ABB PCS100 UPS-I User manual

—
2UCD120000E001 I
PCS100 UPS-I
Industrial Uninterruptable Power Supply
User Manual
© Copyright 2022 ABB, All rights reserved.
— PCS100 UPS-I 150 kVA to 3000 kVA

2PCS100 UPS-I User Manual
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ABOUT THIS DOCUMENT
Introduction
Voltage sags, surges and short outages are common events that often cause electric and electronic equipment to
malfunction. When such events occur in critical control operations, they can cause the complete shutdown of a
facility. T
he PCS100 UPS-I is an industrial strength uninterruptible power supply designed to solve these problems. It is a
robust single conversion UPS for industrial or commercial loads. It is used to protect sensitive loads from sags,
surges and outages using Ultracapacitor or battery energy storage.
For a comprehensive overview of publications available for the PCS100 UPS-I, refer to the inside cover of this
publication. Web links and QR code are also included.
The Company
We are an established world force in the design and manufacturing of power electronics and power protection
equipment.
As part of ABB, a world leader in electrical technology, we offer customers application expertise, service, and
support worldwide.
We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and
support.
The quality, accuracy and performance of the Company’s products result from over 100 years’ experience,
combined with a continuous program of innovative design and development to incorporate the latest technology.
Quality Control
The products listed in this catalogue are manufactured in an ISO 9001 accredited facility.
For More Information
Further publications for the PCS100 UPS-I are available for free download from
http://new.abb.com/ups/systems/industrial-ups/pcs100-ups-i
or by scanning this code:
Registration No. 2469
https://new.abb.com/ups/

PCS100 UPS-I User Manual 3
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Document Information
Copyright notice
The information in this manual is subject to change without notice. This manual and parts thereof must not be re-
produced or copied, or disclosed to third parties, nor used for any unauthorized purpose without written permis-
sion from ABB Ltd. The hardware and software described in this manual are provided under a license and may be
used, copied, or disclosed only in accordance with the terms of such license.
Document identification
Ownership: ABB Ltd., Power Conditioning Products
Document number: 2UCD120000E001
Issue date: 3/31/2022
Revision: Rev I
Contact information
Address: ABB Ltd. 111 Main North Road, Napier, New Zealand.
Website: https://new.abb.com/ups
This Document
This manual contains information regarding:
–the general functions of the PCS100 UPS-I
–the component enclosures making up the PCS100 UPS-I
–operation of the PCS100 UPS-I
–the user interface (GDM)
–control and adjustments of the PCS100 UPS-I
Usage
This manual should be used during operation and adjustment of the PCS100 UPS-I. It should be referenced for:
–commissioning the PCS100 UPS-I
–servicing
–operation and adjustment of the PCS100 UPS-I
Who Should Read This Manual?
This manual is intended for:
–installation personnel
–service personnel
–maintenance personnel
–operators
Prerequisites
An installation/repair/operator person working with the PCS100 UPS-I must:
–be trained by ABB and have electrical operational and safety knowledge
have sufficient training to operate in an accidental touch safe service environment
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4PCS100 UPS-I User Manual
Hardware Revision
This User Manual applies to PCS100 UPS-I systems with:
–Ultracapacitor Energy Storage Enclosures Mk2
–Utility Disconnect Enclosure Mk2
Software Revision
This manual applies to PCS100 AVC-40 systems with software revision R2JX.

PCS100 UPS-I User Manual 5
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SAFETY
Safety Instructions
IT
Attenzione: Tensione pericolosa!
Fare riferimento alle istruzioni per l’uso.
Prima di intervenire su questo dispositivