controller Board ....................................................................37
6.2.4 SDR03 SCR Driver Board ...............................................................................38
6.2.5 ITF2 Interface Board .......................................................................................39
6.2.6 ITF3 Interface Board .......................................................................................39
6.2.7 RS330 Communication Board..........................................................................40
6.2.8 3PVS2 Voltage Sense Board ...........................................................................40
6.2.9 PTR3P 3 Phase Transformer Board .................................................................40
6.2.10 P3PANEL LCD Panel Board .........................................................................40
6.3 OTHER FAILURES AND TROUBLE SHOOTING.......................................................40
6.3.1 Real Time Clock Failures ................................................................................40
6.3.2 Parameter Saving Failures ................................ ................................ ..............40
7.
PARALLEL OPERATION (optional) ..........................................................................41
7.1 Introduction 41
7.2 Parallel Operation Modes .........................................................................................41
7.2.2 Symetric Parallel Mode ..........................................................................41
7.2.3 Parallel Redundant Mode.......................................................................42
7.2.4 Hot Standby Mode .................................................................................42
7.3 Parallel Operation Mode Fault Codes ........................................................................43
7.4 Parallel System Accessories .....................................................................................43
7.5 UPS Switch on Procedure in Parallel Mode:...............................................................52
7.6 Transfer to Maintenance By-Pass Mode ...................................................................53
7.7 Transfer from Miantenance By Pass to Inverter Mode.................................................53
8.
REMOTE MONITORING AND CONTROL (optional)...............................................54
8.1 Serial Link Interface.................................................................................................54
8.2 Serial Link Interface Cable ........................................................................................54
8.3 Modem Connection TELESERVICE ..........................................................................55
8.3.1 Hardware Configuration ..................................................................................55
8.3.2 Function Principle ...........................................................................................55
8.3.3 SMART Modem Programming (PC modem) .....................................................55
8.3.4 DUMB Modem Programming ...........................................................................55
8.4 Dry Contact Interface Connection .............................................................................55
8.5 Remote Monitoring Panel .........................................................................................55
9.
REPAIR and MAINTENANCE ....................................................................................57
9.1 Safety Discharge Operation................................ ................................ ......................58
9.2 Scheduled Maintenance ...........................................................................................58
9.2.1 Routine Controls .............................................................................................58
9.2.2 Vision Test .....................................................................................................58
9.3 Storage ...................................................................................................................58
9.4 Batteries Maintenance................................ ................................ ..............................59
9.5 Battery Test .............................................................................................................59
9.5.1 Vision Test .....................................................................................................59
9.5.2 Test on Place .................................................................................................59
9.6 Battery Changing .....................................................................................................60
9.7 IGBT Output Group ..................................................................................................61
9.7.1 Output Transistors Controlling / Changing ........................................................61
10. ELECTRICAL SCHEMES.........................................................................................62
1. SAFETY
Thank you for choosing Inform UPS Systems. This document provides all the instructions
necessary for the instllation and the operation of the PYRAMID-PLUS Uninterruptible Power
Supply.
For the staff and the equipment safety, it is necessary for the users to fully read and understand
this manual before working on this equipment.
DESCRIPTION OF THE SYMBOLS ON THE UPS:
DANGER DANGEROUS VOLTAGES (red-yellow)
READ THE OPERATING INSTRUCTIONS (black -yellow)
GROUNDING TERMINAL BLOCK (black-silver).
IMPORTANT NOTICES
1.
2.
3.
4.
5.
6.
7.
Please read and save the manual before operating the system.
Please do not remove the protection panels; internal voltage is dangerous.
Please follow all the instructions and warnings.
Please do not operate the unit without grounded source.
Power cord of the UPS should be routed carefully so that they are not to be walked on.
Please save or recycle the packaging materials.
The equipment should be always kept in vertical position.
8. This equipment is compliant with the European directives, which shall be applied to this product.
Hence it is marked:
WARNING!
• Do not insert any object into ventilation holes or other openings.
• Avoid the sudden temperature changes, which could cause condensation inside the UPS.
Otherwise, wait for at least two hours before switching on.
• To reduce the risk of fire or electric shock, install in temperature and humidity controlled indoor
area.
• This equipment complies with standards EN50091-2 for electromagnetic compatibility. In a
domestic environment, it can cause radio interference; accordingly, complementary measures
must be made.
2
• To reduce the risk of fire, replace fuses with the same type and rating when necessary.
CAUTION!
• Only authorized person has to make installation or maintenance of UPS and batteries.
• Risk of electric shock! Please do not remove cover. No user serviceable parts inside,
please contact to authorized service.
• The output may be energized when the unit is not connected to a mains supply.
• Risk of electric shock! Hazardous live parts inside the unit are activated by the battery
supply even when the input AC power is not connected.
• Switch the UPS OFF before connecting the computer interface signal cable. Reconnect the
power cord only after signaling interconnections have been made.
BATTERY WARNINGS
• Risk of electric shock! The following precautions have to be taken during the operation on
battery:
* Remove watches, rings or other metal objects.
* Use tools with insulated handles.
• Batteries in the UPS are recyclable. Batteries must be disposed of according to local
environmental laws. If not disposed of properly, batteries contain lead and may cause danger for
the environment and human health.
• Do not dispose the batteries in a fire. Batteries will explode. Do not open or mutilate the
batteries. They contain an electrolyte that is toxic and harmful to the skin and eyes. In any
contact with the electrolyte, please wash the zone immediately.
• Please do not discharge the battery.
3
2. HANDLING
NOTE: THE UPS CABINETS MUST ALWAYS BE HANDLED VERTICALLY DURING
TRANSPORT.
Do take care to the UPS balancing during handlings.
Handling :
You can either use a pallet truck or
a lift truck for side handling,
provided that the removable sidepanel is unscrewed.
PYRAMID-PLUS
Battery cabinet
It is possible to use slings provided
they are at least 1.5 m long.
Suitable lifting eyes with nuts can be
supplied on request.
Remove the top panel to gain
access to the 4 holes designed
for the fixing of the lifting eye
screws.
If the height of the ceiling does not
make it possible to us e slings, use a
lifting beam with shorter slings.
4
UPS cabinet
3. IN STAL LA TIO N
Non-compliance with the installation guidelines contained in the present manual could adversely
effect the working and/or reliability of the UPS.
3.5 Introduction
WARNING!!!
• Do not apply electrical power to the UPS equipment before the arrival of authorized service
personnel.
• Installation and maintenance has to be done by authorized service person only.
3.6 Unpacking
The UPS is packed and enclosed in a structural cardboard carton to protect it from damage.
1. Inspect for damage that may have occurred during the transport, if any damage is noted, please
call the forwarder or insurance company immediately and retain the shipping carton and the
UPS.
2. Carefully open the carton and take the UPS out.
3. Keep the carton and packing material for future re-use.
3.7 Equipment Positioning
1. The equipment’s installation place must be easy to service.
2. Install the UPS in a protected area with adequate airflow and free of excessive dust.
3. You must therefore allow for a minimum gap of 250 mm behind the unit to allow adequate air
flow (See Figure 3.1)
4. Select a suitable place (temperature is between 0°C and 40°C) and the relative humidity (%90
max)
5. It is recommended to use air-conditioned room (24°C)
6. Temperature is a major factor in determining the battery life and capacity. Battery manufacturers
quote figures for an operating temperature of 20°C. On a normal installation the battery
temperature is maintained between 15°C and 25°C. Keep batteries away from main heat sources
or main air inlets etc.
7. In case of UPS operation in a dusty environment, please clean the air with a suitable air filtration
system.
8. Keep out of your equipment from the explosive and flammable items.
9. Avoid direct sunlight, rain, and high humidity.
WARNING!!!
Check the capacity of the forklift if it is available for lifting.
DO NOT MOVE THE BATTERY CABINET WHILE THE BATTERIES ARE INSTALLED.
5
250 cm
Air inlet are designed at the bottom
and the rear of the UPS, whereas air
outlet are located on the top of the
unit : it is therefore useless to leave a
lateral clear-distance.
PYRAMID-PLUS
Front face
Figure 3-1 Installation Diagram
3.4 Connections of Power Cables
CAUTION! Only authorized person has to install or maintain UPS / batteries.
The AC input of the UPS should be supplied by a separate line from the AC distribution board.
The input/output cables can be sized to suit the modules rating according to the table below.
The connections of the electric panel should be supplied by grounded outlet. Cables enter the UPS modules
via entry panels in the base of cabinet. All control cables should be screened and run in a separate trunking
to the power cables.
The input/output cables can be sized to suit the modules’ rating according to the table below.
BUS BAR CONNECTION
STUD SIZE
2
NOMINAL CURRENT : Ampere / Recommended Cable Size (mm )
UPS
POWER
(kVA)
Input Mains
With full battery Recharge
380V
A / mm
400V
2
A / mm
Bypass / output
At full load
415V
2
A / mm
380V
2
A / mm
400V
2
A / mm
415V
2
A / mm
2
Battery Input/Output
Battery
at min.
Cable
Terminations
Battery Terminations
Voltage
A / mm
2
U-V-W-N
+&-
2
16mm
Terminals
2
2
16mm
Terminals
2
16mm
Terminals
2
10
22A / 6
20A / 6
19A / 6
16A / 6
15A / 6
14A / 6
28A / 6
16mm
Terminals
15
32A / 6
30A / 6
28A / 6
23A / 6
22A / 6
21A / 6
41A / 10
16mm
Terminals
20
43A / 10
39A / 10
37A / 10
31A / 10
29A / 10
28A / 10
55A / 16
16mm
Terminals
30
64A / 16
59A / 16
56A / 16
46A / 10
44A / 10
42A / 10
82A / 25
35mm
Terminals
35mm
Terminals
40
85A / 25
78A / 25
73A / 25
61A / 16
58A / 16
56A / 16
110A / 35
M6
M8
60
128A / 35
117A / 35
109A / 35
91A / 25
87A / 25
84A / 25
163A / 50
M6
M8
80
168A / 50
160A / 50
154A / 50
121A / 35
115A / 35
111A / 35 220A / 70
M6
M8
100-120 256A / 70
234A / 70
218A / 70
182A / 70
174A / 70
168A / 70 326A/100
M8
M8
160
329A / 95
312A / 95
301A / 95
230A / 70
218A / 70
210A / 70 430A/120
M8
M8
200
357A /185 339A /185 327A /185 243A /150 230A /150 223A /150 560 /185
M8
M10
2
2
2
NOTES: The neutral conductor should be sized for 1,5 times the output/bypass phase current.
The Earth conductor should be sized at 2 times the output/bypass conductor (this is
dependent on the fault rating, cable lengths, type of protection etc.) These
recommendations are for guideline purposes only and are superceded by local
regulations and codes of practice.
6
3.4.5 Safety Earth
The safety earth cable must be connected to the earth BUS BAR and to each cabinets in the
system and also the earthing and neutral bonding arrangements must be in accordance with the
local laws.
ATTENTION!!! Failure to follow adequate earthing procedures can result in electric shock hazard
to personnel, or the risk of fire.
3.4.6 Cable Connections
ATTENTION!!!
All the cable connections of the UPS must be done by the authorized service
person. Once the equipment has been finally positioned and secured, connect the power cables as
described in the following procedure:
+
F1
BATTERY
FUSES
BATT (+)
F2
F3
RECTIFIER
INPUT FUSES
Split (Exte rnal) By-Pass
Supply Connections
WHITE
CABLES
BATT (-)
a. The three white cables shown in
Figure 3-2 are removed.
b. The three phase + neutral cables
coming from the split by-pass supply
are connected to terminals U3-V3W3 and N3.
Figure 3-2-a
10-15-20 kVA Cable Connections
+
BATTERY
FUSE
F1
F2
F3
RECTIFIER
INPUT FUSES
c. The three phase + neutral AC Input
cables are con nected to terminals
U1-V 1-W1 and N1, to supply the
necessary operational input power
of the UPS.
S1
d. Note that in this connection the
neutrals of the split by-pass supply
and the line are connected together.
INPUT
SUPPLY
WHITE
CABLES
BATT (+) BATT (-)
Figure 3-2-b
30 kVA Cable Connections
7
e. The split by-pass supply’s voltage
and frequency must be compatible
with the UPS output voltage and
frequency.
1. Verify that the UPS’s switches are totally at “0” position.
2. Connect the AC input supply cables between the mains distribution panel and the UPS “AC Input” (U1-V1W1-N1) terminals.
ATTENTION!!!
ENSURE CORRECT PHASE SEQUENCE
If there is a phase sequence fault, A21/A39 “ROTATE PHASE” message appears on
the front panel and the UPS can’t work.
3. Connect the UPS output cables between the UPS output “AC output” (U2-V 2-W2-N2) and the load
distribution panel.
4. Make the connection of the battery groups. Please look at the Battery Installation item for it.
ATTENTION!!!
Remove the battery fuse before making the connection of the battery circuit
breaker during the battery installation. (Turn off into “0” (OFF) position)
5. The “BATT(+)” and “BATT( -)” cables, coming from the battery group terminals must be connected to the
lower ends of the BATTERY “+” and “-” respectively.
6. If a battery circuit breaker is going to be used, it should be connected in series with the “BATT(+)” and
“BATT(-)” cables.
8
Normal Connections
AC
AC
A
B
Split By-Pass Connections
AC
AC
A
B
Figure 3-2-c
40-60 kVA UPS Power Connections
9
Normal Connections
AC
AC
A
B
Split By-Pass Connections
AC
AC
B
A
Figure 3-2-d
80 kVA UPS Power Connections
10
S4
U2
A
These links
must be
removed for
split bypass
system
S3
Output
connections
(To load)
B
S2
Input
connections
V2
W2
N2
U3
Battery power
connections
V3
W3
N3
C
S1
UPS rectifier and inverter input connections. Normally
these terminals are not used for the input connections.
Split (External) By-pass Connection
a. Remove the shown links (in the figure)
b. Connect the R-S-T-N cables to the B terminals
from the external by-pass source.
c. Connect the mains input R-S-T-N cables to
the C terminals.
d. The external by-pass’s voltage and frequency
must be suitable With the UPS’s.
Figure 3-2-e
100-120-160-200 kVA UPS Power Connections
1) Verify that the UPS’s switches are totally at “0” position.
2) Connect the AC input supply cables coming from the input mains distribution panel to the B
terminals as in Fig. 3-2-c,d,e.
ATTENTION!!! PLEASE BE SURE OF CORRECT PHASE SEQUENCE.
If there is a phase sequence fault, A21/A39 “ROTATE PHASE” message appears on the front
panel and the UPS can’t work.
THE CORRESPONDING AC INPUTS OF BOTH UPS’s (U3-V3-W3) MUST BE EXACTLY OF THE SAME PHASE.
3) Connect the UPS output cables from the output terminals to the load distribution panel.
ATTENTION!!! For proper load sharing during parallel operation the cables between the
AC distribution panel and the AC output terminals of one UPS must be
exactly the same size and length as the cables between the distribution
panel and the AC output terminals of the second UPS.
4) Make the connection of the battery groups. Please look at the 3.3 Battery Installation item for it.
11
ATTENTION!!!
Remove the battery fuses before making the connection of the battery circuit
breaker during the battery installation. (Turn off into “0” (OFF) position)
5) Connect the copper earth bus, which is under the safety earth and the cables power connection.
Note: The earth and the neutral connections must be done according to national rules.
If the REMOTE STOP option is going to be used, you should connect the remote stop button
(normally open), to the pins 4 and 5 of the remote stop connector (CN3) on the PCB ITF3.
3.4.7
Battery Installation
ATTENTION!!!
Remove the battery fuse before making the connection of the battery circuit
breaker box during the battery installation.
The batteries of the UPS equipment are usually contained in a purpose-built battery cabinet, which
sits alongside the main UPS equipment. Sealed, maintenance-free batteries are normally used in
this type of installations.
Where battery racks are used, they should be positioned in accordance with the battery
manufacturer’s recommendations. In general, batteries require a well-ventilated, clean and dry
environment at reasonable temperatures to obtain efficient battery operation.
In general a minimum space of 10 mm must be left on all vertical sides of the battery block. A
minimum clearance of 20 mm should be allowed between the cell surface and any walls. A
clearance of minimum150 mm should be allowed between the top of the cells and the underside of
the shelf above (this is necessary for monitoring and servicing the cells). All metal racks and
cabinets must be earthed. All live cell connections must be shrouded.
The batteries are connected to the UPS through a circuit breaker (optional), which is manually
closed and electronically tripped via the UPS control circuitry. If the batteries are cabinet-mounted
this circuit breaker is fitted within the cabinet; however, if the batteries are rack-mounted or
otherwise located remote to the main UPS cabinet then the battery circuit breaker must be mounted
as near as possible to the batteries themselves, and the power and control cables connected to the
UPS using the most direct route possible.
1. Unpack each battery and check its terminal voltage. If any battery has terminal voltage less than
10,5 V it must be charged before.
2. Please check the battery connecting materials.
3. Please put 8 pieces of the batteries to each rack.
4. Start installing the batteries from top to the bottom on the racks.
5. Connect the cable between the battery circuit breaker’s positive port (BAT+) first then battery
tray (+) at the left topside as in the figure 3-3
6. Connect the cable between the battery circuit’s negative port (BAT-) first then battery tray (-) at
the right bottom side as in the figure 3-3
7. Please pay attention to the connections and the poles’s directions between the racks.
12
8. Connect the battery circuit breaker’s “UPS(+) ⇒ BATT(+)” and “UPS (-) ⇒ BATT(-)” Ports to the
battery group connection terminals at the UPS cabinet.
9. Connect the shielded control cable between the UPS and the battery circuit breaker as in the
following.
Battery circuit
Inside of the UPS
Breaker box
1.....................1
ITF3 Board
BAC60 Board
2.....................2
BATT. CB
CN1
3.....................3
CN3
Battery
Fuse
To UPS Cabinet
Figure 3-3-a
13
UPS Battery Group Connection
(With Battery Fuse)
Electronically
Controlled
Battery Circuit
Breaker
BAC60
CN1
Control
Cable
1 2 3
To ITF3
Figure 3-3-b
To UPS
Cabinet
UPS Battery Group Connection
(With Battery Circuit Breaker)
(OPTIONAL)
Battery Circuit
Breaker Input
Emergency
Stop
CN3
14
3.4.8
Communication (UPS-Server)
Dry relay alarm contacts or RS232 communication port can be used for communication with UPS. Users can
get information about any possible alarm like “Battery Low” “Line Failure” “Load On By-pass”. The relay
interface AS400 and Windows NT is an special edition for the systems.
You should use ITF3 and RS330 board for the communication with the PC. For this connections there must
be a dedicated serial port.
ATTENTION!!!
The communication cables of this option must be shielded and must install away from the
voltage cables.
The RS232 port (at RS330 board and DB9 female) definition :
RS232 Signal Gnd (isolated)
RS232 Receive
RS232 Transmit
7
6
9
The settings for the Microsoft NT server , IBM AS400  connections will be done by the system’s operator in
accordance to the each user’s needs.
Battery Circuit
Breaker Input
Emergency Stop
Line Failure
Relay
Battery Low Relay
or Common Alarm
Relay
CN3
CN4
Figure 3.4
ITF3 Board Connection Details
15
By-Pass
Relay
4. FRONT PA NE L
4.1 Introduction
The front panel of UPS, consisting of a 2 lines alphanumeric display, 6 status lamps, plus 4 function
keys, allows the complete monitoring of the UPS status. The mimic flow diagram helps to
comprehend the operating status of the UPS. By using the function keys operator can move on
menus and change some parameters .
Figure 4-1
Line
Battery
By-pass
Maint.Sw.
Inverter
O/P Sw.
Control and display panel
If lamp is lit mains is okay
If lamp is lit UPS is operating on batteries
If lamp is lit static bypass is active and load is connected to mains voltage
If lamp is lit mechanical bypass switch is on
If lamp is lit inverter feeds the load
If lamp is lit S4 power output switch “1” on position.
There are 4 function keys on front panel these are ENTER, DOWN, PLUS and MINUS.
DOWN key helps moving on menus, PLUS and MINUS keys select options , ENTER key means
the selected option or menu is valid.
16
4.2
Alarms and Troubleshooting
Totally 64 alarms and status messages (might be extended, please consult us) are used in UPS,
which helps the user. Messages are coded for easy dialog with service organization, all messages
contains numbers A1-A2-A3….An. Messages and events in UPS are recorded to a log file with
event time and date
ALARM
DESCRIPTION
A1 BYPASS FAILURE
Possible Causes:
A2 INVERTER FAILURE
Possible Causes:
A3 3 OVERTEMP
Possible Causes:
Bypass system failure
1) Maybe bypass parts are defective call service
Inverter digital start system is failed
Internal failure. Call service.
Overload in UPS repeated at 3 times in 30 min.
1) Overload
2) Fan failure or durty air inlets,outlets
3) Bad UPS settling
UPS output voltage is out of tolerance at 3 times in 30 min.
Internal failure. Call service.
Batteries empty at last of line out. Wait to return of electric.
Rectifier is not to produce DC bus voltage.
Batteries are low.
1) UPS wrought long time when line out
2) Charger system failure
Inverter output voltage is over than max. tolerance voltage value.
Inverter is stopped.
1) Inverter failure
UPS loaded over than max. %100 load level.
Load on the UPS output is over than max. Load capacity. This state is maybe
continous or short time. When this alarm is continous to check loads.
Line failure.
1) Maybe line out
2) There is a problem on the UPS input board. Please Check.
3) UPS input fuses are blowned.
Over temperature. (inverter or rectifier section)
1) Overload for inverter
2) Over temperature
3) Fan failure or durty air inlets
4) Bad UPS settling. There is not vantilation area.
Inverter output system failure.
1) Overload.
2) Short circuit.
3) UPS is out of order. Call service.
Inverter output voltage is under than min. tolerance voltage value.
Inverter is stopped.
Battery voltage is over than max. tolerance.
Fuse blowned. (not used at this power range)
During transfer to bypass, Voltage or frequency value of bypass source is
incorrect and the UPS turn off the load power.
During normal (inverter) operation some times you can see this message.
During bypass if the bypass protection option is on and if the bypass source is
tolerant out UPS switch off the static bypass for load protection.
Battery circuit breaker is off, batteries are not connected to UPS
At start up if the mains is okay you can start operation but this message is
active
A4 OUT FAILURE
A5 BATT AUT END
A6 CHARGER FAULT
A7 BATTERY LOW
Possible Causes:
A8 OUTPUT HIGH
Possible Causes:
A9 OVERLOAD
Possible Causes:
A10 LINE FAILURE
Possible Causes:
A11 HIGH TEMPER
Possible Causes:
A12 IGBT FAILURE
Possible Causes:
A13 OUTPUT LOW
A14 BATTERY HIGH
A15 FUSE FAILURE
A16 BYP INPUT BAD
A17 BATT CB OPEN
17
At start up during line failure UPS waits for turn on battery CB and then it starts
ALARM
DESCRIPTION
If the battery charge is low this message indicates that charge period is not
completed. If mains failure occurs during this message battery operating time is
A18 BATT.CAPA.LOW
not valid.
UPS will beep once every 15 sec.
Battery test aborted. And batteries are not normal
A19 BATT FAULT
UPS gives beep sound whitin 15 sec
You can clear this message by pressing 3 seconds to ENTER key
Possible Causes: 1) Rectifier fault
2) Battery cells damaged
3) PURE battery connection
Boost charge is active for 10 hours. At the end of this time UPS stops the boost
A20 BOOST CHARGE
charge.
UPS gives beep sound whitin 15 sec
A21 ROTATE PHASE
Phase sequence is changed on the UPS input. Please change.
A23 MODE FAILURE
In parallel system, the operation mode of 1 UPS is differenf from the other
A24 P.FAILURE 17
Parallel controller board failure
A25 P.FAILURE 18
Parallel controller board failure
A26 P.FAILURE 19
Parallel controller board failure
A27 P.FAILURE 20
Parallel controller board failure
A28 P.FAILURE 21
Parallel controller board failure
A29 P.TEST MODE
Paralel controller is in test mode
A30 P FAILURE 23
Parallel controller board failure
A31 DUBL UPS NR.
Same UPS number is used in parallel system.
Possible Causes: 1) Change from settings menu
Power supply is not functioning possibly because either of a wrong phase
A39 PSP FAILURE
sequence or rectifier fault.
One of parallel modes is selected but there is no parallel control board on UPS
A40 CANT FIND PR
Change mode from settings menu
A41 P.BAL.FAILURE
In parallel operation current sharing is not okay
A42 BATTERY TEST
Performing battery test
A43 P.SYNC.FAIL
In parallel system SLAVE UPS is not synchronized to MASTER UPS
A44 BT.OPERATION
UPS is operating from batteries
Possible Causes: 1) Central system is black-out
2) Distribution problems upfront of the UPS
After mains failure, mains voltage restored again. This message appears on
A45 MAINS OK
screen for 15 seconds after mains restored.
A46 BOOST CH.END
Boost charge mode is finished, normal charge is valid.
A47 CANNOT START
Analog start system in UPS is failed.
Status messages:
This message group simply shows the UPS STATUS at the upper line of LCD PANEL.
RECTIFIER START !
INVERTER START !
MAINT SWITCH ON !
MANUEL BYPASS !
STATUS ALARM !
STATUS NORMAL !
EMERGENCY STOP !
WAITING SYNC !
STATUS FAULT !
CLOSE BATT.CB !
:
:
:
:
:
:
:
:
:
:
UPS started the rectifier
UPS started the inverter
Maintenance bypass switch is on
Load is transferred to mains manually
Alarm status
UPS is operating
External emergency signal is detected.
Inverter started waiting for syncronization
Fault status
UPS is waiting for battery CB close
18
STATUS WARNING ! : Warning message is valid on LCD panel
RECTIFIER START :
At start up the UPS controller board check for input voltage, frequency, battery voltage, for starting,
if these parameters are normal then UPS starts.
INVERTER START :
If the inverter stops controller board tries to start again, during inverter start this message appears
on first line of LCD PANEL.
MAINT SWITCH ON:
Maintenance bypass switch is connected from input to the output of UPS directly, controller stops
inverter for accidental short circuits between mains voltage and inverter output. If the user turn off
the maintenance switch then the inverter starts again.
EMERGENCY STOP :
If an external EPO switch is installed to system (connected to interface board) ,to stop all UPS parts
(rectifier ,static bypass ,inverter ,etc….) is possible . After pressing EPO switch all parts of the UPS
stops,for restart turn off S1 (inverter input) switch and turn on again.
FAULT STATUS :
In some cases controller checks events but can not find solutions, in this case controller decide to
stop system ,for restart user must be turn off S1 (inverter input) switch and turn on again.
WARNING STATUS :
Some events recorded to log event file stays on LCD PANEL but UPS continues to work, these
messages named as warning messages, user can clear this messages by pressing ENTER key for
3 seconds.
These are:
• A20 Boost charge alert
• A6 Charger fault
• A18 Batt capacity low
Shutdown Messages :
UPS is communicating with operating system, by using softwares that you can send commands to
UPS from operating system .UPS takes these commands and produces some messages. These
are:
Shutdown command is performed from operating system and UPS is
waiting for a certain delay for shutdown.
UPS SHUTDOWN
: UPS is in shutdown status
WAITING RESTART
: UPS is shutdown but it is waiting for a certain delay to restart
PAR.SHUTDOWN
: In parallel system the other UPS send shutdown command and UPS is in
shutdown status.
CANCEL SHUTDOWN : Shutdown command is canceled.
WAITING SHUTDOWN :
Only operating system or a PC computer c an send this commands.
If the shutdown command is performed during line failure UPS shutdown and if the mains is normal
UPS starts again automaticaly.
19
4.3 Menu Description
By using DOWN function key on front panel you can move on main menu functions, when main
menu appears on LCD panel if you press ENTER key you can go to submenu item.
In submenu you can move by DOWN key, if there is option on submenu item, you can change
options by pressing PLUS and MINUS keys. If you press ENTER key the option is valid.
MEASURES submenu
LD% (output load percentage)
OPV (output voltages)
FREQU (output frequency)
IPV (input voltages)
BYP (bypass source voltages)
BATT (battery voltage and current)
...... etc
SAMPLE menu selection:
If you want to go measures menu use UPS and DOWN keys find MEASURES MENU, press ENTER key,
now you can move on measures menu sub items by DOWN key.
At the end of sub menus ENTER EXIT is located, during this message if you press ENTER key you can go
back main menu.
At ALARMS MENU you can see LOG HISTORY, log events are recorded with event time and date.
PASSWORD Menu is located for service purposes. This menu is developed only for adjustment.
20
Menu and submenu items
MAIN MENU
MEASURES MENU
ALARMS MENU
INFORMATION MENU
PASSWORD MENU
SETTINGS MENU
COMMAND MENU
TIME MENU
SUBMENU
MEANING
LD%: 050 030 060
OPV: 220 221 219 V
FREQU: 50.0 Hz
IPV: 240 230 226 V
BYP: 225 221 219 V
IPI: 031 040 020 A
BATT: 405 V 06.7A
TEMP: 24 C
CHARGE LEVEL: 60%
ENTER EXIT
UPS STATUS
000>Date and alarm
ENTER CLEAR LOG
PARR.ERR.NR
ENTER EXIT
SYNC :OK COMM :OK
POWER: ……… VA
VERSION : MC1XX
FREQUENCY : PLL/XTAL
ENTER EXIT
(password required )
ENTER EXIT
MODE:
UPS No :
REMOTE :ENABLE
RESTART:ON/OFF
BYP.PROTECT ON
ENTER EXIT
SOUND : ON/OFF
ENTER B.TEST>432
ENTER <BYPASS>
ENTER:MODEM INIT
ENTER <BOOST>
SIMULATION OFF
ENTER EXIT
TIME : 23 :15
DATE : 11-10-2001
SET HOURS: 11
SET MINS : 38
SET DAY : 21
SET MONTH : 06
SET YEAR : 2001
ENTER <UPDATE>
ENTER EXIT
21
Output load
Output voltage
Output frequency
Input voltages
Bypass source voltages
G input currents
Battery voltage and charge current
Cabinet inside heat
Battery charge level
Exit from submenu
Valid alarm
Recorded log events
Clearing log records
Parallel control board error nr.
Exit from submenu
Syncronization and comminication
Output power of the UPS
Version of UPS
Frequency generation mode
Exit from submenu
System settings
Exit from submenu
Operation mode selection
UPS number selection
Remote access on/off
Mains restored setting
Bypass load protection
Exit from submenu
Sound alert on/off
Manuel battery test
Manuel bypass
Modem settings
Boost charge on/off
Simulation mode selection
Exit from submenu
time
date
Adjust hours
Adjust minutes
Adjust day
Adjust month
Adjust year
Write new time and date
Exit from submenu
4.4
MAIN Menu
The main menu items are given at the following table you can move on main menu items by using DOWN
key.
Main Menu item
STATUS MENU
MEASURES MENU
ALARMS
INFORMATION MENU
PASSWORD MENU
SETTINGS MENU
COMMAND MENU
TIME MENU
Go to STATUS MENU
Function
The status message which shows the UPS status
→ Enter
"go to Meausures submenu"
→ Enter
"go to Alarms submenu"
→ Enter
"go to Information submenu"
→ Enter
"go to password submenu"
→ Enter
"go to Settings submenu"
→ Enter
"go to Command submenu"
→ Enter
"go to Time and date submenu"
4.5 MEASURES MENU Items
At this menu you can see all measured values, use DOWN key for moving on submenu items.
1
2
3
4
5
6
7
8
9
10
Submenu item
LD%: 060 074 080
OPV: 220 221 220
FREQU: 50.0 Hz
IPV: 240 235 220
BYP: 230 232 231
IPI: 022 010 030
BATT: 405 V 22.1 A
TEMP: 030 c
CHARGE LEVEL :%100
ENTER EXIT
Goto first submenu item
Function
Output load percentage (capacity %)
Output voltages
Output frequency
Input voltages
Bypass source voltages
Input currents (amperes)
Battery voltage and charge current
Cabinet inside temperature
Battery charge level
→ Enter
(↵ ) exit from menu
4.6 ALARMS Menu Items
At this menu you can see recorded log events and valid alarms
1
Submenu item
UPS STATUS
2
000>311201 23:15
3
ENTER CLEAR LOG
4
PARR.ERR.NR : 017
5
ENTER EXIT
Goto first submenu item
Function
Valid alarm is on LCD PANEL
See recorded log events :
At the first line the first 3 numbers shows the event number. 000 numbered
event is the last event. Date ddmmyy time:hh:mm
At the second line of LCD PANEL you can see all recorded alarms.
Use PLUS and MINUS keys for moving on events.
→ Enter
(↵ ) clear log event records
After you cleared events you see EMPTY LOG message at lines
Parallel control board fault number. (use if the parallel board is installed)
0 means that there is no error on parallel board
→ Enter
(↵ ) exit from submenu
22
4.7 INFORMATION Menu Items
This menu gives information about UPS.
Submenu item
1
SYNC :OK COMM :OK
2
3
POWER: ……. VA
VERSION : MC1xx
4
FREQUENCY : PLL
5
ENTER EXIT
Goto first submenu item
Function
If the UPS is operating syncron to mains SYNC:OK ,if not syncron SYNC:-If communication is active COMM:OK ,if not active COMM:-The maximum power rating of the UPS
Shows the UPS version
Frequency generation mode
PLL :phase locked loop is generating the frequency
XTAL : XTAL oscillator is generating the frequency
SLAVE : in parallel system master is generating the frequency
→ Enter
(↵ ) exit from submenu
4.8 SETTINGS Menu Items
From this menu user can set some important options.
Submenu item
1
MODE: ONLINE
2
UPS No : 001
3
REMOTE :ENABLE
4
RESTART:ON/OFF
5
BYP.PROTECT ON
6
ENTER EXIT
Goto first submenu item
Function
By using PLUS and MINUS keys you can move on 4 operation mode
options
ONLINE : stand alone mode
PARALLEL : 2 UPS in symmetric parallel operation
HOT STANDBY : 1 UPS main the other UPS spare mode
REDUNDANT : 2 UPS in redundant parallel mode.
→ press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change number 0 to 3.
In parallel operation select different number for each UPS. If you select the
same number DUBL UPS NUMBER message tells the fault.
→ press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change enable and disable
options.
enable : remote battery test, shutdown and bypass function is enabled
disable : these functions are disabled
→ press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change on and off options.
ON : during mains failure at the end of battery discharge UPS shutdowns,
after mains restored UPS startes again.
(battery trip out is on every time)
OFF: during mains restore UPS don’t start again.
(battery trip out is off)
→ press ENTER for 3 seconds and the selection is valid
By using PLUS and MINUS keys you can change on and off options.
ON: if the bypass source is out of tolerance UPS turn off load power.
OFF : UPS turn off load power only during bypass moves. If bypass period is
completed UPS continues to feed load.
→ Enter
(↵ ) exit from submenu
23
4.9 COMMAND Menu Items
You can give immediate commands to UPS by using this menu.
Submenu items
1
SOUND : ON/OFF
2
ENTER B.TEST>432
3
ENTER <BYPASS>
Function
Use for turn on/off beep alert sound.
If you press ENTER key the option will change ,one press ON ,one press
OFF.
If the OFF option is used, sound alert is turn off but if a new different
alarm is valid UPS changes de option to ON state.
If you press enter for 3 seconds battery test starts for 15 seconds.
If battery test failes A6 BATT FAULT message is on panel and this
message stays until you press ENTER key for 3 seconds.
Numbers at the right shows the battery voltage.
Starting of battery test time is recorded to log event menu if the test is
successful you can see only BATTERY TEST message on log records..
If you press ENTER key for 3 seconds UPS transfers load to bypass.
If the load is on bypass in this submenu you see ENTER<INVERTER>
message at this position if you press ENTER key for 3 seconds UPS
transfers the load on inverter.
In parallel modes this function disables and you see
BYP.FUNC.DISABLE message on this submenu item.
ENTER:MODEM INIT
If you press ENTER key the connected modem of RS232 port is installed
UPS sends AT command set to modem for installation.
If the function is completed you must hear a beep sound.
At the end of this function modem is ready to answer dial up connection.
ENTER <BOOST>
If you press ENTER key for 3 seconds boost charge starts. The given
time for boost charge is 10 hours. At the end of this time UPS stops the
boost charge.
If the boost charge is active this submenu item changes to STOP
BOOST> 005H message the 005H shows that boost charge is started
before 5 hours.
If the number is 10 boost charge stops. If you press ENTER key boost
charge stops immediately.
Boost charge starting and boost charge end time is recorded to log event
menu.
If boost is active UPS beeps in each 15 seconds
6
SIMULATION OFF
The purpose of this submenu to check dry contact connections. Normally
to check line failure contact you must turn off mains power. This is not
necessary with this utility. 3 options are avalible.
SIMULATION OFF simulaion mode is off
SIM:LINE FAILURE if you press ENTER key for 3 seconds line failure
lamp on interface board lits
SIM:LIN.F+BT.LOW if you press enter key for 3 seconds line failure and
battery low lamp on interface board lits
SIM:BYPASS if you press ENTER key for 3 seconds bypass (aux) lamp
on interface board lits.
So you can check the connections
7
ENTER EXIT
→ Enter
4
5
(↵ ) exit from submenu
Goto first submenu item
24
4.10
TIME Menu Items
You can see date and time of RTC (real time clock) on UPS. And you can adjust date and time.
1
2
3
4
5
6
7
8
9
4.11
Submenu item
TIME : 23 :15
DATE : 11-10-2001
SET HOURS: 11
SET MINS : 38
SET DAY : 21
SET MONTH : 06
SET YEAR : 2001
ENTER <UPDATE>
ENTER EXIT
Goto first submenu item
Function
time
date
(+) and (-) adjust hours (0-23)
(+) and (-) adjust minutes (0-59)
(+) and (-) adjust day (1-31)
(+) and (-) adjust month(1-12)
(+) and (-) adjust year (2000-2099)
→ Enter update new date and time
→ Enter
(↵ ) exit from submenu
PASSWORD Menu Items
Only authorized person can use this menu, incorrect usage of this menu can damage the UPS.
Submenu item
1
PASSWORD : XXX
2
ENTER EXIT
Goto first submenu item
Function
Service password input
(-) key 100 ,
DOWN key 10,
(+) key 1 changes
after you write the password on screen press ENTER key ,if the
password is wrong than there is no action.
If the password is valid, a beep sounds and you see ADJUST MODE at
the second line.
→ Enter
(↵ ) exit from submenu
25
5. OPERA TIN G I NS TRU CT IONS
5.1
UPS Switch on Procedures 10 to 30kVA
The following stages have to be carried out chronologically. If alarms are displayed on the mimic panel, the problem has to be solved before going any further.
1. Open the UPS doors to gain access to the main power switches.
2. Make sure that the S3 switch (maintenance bypass) is in “0” (OFF) position.
3. Turn on the rectifier input fuses (F1-F2-F3) and inverter input switch S1 , by bringing them into
“1” (ON) position. (Upwards)
4. Turn on the static by-pass switch S2 into “1” (ON) position.
5. Turn on the S4 fuse/switch (UPS output), into ”1” (ON) position.
RECTIFIER START!
INVERTER START!
STATUS NORMAL!
: Rectifier is working and static bypass continues to feed the load.
: Inverter is working and static bypass continues to feed the load.
: The UPS is operating normally, its inverter supplying the outlet.
6. Turn on the BATT.(+) and BATT.(-) fuses into “1” (ON) position. By this way it is ensured to
connect the battery group to the UPS.
7. Your UPS system is ready to use. You can start up your load.
ATTENTION: At this stage, the load is supplied by the inverter.
5.2
UPS Switch on Procedures 40 to 200kVA
1) Make sure that all the switches and fuses (S1, S2, S3, S4 and S5) are in “OFF” position and S6
is in “NORMAL” position.
NOTE THAT S6 SHOULD ALWAYS BE IN “NORMAL” POSITION FOR ONLINE OPERATION
2) Turn S2 switch (static bypass) into “1” (ON) position.
3) Turn on S4 (output switch), now the load is connected to bypass supply.
4) Turn on the S1 switch (inverter input), into ”1” position. By turning on S1, all lights on the front
panel will be lit for 4 secs (lamp test) and then, the following messages will appear on LCD.
“RECTIFIER START” : Rectifier is operating and static bypass continues to supply the load.
“INVERTER START”: Inverter is operating and static bypass continues to supply the load.
“STATUS NORMAL” : The UPS is operating normally and the inverter is supplying the load.
ATTENTION : AC output voltage is applied to the load at this step.
26
5) Turn on the S5 (The battery circuit breaker) into “1” position or insert the battery fuse. By this
way, the battery group is connected to the UPS.
6) Once you see the green inverter led on the front panel then the UPS system is now ready for
use. You can start up your loads.
ATTENTION :
•
•
•
In a single unit application, the UPS must be operated in “ONLINE” mode.
And the mode selection should be followed up as follows :
Using the UP-DOWN buttons on the front panel, select “SETTINGS MENU” on LCD and press
“ENTER”. When you see “MODE” display, using “+” and “-“ buttons select “ONLINE” mode.
After selecting ONLINE mode press “ENTER” until the beep sound stops.
Turn S1 off and few seconds later, turn it on again. You will see “INVERTER START” and than
“STATUS NORMAL” messages on the LCD.
5.3 Transfer to Maintenance By Pass 10 to 30kVA
The manual by-pass enables direct supply of the load from mains without the control functions of
the UPS. It is used for the UPS maintenance.
1. Press on the DOWN button when there is “COMMAND MENU” message on the front panel of
the UPS. Then press “ENTER” button.
2. Press on the DOWN button when there is “ENTER <BYPASS>” message on the front panel of
the UPS. Then press “ENTER” button for 3 seconds. static by-pass led lit and inverter led off.
Now your load is feeding from the Static By-pass.
3. Take out the lock from the S3 (maintenance bypass) switch.
4. Turn on (into “1” position) the S3 (maintenance bypass) switch.
5. F1-F2-F3-S1 (rectifier input fuses-inverter input),
S4 (UPS output)
S2 (static by-pass),
BATT(+) and BATT(-) Open this fuses and the switches. Into “0” (OFF) position
WARNING!!!
Inside the UPS the following points will be on operation:
* By-pass AC input mains terminals
* Maintenance by-pass switch
* Static by-pass switch
* UPS output terminals
Now the load is completely supplied from the maintenance by-pass and the
UPS is closed.
WARNING!!!
During the maintenance or static by-pass the connected load at the UPS output
is not protected against the mains failure.
27
5.4 Transfer to Maintenance By Pass Mode 40 to 200kVA
This procedure should be followed when turning from normal operation to maintenance bypass.
This procedure can be used for supplying temporary mains voltage to the system during the
maintenance of the UPS or in case of failure.
1. Press on the DOWN button when there is “COMMAND MENU” message on the front panel of
the UPS. Then press “ENTER” button.
2. Press on the DOWN button when there is “ENTER <BYPASS>” message on the front panel of
the UPS. Then press “ENTER” button for 3 seconds. Static by-pass led lit and inverter led off.
Now your load is supplied via Static By-pass.
NOTE :
Using the procedure in 4.2.2.1 and 4.2.2.2 you can switch the load to by-pass
manually. (MANUAL BY-PASS)
3. Take out the lock from the S3 (maintenance bypass) switch.
4. Turn on (into “1” position) the S3 (maintenance bypass) switch.
5. Turn off all the following switches into “0” position.
S1 (inverter input)
S2 (static bypass)
S4 (UPS output)
S5 (Battery circuit breaker or battery fuse)
WARNING!!!
Inside the UPS the following points will be on operation:
* By-pass AC input mains terminals
* Maintenance by-pass switch
* UPS output terminals
Now your load is completely supplied via maintenance by-pass and the
UPS is not operating.
WARNING!!!
During the maintenance or static by-pass the connected loads at the UPS output
are not protected against the mains (by-pass source) failure.
5.5 Transfer from Maintenance By Pass to Inverter Mode 10 to 30kVA
1. While the S3 switch in closed position ”1” (ON) ;turn on (into “1” position) the F1-F2-F3-S1
(rectifier input fuses- inverter input), S2 (static bypass) and S4 (UPS output) Switch.
2. Turn on (into “1” position) the S1 (inverter input) switch.
3. When “MAINT SWITCH ON!” message appears on the front panel, turn off (into “0” position) the
S3 (maintenance by-pass) switch. By this way the load will be fed from the static by-pass.
4. See “STATUS NORMAL!” message on the front panel and the green inverter led lit.
5. Turn on the BATT.(+) and BATT.(-) fuses into “1” (ON) position. Now the UPS system is in
normal operation. You can start-up your load.
28
5.6 Transfer from Maintenance By Pass to Inverter Mode 40 to 200kVA
1. While the S3 switch in closed position”1” (ON) ;
turn on (into “1” position) the S2 (static bypass) and S4 UPS output) Switch.
2. Turn on (into “1” position) the S1 (inverter input) switch.
3. When “MAINT SWITCH ON!” message appears on the front panel, turn off (into “0” position)
the S3 (maintenance by-pass) switch. By this way the load will be fed from the static by-pass.
4. See “STATUS NORMAL!” message on the front panel and the green inverter led lit.
5. Turn on the battery circuit breaker into “1” (ON) position (or insert the battery fuse).
Now the UPS system is in normal operation. You can start-up your PC, printer etc.
5.7 Transfer from Static By Pass to Inverter Mode
1. Press on the DOWN button when there is “COMMAND MENU” message on the front panel of
the UPS. Then press “ENTER” button.
2. Press on the DOWN button when there is “ENTER <INVERTER>” message on the front panel of
the UPS. Then press “ENTER” button for 3 seconds, static by-pass led off and inverter led on.
Now your load is fed from the Static By-pass.
3. See “STATUS NORMAL!” message on the front panel. Now the UPS system is on normal
operation. You can start-up your PC, printer etc.
5.8 UPS Shutdown Procedures 10 to 30kVA
All the power switches, isolators and circuit breakers will on open position. (Turn into “0” (OFF)
position). There will be no voltage on the load.
WARNING!!! This procedure will leave the load without energy.
10-15-20 kVA : S1 (inverter input)
S4 open (UPS output) switch (Turn off into”0” position).
S2 (static by-pass)
F1-F2-F3 rectifier input fuses
BATT.(+) and BATT.(-) Open this fuses and the switches into “0” (OFF) position
30 kVA
: F1-F2-F3-S1 (rectifier input fuses-inverter input)
S4 open (UPS output) switch (Turn off into”0” position).
S2 (static by-pass)
BATT.(+) Open this fuses and the switches into “0” (OFF) position
29
5.9 UPS Shutdown Procedures 40 to 200kVA
All the power switches, isolators and circuit breakers should be turned off, with the following
sequence. (Turn off into “0” (OFF) position). There will be no voltage on the load.
WARNING!!! This procedure will cut the energy of all the equipments that are connected to UPS
output.
S4
S2
S1
S5
(UPS output)
(static by-pass)
(inverter input)
(Battery circuit breaker or battery fuse)
5.10 Utility Interruption
When there is a utility power interruption, the inverter led continuously lit also battery and on the
LCD
“A10 LINE FAILURE” message appears. Additionally an audible alarm sounds. Your UPS
continues to convert the battery voltage to AC voltage and protect against loss of data and failure.
The autonomy can be increased by disconnecting relatively unimportant loads. But do not connect
this load again before the end of autonomy time. When the utility power is restored the UP S will
return to normal operation and on the front panel of the UPS “ A45 MAINS OK” mesage appears.
When there is “A7 BATTERY LOW” message appears and audible alarm sounds, shut down your
PC. If not, than all the batteries will be discharge in a few minutes.
After you shut down the critical load (computer system). Apply the completely powering down the
UPS.
Apply the normal operation procedure to start up the UPS again after a long time later.
NOTE:
Do not forget to turn on the battery circuit breaker into “1” (ON) position when
the mains voltage return. If not, in case of a second power cut there will be no voltage for
the critical load.
If you have a reserve generator, you can use it to feed the UPS’s input and the batteries
starts to charge. By using UPS and the generator at the same time ensures to charge the
batteries faster.
30
6. SY STE M AND B OARD LEV EL IN FO RM ATI ON
6.4 Information About Boards
6.4.1 Information About DC Bus And Rectifier Controller Board
Nominal DC bus voltage of Pyramid-Plus series UPS’s are 405 volts. Rectifier controls the voltage
of DC bus according to battery charge voltage, DC bus voltage varies from 300 volts (battery low
level) to 405 volts (battery charge voltage).
If batteries are empty rectifier limits the battery current to adjusted maximum current value. Current
limiting majority is higher then battery voltage. If the charge current is high DC bus voltage will be
lower, if the current goes down the voltage approaches to the nominal battery voltage.
DC bus is connected to inverter IGBT group by the way of DC bus fuse.
A serial connected DC bus capacitor is installed on the output IGBT group. The voltage sharing of
DC bus capacitors are obtained from sharing resistors. At old UPS’s during service check for
voltage sharing of DC bus capacitors. Voltages measured on DC bus capacitors must be same
otherwise DC bus capacitors maybe defected.After turn off the input CB (S1) wait for 3 minutes for
capacitor discharge.
The function of Rectifier controller board is as fallows
• Drives the rectifier SCR’s according to line syncronisation
• Controls the DC bus voltage
• Controls the charge current of batteries
• Performs the battery test
• Produces phase sequency failure signals to the main controller
6.4.2 Information About Main Controller Board (P3MC)
A microcontroller controls all functions of UPS, analog voltages are directly connected to main
controller board and all stop and start functions are made from main controller board.
Output voltage adjustment, frequency adjustment and line syncronisation adjustments are located
on main controller board.
Communication functions are controlled from main microcontroller.
During measurements on main controller board, service personnal must be carefully because
accidental short circuits on board may be cause defected components.
During UPS operation do not connect the Oscilloscope probes maybe damage the UPS, first stop
the UPS, connect oscilloscope probes to mother board than turn on UPS again.
IMPORTANT NOTE : If oscilloscope is grounded do not connect probes to the main controller
board, disconnect ground connection of oscilloscope and make measurements.
6.4.3 Information About Interface Board (ITF3)
The function of interface board is as fallows
• Connects circuit breakers and bypass switches to main controller board
• Connects thermal sensors to main controller board
• Connects battery CB to main controller board
• Gives information about line failure, battery low and bypass by dry contacts to the outside of
UPS.
• Connects emergency shutdown switch to main controller board
31
• Senses the power supply of periferals to the main controller board
• Sends battery trip signal to the battery CB
6.4.4 Information About Voltage Sense Board (3PVS2)
The function of voltage sense board is as fallowed
• Senses the output voltage of inverter to the main controller board
• Senses the bypass and input voltage to the main controller board
6.4.5 Information About IGBT Driver Board (IGD3P)
The function of voltage sense board is as fallowed
• Isolates drive signals of IGBT components
• Main power supply is installed on this board
• IGBT drivers are installed on this board
• DC bus sense components are installed on this board
• DC bus undervoltage circuit and relay is installed on this board
• It connects IGBT fault signals of IGBT drivers to the main controller board
6.4.6 Information About SCR Driver Board (SDR03)
The function of SCR driver board is as fallowed
• It isolates SCR drivers from main board power supply level
• By-pass SCR drivers are installed on this board
• Inverter SCR drivers are installed on this board
• An optional inverter output CB driver is installed on this board
• It interfaces signals from main controller board to the rectifier controller board.
6.4.7 Information About 3 Phase Transformer Board (PTR3P)
The function of 2 phase transformer board is as fallowed
• Optains power supply voltage for rectifier controller board
• Connect 3 phase line syncronisation signals to the rectifier controller board
6.4.8 Information About Communication Board (RS330)
The function of communication board is as fallowed
• Isolates RS232 signals from main controller board
• Drives RS232 line
• Receives RS232 line signals
• Interfaces dry contact outputs from interface board to standart communication cable
6.4.9 Information About LCD Panel Board (P3PANEL)
The function of LCD panel board is
• LCD alphanumeric panel is installed on this board
32
• Mimic lamps are installed on this board
• It connect front panel keys to the main controller board
• Sound alert component (buzzer) is installed on this board
6.5 BOARD LEVEL MAINTENANCE
6.5.1
P3MC Main Controller Board
P3MC board Function of connectors
•
CN1 : Start up power supply 2x15 volts(AC) is connected to this connector
Pin1
Pin2
Pin3
•
15 volts AC start up power supply input
0 volt Start up power supply
15 volts AC start up power supply input
CN2 : SCR driver board and rectifier controller board connections are on this connector
Pin1-pin2
Pin4
Pin6
Pin7
Pin8
Pin9
Pin10
Pin11
Pin12
Pin13-pin14
O volt DC output
Rectifier start signal output
Boost charge active signal output
Battery current sample input
Bypass system enable/disable output
Rectifier fault input
Inverter output CB/SCR drive output
Rotate phase alarm signal input
Battery test signal output
+12 volts power supply output
• CN3 : INTERFACE board connections are on this connector
Pin1
Pin2
Pin3
Pin4
Pin5
Pin6
Pin7-pin9
Pin10
Pin11-pin13
Pin12
Pin14
Pin16
Pin18
Pin19
Pin20
Bypass relay drive output
Battery low relay drive output
Line failure relay drive output
Emergency stop input
Battery trip relay drive output
Battery trip input
+12 volts power supply output
Power supply sense input
0 volt Power supply output
Spare input 2
Spare input 1
Manuel bypass switch sense input
Fuse-fault sense input
Thermal CB sense input
Maintenance bypass sense input
33
•
CN4 : Front panel connections are on this connector
Pin1,3,5,7,9
Pin11-pin13
Pin2
Pin4
Pin6
Pin8
Pin10
•
CN5 : RS232 communication board connections are on this connector
Pin1-pin3
Pin5-pin7
Pin2
Pin4
Pin6
Pin8
•
0 volt power supply output
+5 volts power supply output
Optional Com2 RX input
Optional Com2 TX output
Com1 RX input
Com1 TX output
CN6 : Cabinet inside temperature sensor connections are on this connector
Pin1
Pin2
Pin3
•
0 volt power supply output
+5 volts power supply output
Key5 input
Key4 input
Key3 input
Key2 input
Key1 input
0 volt cabinet inside temperature sensor input
Not used
Cabinet inside temperature sensor + input
CN7 : Inverter output current transformer connections are on this connector
Pin1
Pin2
Pin3
Pin4
Pin5
Pin6
L1
L1
L2
L2
L3
L3
phase
phase
phase
phase
phase
phase
output
output
output
output
output
output
current
current
current
current
current
current
transformer
transformer
transformer
transformer
transformer
transformer
+ input
- input
+ input
- input
+ input
- input
• CN8 : Option board connections are on this connector
• CN9 : Inverter output voltage sense connections and bypass-input voltage sense connections
are on
this connector
Pin4-pin6
Pin1-pin2
Pin3-pin5
Pin15-pin16
Pin12-pin14
Pin8-pin10
Pin11-pin13
L1
L2
L3
L1
L2
L3
+6
line voltage sample input (2x12 volts AC)
line voltage sample input (2x12 volts AC)
line voltage sample input (2x12 volts AC)
inverter output voltage sample input (2x12 volts AC)
inverter output voltage sample input (2x12 volts AC)
inverter output voltage sample input (2x12 volts AC)
volts output – voltage sample transformers common connection
• CN10 : IGBT driver board connections are on this connector
Pin1
Pin2
Pin3-pin4
Pin5-pin6
IGBT fault input
DC BUS(battery) voltage sense input
+12 volts power supply output
0 volt power supply output
34
Pin9-pin10
Pin11-pin12
Pin13-pin14
Pin15-pin16
Pin17-pin18
Pin19-pin20
R phase drive signal
R phase drive signal
S phase drive signal
S phase drive signal
T phase drive signal
T phase drive signal
• CN11 : Parallel controller board connections are on this connector
P3MC board Adjustments
• VR1 : L3 phase DC balance adjustment
• VR2 : L3 phase output voltage fine adjustment
• VR3 : L2 phase DC balance adjustment
• VR4 : L2 phase output voltage fine adjustment
• VR5 : L1 phase DC balance adjustment
• VR6 : L1 phase output voltage fine adjustment
• VR7 : All phases common output voltage adjustment
• VR8 : PLL mode Frequency adjustment
• VR9 : Line sysncronisation adjustment
How to adjust output voltage of inverter?
Set up a voltmeter to the output of inverter
First of all turn VR2-VR4-VR6 to center position
adjust common output voltage (VR7 clockwise increase) to nominal value
Then adjust all phase output voltages seperately (VR2-VR4-VR6)
How to adjust DC balance ?
Connect oscilloscope to the output of inverter, connect %50 linear load to the output
See zero cross signals on oscilloscope for each phase
Adjust for sysmetrical view by VR1-VR3-VR5
How to adjust PLL frequency ? (for 50 hertz nominal value)
Set up frequencymeter to the output of inverter
Adjust VR8 for nominal frequency
Short circuit TP18-TP12
Adjust frequency to 51Hz for (50 Hz nominal)
Short circuit TP18-TP9
Adjust frequency to 49 Hz for (50 Hz nominal)
Repeat adjustment until the upper and lower limit bandwidth is equal (center frequency is 50 Hz)
How to adjust line syncronisation ?
Connect a voltmeter to the L1 inverter output phase and L1 mains input phase
See the voltage between inverter output and line voltage
Adjust VR9 for minumum voltage
The other parameters must be set from PASSWORD MENU please calibrate these parameters
from this menu.
35
P3MC board - Function of LD1 lamp
If the controller send start signal to the analog system this lamp lits
P3MC Board - Test Points
• TP3 : Triangle wave test point
• TP5 : +5 volts supply
• TP6 : +20 volts supply
• TP8 : +6 volts supply
• TP9 : 0 volt COMMON
• TP12 : +12 volts supply
• TP18 : PLL analog signal, this TP is connected to +12 volts and 0 volt during frequency
adjustment
• TP106 : L1 phase 50 hertz square wave signal
• TP206 : L2 phase 50 hertz square wave signal
• TP306 : L3 phase 50 hertz square wave signal
• TP104 : Error signal of L1 phase
• TP204 : Error signal of L2 phase
• TP304 : Error signal of L3 phase
P3MC board - Additional test points :
REF 1
: 2.5 volts reference zener diode
U10-pin7 : 11 volts DC
U10-pin6 : 2.5 volts DC
U10-pin1 : 0 volt DC
U16-PIN11 : 0 volt DC
U38-pin10 : 19200 Hz square wave
U39-pin3 : 50 Hz square wave
U39-pin14 : 50 Hz square wave
ALL integrated circuit power supply pins.
P3MC board - Function of jumpers :
JP1 : Protection jumper, do not disconnect this jumper, otherwise some protection functions out of
function.
6.5.2 IGD3P IGBT Driver Board
Power supply and IGBT drivers are located on this board. There is an undervoltage circuit at the
output of power supply this circuit measures the DC BUS voltage. If the DC bus voltage is lower
then 250 volts undervoltage relay turns off the power supply output.
IGD3P board - Function of connectors
• CN1 : DC bus input
• CN2 : IGBT drive signal
• CN3 : IGBT drive signal
• CN4 : IGBT drive signal
• CN5 : IGBT drive signal
• CN6 : IGBT drive signal
• CN7 : IGBT drive signal
• CN8 : Main controller board connection
• CN9 : Power supply output
• CN10 : Power supply output
36
• CN11 : Power supply output
• CN12 : Power supply output
• CN13 : Optional current sensor input
• CN14 : Optional mains supply input
IGD3P board - Adjustments
• VR1 : Power supply output voltage adjustment
How to adjust power supply output
Set up a voltmeter to the IGBT drive supply (VEE1 to VCC1)
Adjust voltage to 15.5 volts by VR1
See the voltage on R46 app. 24 volts DC
IGD3P board - Additional test points :
VEE1-VCC1 :
TP12
–
D18 cathode
VEE2-VCC2 :
TP10
–
D17 cathode
VEE3-VCC3 :
TP8
–
D16 cathode
VEE4-VCC4 :
TP6
–
D15 cathode
VEE5-VCC5 :
TP4
–
D14 cathode
VEE6-VCC6 :
TP2
–
D13 cathode
ZD25
: 15 volts DC
16Vdc min – 18Vdcmax
16Vdc min – 18Vdcmax
16Vdc min – 18Vdcmax
16Vdc min – 18Vdcm ax
16Vdc min – 18Vdcmax
16Vdc min – 18Vdcmax
IGD3P board - Functions of lamps
• LD1 : If there is voltage at DC BUS upper than 100 volts this lamp lits
• LD2 : If undervoltage circuits turns on the power supply output this lamp lits (DC BUS voltage is
higher than 250 volts)
IGD3P board - Function of jumpers :
• JP1 :IGBT failure signal way test jumper, if this jumper is connected an IGBT failure alarm
occurs so alarm simulation can be made by this way.
6.5.3 REC3P Rectifier Controller Board
REC3P board - Function of connectors:
• CN1 : rectifier SCR gate drive signals
• CN2 : rectifier SCR gate drive signals
• CN3 : rectifier SCR gate drive signals
• CN4 : rectifier SCR gate drive signals
• CN5 : rectifier SCR gate drive signals
• CN6 : rectifier SCR gate drive signals
• CN7 : 3 Phase transformer board connection (power supply and syncron signals)
• CN8 : Control signals from/to main board by SCR driver board interface
• CN9 : LEM1 battery current sensor connection
• CN10 : optional 12 pulse rectifier connections
REC3P board - Adjustments
• VR1 : Battery test voltage level adjustment
• VR2 : Battery current limit adjustment
• VR3 : DC bus voltage adjustment
37
•
VR4 : Boost charge voltage adjustment
How to make nominal battery voltage adjustment ?
Disconnect batteries and set up voltmeter to the DC bus
If 30 batteries are used Adjust VR3 for DC BUS voltage to 405 volts DC (standart)
If 32 batteries are used Adjust VR3 for DC BUS voltage to 432 volts DC (optional)
How to make battery current limit adjusment ?
This adjustment can be made by two ways
Discharge batteries fully and start to charging again
Adjust the charging current by VR2
Supply a DC load which the current is 15 amps at 405 volts DC (30 batteries standart)
Supply a DC load which the current is 15 amps at 432 volts DC (32 batteries optional)
Disconnect batteries
Connect DC load to the battery output of UPS
Adjust the charging current by VR2
You can see battery charge current from measure menu
How to adjust boost charge voltage ?
Disconnect batteries
Set up a voltmeter to the DC BUS
From command menu start boost charge
Adjust DC BUS voltage to 421 volts DC by VR4 (at 30 batteries standart)
Adjust DC BUS voltage to 450 volts DC by VR4 (at 32 batteries optional)
How to adjust battery test voltage ?
Set up a voltmeter to the DC BUS
Short the JP42 jumper
Adjust DC BUS voltage to 360 volts by VR1 (30 or 32 batteries)
Take of JP42 jumper
REC3P board - Function of lamps :
• LD1 : Phase sequency indicator, if this lamp lits continuously mains is okay
If LD1 lamp blinks phase sequency is not okay or phase loss is occured.
• LD2 : Rectifier start pilot lamp, if this lamp lits main controller board sends start signal to
rectifier
• LD3 : Boost charge active pilot lamp, if this lamp lits main controller board sends boost charge
signal to rectifier
• LD4 : Battery test lamp, if battery test is active this lamp lits.
REC3P board - Function of jumpers :
• JP41 : Rectifier direct start jumper, if this jumper on ,rectifier do not stops, from main controller
board signal.
Normally take off this jumper.
• JP42 : Battery test voltage adjustment jumper
6.5.4 SDR03 SCR Driver Board
All the bypass driver components are located on this board. Interface signals from main controller
board to rectifier controller board are connected from CN7 to CN6.
38
SDR03 board - Function of connectors :
• CN1 : L3 phase bypass SCR drive signal
• CN2 : L2 phase bypass SCR drive signal
• CN3 : L1 phase bypass SCR drive signal
• CN4 : Optional output CB drive output
• CN5 : Parallel system common bypass control signals
• CN6 : Interface to rectifier controller board
• CN7 : Main controller board connections
• CN8 : Optional output CB sense input
• CN9 : Power supply from IGBT driver board
• CN10 : 2X15 volts AC Start up power supply connections
• CN11 : Optional L3 phase inverter static switch SCR drive signal
• CN12 : Optional L2 phase inverter static switch SCR drive signal
• CN13 : Optional L1 phase inverter static switch SCR drive signal
Standart Pyramid-Plus series bypass system contains bypass SCR group for 3 phase and one
inverter output circuit breaker. But at parallel systems inverter output CB replaced with static
inverter SCR group.
There is no adjustment on SCR driver board
SDR03 board - Function of lamps :
• LD1 : Optional inverter output CB pilot lamp, if this lamp lits main controller board sends
signal to inverter output CB.
• LD2 : Static bypass SCR trigger pilot lamp, if this lamp lits static bypass SCR group activates
all SCR’s are conducted.
• LD3 : Optional inverter static switch pilot lamp, if this lamp lits inverter output SCR group
activates all SCR’S are conducted.
SDR03 board - Function of jumpers :
• JP31 : Optional output CB enable jumper, if the output CB is installed connect this jumper
• JP32 : Optional output CB sense in jumper, disconnect this jumper if output CB is installed to
UPS.
6.5.5 ITF2 Interface Board
This board connects all contacts to main controller board, outputs the dry contacts to the outside of
UPS. Power supply sense component is located on this board, if power supply input of this board is
not connected UPS does not operate. ITF2 is basic form of interfacing components to main
controller board if the additional bypass switch and output switch monitoring is needed use ITF3
board. At parallel systems this board is not used replace with ITF3 board.
ITF2 board - Function of connectors:
• CN1 : Main controller board connections
• CN2 : Power supply connection to IGBT driver board
• CN3 : Battery trip and emergency shutdown connection
• CN4 : Dry contact interface (line failure, battery low,bypass)
39
• CN5 : Dry contact output to serial communication board.
• CN6 : Interconnection of UPS internal switches
There is no adjustment on this board
ITF2 board - Function of lamps :
• LD1 : Battery trip output pilot lamp
• LD2 : Line failure alarm pilot lamp
• LD3 : Load on bypass pilot lamp
• LD4 : Battery low alarm pilot lamp
You can check the function lamps and dry contacts from command menu by selecting simulation
mode.
6.5.6 ITF3 Interface Board
This board is developed for parallel signal interfacing to parallel control board the structure of board
is the same with ITF2 except parallel control connection and 2 additional swictc sample input.
These are manuel bypass switch and output switch. At parallel operation these switches are
important output switch enables current sharing at parallel operation manuel bypass switch
transfers two UPS’s to bypass together.
ITF3 board - Function of connectors:
• CN1 : Main controller board connections
• CN2 : Power supply connection to IGBT driver board
• CN3 : Battery trip and emergency shutdown connection
• CN4 : Dry contact interface (line failure, battery low,bypass)
• CN5 : Dry contact output to serial communication board.
• CN6 : Interconnection of UPS internal switches
• CN7 : swicth position samples to Parallel control board
ITF3 board - Function of lamps :
• LD1 :
Battery trip output pilot lamp
• LD2 :
Line failure alarm pilot lamp
• LD3 :
Load on bypass pilot lamp
• LD4 :
Battery low alarm pilot lamp
You can check the function lamps and dry contacts from command menu by selecting simulation
mode.
ITF3 board - Function of jumpers :
• JP21 : At parallel operation disconnect this jumper,at stand alone connect jumper
• JP22 : At parallel operation disconnect this jumper,at stand alone connect jumper
• JP23 : At parallel operation disconnect this jumper,at stand alone connect jumper
• JP24 : At parallel operation disconnect this jumper,at stand alone connect jumper
6.5.7 RS330 Communication Board
This board isolates RS232 signals from host computer to UPS main controller board, and interfaces
dry contact signals to standart connection cable.
RS330 board - Function of connectors:
• CN1 : Power supply connection from IGBT driver board
• CN2 : Interface to comm2 seril port
• CN3 : Connection to main controller board
40
• CN4 : Dry contact inputs from interface board
• CN5 : Host computer or remote panel connection
6.5.8 3PVS2 Voltage Sense Board
On this board bypass input voltage sense transformers and inverter output voltage sense
transformers are located. Neutral is used for measurements.
3PVS2 board - Functions of connectors :
• CN1 : Common neautral connection
• CN2 : Inverter output voltage sense connection (3x220V AC)
• CN3 : Bypass and Mains voltage sense connection (3x220V AC)
• CN4 : Connection to main controller board
6.5.9 PTR3P 3 Phase Transformer Board
Rectifier controller board power supply and sysncronisation sense transformers are located on this
board. Inputs are 3x380 V AC neutral is not used.
PTR3P board - Functions of connectors :
• CN1 : 3X380 volts sense input
• CN2 : Connection to rectifier controller board
6.5.10 P3PANEL LCD Panel Board
LCD PANEL, Mimic lamps, buzzer for alarm sound are located on this board.
P3PANEL board - Functions of connectors :
• CN1 : Connection to main controller board
• CN2 : Connection to SW15 key board
6.6 OTHER FAILURES AND TROUBLE SHOOTING
6.6.1
Real Time Clock Failures
Failure
After restart, RTC clock resets
RTC does not working
A <*> sign seems on time menu
Trouble shooting
Check for lithium battery on main controller board
Check for XT1 XTAL(32 KHZ) on main controllor board
Check for U21 on main controller board
Set up time and date, and update
6.6.2 Parameter Saving Failures
If log events are not recorded well, the memory device U27-93C86(eeprom) maybe defected. At
some cases adjusted parameters such as output voltage,input voltage etc.. maybe changed, re
calibrate the changed parameter, save it again, turn off UPS and turn on again if the last recorded
value is changed, replace U27 by new one. But you must calibrate all parameters again.
41
7. PARALLEL O PER AT ION (optional)
7.1 ntroduction
The PARALLEL connection of PYRAMID -PLUS SYSTEMS allow high security by power redundant
operation.
7.2 Parallel Operation Modes
Parallel operation is in 3 modes:
• SYMETRIC PARALLEL operation
• REDUNDANT parallel operation
• HOT STANDBY operation
CAUTION!!! Do not set the operation modes of the parallel connected UPSs to ON-LINE,
otherwise serious damage may occur.
User can select one of the operation modes according to purpose if parallel control board is
installed on UPS.You can select operation mode from SETTINGS MENU, in this chapter you can
find parallel operation mode informations.
7.2.1 Symetric Parallel Mode
On UPS panel, shortly “PARALLEL MODE” word is used. This mode is useful for increasing power
capacity. Mains power is used as the spare energy supply. In case of an Inverter failure in one of
the UPS’s, the static bypass system of all UPS’s go to bypass together. If everything returns to
normal, than the inverters resume the load together. If current sharing is active, current is shared
50%-50% by two UPS’s. During bypass, the UPS’s also share the load.
If this mode is active, on the LCD panel of one UPS, you will see “PARALLEL MODE/SL”, and on
the LCD panel of the other UPS, you will see “PARALLEL MODE/MS” : (SL means SLAVE, MS
means MASTER)
The inputs of two UPS are connected to mains, outputs of two UPS are connected to each other,
there are two battery groups.
SB1 and SB3 static bypass switches work always together. They turn on/off together. If these static
switches are conducted,than the load is connected to mains directly.
SB2 and SB4 static switches work always together. If these static switchs are conducted,than the
load is connected to inverter. In this position current sharing is active.
If a failure occurs at one of the UPS, bypass system transfer load to by pass.
42
MB1
UPS1
SB1
CB1
SB2
BATT.1
AC/DC -1
CB2
INVERTER 1
MB2
OUTPUT
LINE
UPS2
SB3
CB3
SB4
BATT.2
AC/DC -2
Figure 7-1
CB4
INVERTER 2
Parallel connection
7.2.2 Parallel Redundant Mode
At this mode if one of the UPS fails, the other UPS continues to feed load.
Assume that UPS1 on figure 6-1 is failed, SB1 and SB2 static switches shall turn off and the UPS 1
is isolated from load.
The SB4 static switch of the UPS 2 shall stay in conducted position and it continues to feed the
load.
If UPS 1 is operating after a delay this UPS will join the system.
If two UPSs fail than SB3 static switches shall turn on and load is transferred to bypass
This is a 3 level redundancy UPS1+UPS2,UPS2 ,mains
Current sharing is active in this mode.
7.2.3
Hot Standby Mode
In this mode UPS 1 feeds the load and the UPS 2 waits spare, there is no current, it is in standby
mode but it is ready to work.
If a failure occurs on UPS 1, static switch system shall isolate UPS 1 from load and activate the
UPS 2, this is a very fast response.
Current sharing is not active in this mode.
43
7.3 Parallel Operation Mode Fault Codes
FAULT
DESCRIPTION
A23 MODE FAILURE
SLAVE ups search for the same operating mode with MASTER ups ,if they are
different this message locates on LCD panel.
Change the operation mode of SLAVE ups from SETTINGS MENU.
Don’t forget to press ENTER key for 3 seconds
Turn off the SLAVE ups and turn on again.
A24 P.FAILURE 17
A25 P.FAILURE 18
Parallel Controller Board Failure
Parallel Controller Board Failure
A26 P.FAILURE 19
Parallel Controller Board Failure
A27 P.FAILURE 20
A28 P.FAILURE 21
Parallel Controller Board Failure
Parallel Controller Board Failure
A29 P.TEST MODE
Parallel control board is in test position
A30 P FAILURE 23
Parallel Controller Board Failure
A31 DUBL UPS NR.
The same UPS number is selected for SLAVE ups ,you must give separate ups
number to each ups in parallel system.
Go to SETTINGS MENU and change UPS number.
Don’t forget to press ENTER key for 3 seconds.
Turn off the SLAVE ups and turn on again.
A40 CANT FIND PR
Parallel mode is selected but main controller could not find parallel control board.
Select ONLINE mode from SETTING MENU.
Turn off the ups and turn on again.
A41 P.BAL.FAILURE
Current sharing failed in parallel operation, after a delay sharing will try again
A43 P.SYNC.FAIL
In parallel system SLAVE UPS is not synchronized to MASTER UPS
After a delay SLAVE ups will try to syncron again.
A48 STATIC BYP
In parallel system static bypass switch (S6) is in “ON” position.
7.4 Parallel System Accessories
For parallel operation the following parts need to be installed inside the UPS:
•
•
•
•
•
Parallel control board
Current transformers
Digital connection cable
Analog connection cable
Fully static bypass system
IMPORTANT NOTE: Parallel system installation is much more complex from standalone UPS
installation, it needs qualified service staff.
You have to keep 80 cm distance between two UPS for service purposes. The maximum length of
digital and analog cable is 2 meters.
Add %20 tolerance to cables, fuses and circuit breakers in parallel connection.
At figure 6-2 ,the connection of 2 parallel UPSs and load switch panel is shown.
44
U 1 V1 W 1 N 1
U 1 V1 W 1 N 1
AC INPUT
AC INPUT
UPS1
UPS2
AC OUTPUT
AC OUTPUT
U 2 V2 W2 N 2
U 2 V2 W2 N 2
Figure 7-2 Parallel UPS
Connection
45
46
Figure 7-3-a
POWER CONNECTIONS OF TWO UPS’s FOR PARALLEL OPERATION (10-15-20 kVA)
47
Figure 7-3-a
POWER CONNECTIONS OF TWO UPS’s FOR PARALLEL OPERATION (30 kVA)
48
BATTERY
GROUP
Neutral
Figure 7-3-a
(+)
(-)
AC INPUT
3 PHASE+Neutral
LOAD
U VWN
POWER CONNECTIONS OF TWO UPS’s FOR PARALLEL OPERATION (40-60-80 kVA)
(To be supplied by the customer)
(+) BATTERY
(-) GROUP
49
-
+
BATTERY GROUP
LOAD
U VW N
(To be supplied by
the customer)
-
+
BATTERY
GROUP
Figure 7-3-b POWER CONNECTIONS OF TWO UPS’s FOR PARALLEL OPERATION (100-120-160 -200 kVA)
Neutral
Neutral
AC INPUT
3 PHASE + Neutral
Figure 7-4-a
Switch and Fuse Positions and Signal cable connections
for parallel operation (10-15-20 kVA)
Figure 7-4-b Switch and Fuse Positions and Signal cable
connections for parallel operation (30 kVA)
50
DIGITAL
ANALOG
Figure 7-4-c
Switch and Fuse Positions and Signal cable
connections for parallel operation (40-60 kVA)
DIGITAL
ANALOG
Figure 7-4-d Switch and Fuse Positions and Signal cable
connections for parallel operation (80 kVA)
51
52
Figure 7-4-e Switch and Fuse Positions and Signal cable connections for parallel operation (100-120-160 -200 kVA)
ANALOG
DIGITAL
7.5
UPS Switch on Procedure in Parallel Mode:
With all the switches and fuses (S1,S2, S3, S4 and S5) in “OFF” “0” position and with S6 in
“NORMAL” position.
Turn on the parallel connected UPS’s, UPS1 and UPS2 separately as follows:
1. Make sure that two UPS’s are properly connected for parallel operation in accordance with
the diagrams given in “INSTALLATION PROCEDURES” section.
2. Turn on the S1 switch (inverter input) into “1” position. By turning on S1 you will see the
following messages on the LCD panel,
a. “RECTIFIER START”
b. “INVERTER START”
c. “STATUS NORMAL”
After these messages the UPS will start running and the green INVERTER LED on the
front panel will be turned on.
3. Using the UP-DOW N buttons on the front panel select “SETTINGS MENU” on LCD and
press “ENTER”.
When you see “MODE” display, using “+” and “-“ buttons select either one of the
following operation modes which is suitable for your needs.
4. After selecting one of the modes, press “ENTER” until the beep sound stops.
5. Turn S1 off (inverter input) and few seconds later, turn it on again. Now the inverter is ready
to operate in the selected mode.
Perform the same procedure given above for both UPS’s (UPS1 and UPS2). Make sure
that you select the same mode for both UPS’s. If you select different modes, then a fault
signal will be generated.
After selecting the operation modes for both devices then perform the following
procedure:
6. Turn on the Battery Circuit Breaker S5 (Optional) or insert the battery fuse, to connect the
battery group to the UPS for uninterrupted operation.
7. Turn on S2 switches (static by-pass) of both UPS’s.
8. When you restart UPS’s again, make sure that the CB1 and CB2 switches on the AC
distribution panel are in “OFF” position. Then turn on S4 (output) switches of both inverters.
ATTENTION : VOLTAGE AT THE OUTPUT !!!
9. Before going any further, measure the voltage (using an AC voltmeter) between the
corresponding phase outputs of UPS’s at the CB1 and CB2 contacts on the distribution
panel. Only after you are sure that there is no voltage difference between the corresponding
contacts, turn on CB1 and CB2 on the AC distribution panel.
Now the outputs of the UPS’s are connected in parallel and the parallel system is ready for
use with AC loads.
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7.6
Transfer to Maintenance By-Pass Mode
1) Bring S6 (static by-pass) into “STATIC BYPASS” position of either one of the UPS’s.
2) See that the red coloured by-pass leds on the front panels of both UPS’s are lit. (Static bypass
3)
4)
5)
6)
7)
operation)
Turn on S3 switches (maintenance bypass) of both UPS’s.
Turn off S4 switches (AC output) of both UPS’s.
Turn off S1 switches of both UPS’s.
Turn off S2 switches (AC output) of both UPS’s.
Turn off S5 (optional battery circuit breaker ) or remove battery fuses of both UPS’s.
Now, the UPS’s are completely turned off but the load is supplied by the AC -input via the
Maintenance By-Pass switch.
WARNING!!!
Inside the UPS’s the following points will be on operation:
* By-pass AC input mains terminals
* Maintenance by-pass switch
* UPS’s output terminals
Now your load is completely supplied by the maintenance by-pass supply and the UPS’s are not
operating.
WARNING!!!
During the maintenance or static by-pass the connected loads at the UPS output
are not protected against the mains (by-pass source) failure.
7.7 Transfer from Miantenance By Pass to Inverter Mode
With the S6 switches (static bypass) of the inverters (at least one of them) in “STATIC
BYPASS” position, turn on the parallel connected UPS’s UPS1 and UPS2 as follows:
1. Turn on the S2 switches (static bypass) of both UPS’s.
2. Turn on S4 switches (AC output) of both UPS’s.
3. Turn on S1 switches (inverter input) of both UPS’s.
4. Turn on the Battery Circuit Breakers S5 (optional) or insert the battery fuses of both UPS’s to
connect the battery groups to the UPS’s for uninterrupted operation.
5. When “MAINT SWITCH ON!” message appears on LCD, turn off S3 switches (maintenance
bypass) of both UPS’s.
6. Bring S6 switches (static bypass) of both UPS’s to “NORMAL” position.
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8. REMOT E MON IT ORI NG AND CO NTR OL (o ptional)
PYRAMID-PLUS UPS’s can be provided with boards that are designed as communication interface
with computer systems or remote monitoring panels.
-
The dry contacts interface
The serial link interface
The remote signalling/control panel and its connection interface
8.1 Serial Link Interface
Using serial link interface which is installed in your system, user can get all information about UPS .
All measured parameters, alarms can be monitored. This port is interactive and you may use the
following commands:
•
•
•
•
•
•
•
•
•
•
•
Switch to BYPASS
Switch to INVERTER
SOUND on/off
Adjust UPS time and date
Start SIMULATION mode
Short BATTERY TEST
BATTERY TEST until battery low alarm
CANCEL battery test
Turn off UPS output voltage immediately (SHUTDOWN)
Turn off UPS output voltage after delay (WAITING SHUTDOWN)
Turn off UPS output voltage (SHUTDOWN) and turn on UPS output voltage (WAITING
RESTART)
• CANCEL SHUTDOWN
• RENAME UPS
UPS will give response to these commands if the REMOTE: ENABLE opsion is selected from
SETTINGS MENU .
8.2 Serial Link Interface Cable
The maximum length for RS232 communication cable is 25 meters, cable connector pins are as
follows :
UPS side
9 Tx
7 Gnd
6 Rx
PC side
2 Rx
5 Gnd
3 Tx
For remote panel – UPS connection cable is okay.
SERIAL LINK SETUP
BAUD RATE
STOP BIT
DATABITS
PARITY
2400 baud
1
8 BIT
None
55
8.3 Modem Connection TELESERVICE
UPS can be controlled through a normal telephone line by means of a remote operator connected
through a PC with modem device, who performs a phone call to the UPS connected number. So
the operator can see all parameters and control the UPS (if permitted from SETTINGS MENU).
8.3.1 Hardware Configuration
All needs for modem connection is as follows :
• PC with modem
• WINDOWS 98
• Available UPS control software
• DUMP modem which is connected to UPS
In order to perform this function, a PC with UPS control software and an external or internal modem
device connected to telephone line are needed.
A standard modem device, configured according to DUMP and auto answer modes, will be installed
on the UPS and, once programmed, will following a telephone call of the PC-embedded modem
,connect the UPS to the telephone line.
8.3.2 Function Principle
The remote operator, by means of a PC and a modem device and using the remote connection
function of the control software, calls the UPS through the number to which this is connected.
The dumb modem device, connected to the UPS, will answer the call and convert the data coming
from UPS serial on the telephone line. This way all measures and controls allowed by the RS232
serial port can be carried out.
8.3.3 SMART Modem Programming (PC modem)
The connected modem to PC (smart modem) will be programmed from UPS control software
automaticly.
B0 E1 F1 M1 Q0 V1 X3
BAUD = 2400
PARITY = N
WORDLEN = 8
DIAL = TONE
&A3 &B1 &C1 &D0 &H1 &I0 &K1 &M4
&N0 &R2 &S0 &T5 &Y1
8.3.4 DUMB Modem Programming
The connected modem to UPS can be program from COMMAND MENU ,ENTER :MODEM INIT
automatically.
But the user can programme this modem from a PC by following options.
B0 E1 F1 M1 Q0 V1 X3
BAUD = 2400
PARITY = N
WORDLEN = 8
DIAL = TONE
&A3 &B1 &C1 &D0 &H1 &I0 &K1 &M4
&N0 &R2 &S0 &T5 &Y1
56
8.3.5 DUMB Modem – UPS Connection Cable
The connection cable between dumb modem and UPS is as followed:
UPS
DB9 female
MODEM
DB25 male
6
7
9
3
7
2
8.4 Dry Contact Interface Connection
Some important events can be monitored by this connection for each event a relay is located on
interface board and NC-C-NO contacts are connected terminals.
These are:
•
•
•
•
•
•
LINE FAILURE
BATTERY LOW
LOAD ON BYPASS
BATTERY CB input
BATTERY CB output
EMERGENCY STOP input
Battery Circuit
Breaker Input
Emergency Stop
Line Failure
Relay
Battery Low Relay
or Common Alarm
Relay
By-Pa
Relay
CN3
CN4
8.5 Remote Monitoring Panel
Remote minitoring panel can be used from 400 meters away from UPS. Up to 25 meters there is no
need extra hardware RS232 communication is normal. But if the distance is longer than 25 meters
extra RS485 hardware is needed.
Up to 5 remote monitoring panels can be used in system.
57
9. REPAIR an d M AI NTE NA NCE
You will find all details about repair and maintenance information of UPS in this section.
ATTENTION !!!
• Dangerous of electrical shock, burning and injury.
• There is high voltage on UPS even main line have cut-off.
• You must make safety discharge operation before touching inside of UPS.
• You must isolate that ground end of oscilloscope etc. measure instrument or control
instrument which works with main line voltage, from ground end of main line, before make
any measure on UPS.
• The neutral and ground line values of main line never change on UPS., they reach to output
of UPS with same values.
• During to working on UPS as use your right hand as possible. Do not touch with your other
hand to cage of UPS. Take off your metal items (ring, bracelet, watch etc.)
• High amplitude DC voltage might be cause of electrical shock or burning.
• Only authorized persons should do putting batteries on UPS or their maintenance.
• Do not make short circuit on ends of batteries. Batteries have potential dangerous of
electrical shock or burning.
• Do not make hole on body of battery and do not open them.
• Do not dispose batteries in a fire.
• If a battery is leaking electrolyte or any injury on it, it must dispose when it in sulfuric acid
resists case as obeying the local Environment Protection Rules.
• If the acid touch some part of human body by accident, wash this area with water than
send who reach acid to doctor.
• The batteries must dispose as obeying the local Environment Protection Rules.
58
9.1 Safety Discharge Operation
Before open any cover of UPS the DC bar voltage should arrange to safe level. There is high
voltage on DC bar when line voltage cut-off or UPS has been shutdown. Wait approximate 5
minutes for DC bar capacitor totaly empty.
YOU MUST SEE THE DC BAR VOLTAGE HAS DECREASED TO SAFETY LEVEL (~10Vdc)
BEFORE WILL DO ANYHING ON UPS.
9.2 Scheduled Maintenance
There is no any rotated device in UPS inside except cooler funs so there is no any corrosion
problem in it. If ambient conditions are sufficient like ~24 °C and clean as enough, UPS
maintenance need is minimum level. The optimum performance of UPS might keep with under
protection program.
9.2.1 Routine Controls
* Check user front panel functions.
* Check over temperature positions.
* Check any different on working sound.
* Check air circulation holes and rear side of UPS must 20 cm min. away from wall.
* Notice your observations and make sure obeying the required norms.
9.2.2 Vision Test
The vision test is usefulness to routine control.
* As shutdown UPS make safety discharge operation.
* As took covers of UPS out, look at inside of UPS well.
* Check units of UPS carefully with these suggest.
1-) Check electrolytic cvapacitors for their leaking and swelling.
2-) Check transformers over temperatures or control any mechanical movement on them.
3-) Check cable as skinned and hardening and control slacking cable connections.
4-) Check rigidity of connectors that are used on between boards.
5-) Check electronic boards for any blacken on them (blacken means, over current there
were). Change them if it necessary.
6-) Check batteries that any leaking, swelling, oxidizing events on it and control rigidity of pole
ends of batteries.
7-) Clean up inside of UPS with low pressured air.
8-) Put outer cover of UPS back.
9-) Connect line voltage cable on UPS.
10-) Re-start UPS.
9.3 Storage
1. Check the batteries charge with the manual battery test before storage.
2. Connection’s uninstall operation will be done by the authorized service.
3. During the storage period the batteries should be charged once, per six months.
4. Keep the equipment and the batteries in a dry, cool place.
Best storage temperature for the UPS : Between 0°C and 40°C max.
Best storage temperature for the batteries : Between 10°C and 35°C max.
59
9.4 Batteries Maintenance
The batteries are most important part of UPS. Everything is affiliation on batteries when main line
cut-off. Batteries must check in every 6 months for make sure about their performance.
Factors for battery live getting long:
* Battery live time tied ambient temperature. The batteries live getting shorter if ambient
temperature is higher than 20 °C.
* The charge current and voltage of battery charging must on limits.
* If batteries got any damage when they were transferring to somewhere, these make battery live
short.
* If the main line cut-off very often where UPS located, that makes battery live short because
batteries used more.
Normally batteries have got 4 years live time but performance of battery goes down after 2 years,
and it going to need maintenance.
9.5 Battery Test
Do not forget UPS might have high current in it, if a short circuit happed on UPS and this current
independent from voltage level. UPS do not closed or isolate like normal electric circuits.
- Be careful for do not make any short circuit on UPS with tool, ring, bracelets, watch etc.
- Use isolated tools.
- Use goggles during work on UPS.
- Make sure batteries isolated from UPS and UPS has not connected on grounded.
- Keep batteries in sulfuric acid resist case if they cracked.
- If the acid touch some part of your body by accident, wash well this area with washingsoda or soapy water.
9.5.1 Vision Test
Attention those explanation after UPS shut down.
1-) If same white stain appears on terminal covers, it means terminal cover is clarified. CHANGE
TO THE BATTERY.
2-) Check battery cases about cracking and swelling. If you noticed like that on battery, CHANGE
TO THE BATTERY.
3-) Check terminal connections for their strength Control to aver temperature and corrosion
events.
9.5.2 Test on Place
Normally the buffer voltage can not measure before shutdown UPS. But this voltage should
measure time to time. Notice batteries, which has got smaller than 13,4V and bigger than
13,98V on the buffer charge mode. Change these batteries if it necessary.
9.5.3 Battery Capacity Test
There is a two way for measures this. The measuring impedance or the load test.
1-) Impedance Measuring: Special devices be need for impedance measuring. Also this method
shows rate of new battery’s value and measured value. The measured value should not more
2 times bigger than new battery’s value. If the measured value is bigger than this, that
battery’s live comings end. If the measured value is 4 times or more big than new battery’s
value, that battery immediately must change.
60
2-) Discharge test: This method more common than other. Each battery loads on 0,5 Ohm
resistance on high power (300W) for 30 seconds. 12V 18Ah battery voltage must not
measure less then 9V. If the measured value goes down quickly, this battery must change.
9.6 Battery Changing
Obey rules as below during battery changing. If any new batteries want to add on older than 18month-old system, the new batteries cannot be charged. That’s why new batteries must be control.
If it is necessary new batteries get charge. The buffer voltage of new battery might higher. New
battery’s lifetime is limited on default value’s has.
This operation, change one battery or more, cost is expensive so whole group changing cost is
more appropriate. It is also important for stability of system
9.7 IGBT Output Group
IGBTs are used on output (inverter) group. These transistors have fixed on aluminum cooler and
IGD3P board for drive these transistors. IGBT transistors have a different structure from other
transistors. There is a mosfet on input of the transistor and bipolar transistor on output of the
transistor. That’s why input of the transistor so sensitive for static electric discharge.
Note:Do not remove CN2- CN3- CN4- CN5- CN6– CN7 sockets out before the DC bar totally cutoff which connected with output group. IGBT inputs stocked on air ant it might cause of failure
by incorrect connection.
Do not touch to the gate inputs of IGBT transistor specially.
During the output transistor failure fixing/repairing all the fuses must turn to open circuit (“0”
position), UPS both connections (main line and battery group) must cut-off. Wait approximate 5
minutes for touch to UPS. If you do not wait, the capacitors of DC bar might shock you or UPS
might get injured.
The output transistors fixed on aluminum cooler with M5-M6 screw and each transistor module
includes 1-2 IGBT transistor according to the UPS output power. In general three “2-IGBT
transistors modules” are used.
9.7.1 Output Transistors Controlling / Changing
The DC bar fuse, inverter output cables, snubber capacitors, aluminum bars are take out first.
Make attention for connection styles/shapes while doing that.
Set the measure instrument to diode step. Check both transistors’ emitter-collector resistance on
both block (make touch both ends of the measure instrument to C2E1-E2; C2E1-C1 ends of
block on two ways. At one way you must see " OL” (open circuit) and "0.350V " at another.
Make same operation for the gate ends
See Figure 3
"G1-E1; E2-G2 ". You must see "OL" at both ways.
If you noticed short circuit message or another value, which is different from normal value,
change this failure IGBT with new one.
61
Failure Experiences :
* Only one of IGBT module of output group and at the same time the fuse of DC bar failure.
* Only the fuse of DC bar failure.
* Two IGBT moduleand the fuse of DC bar failure.
Do not forget use silicone between transistor and cooler.
Generously when the output transistor get broken, the fuse of inverter is cut-off which connected
on (+) bar and this fuse type is quick cut-off so it must change with original one.
The temperature of cooler that transistor caused, control by thermic relay if this temperature past
900C the inverter automatically stops with over temperature signal. The cooler funs must be
checked.
The driver board might be injured when IGBT transistor get burned, that’s why driver board must
change when output failure fixing. Even only one IGBT failure noticed, both of them must change
and failure board and IGBT blocks must sent to service quarter.
(Take black jumper to G-E ends of IGBT transistor or make short circuit on them by piece of wire
which going to sent service quarter.)
As a snubber capacitor 3uf 1200V, a capacitor used on each IGBT block. This capacitor duty is
stop to suddenly voltage jumping on the DC bar.
C2E1
E2
C1
Figure 9-1
IGBT inside scheme and outer connection
G1E1
10. ELECTRICAL SCHEMES:
62
E2G2
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77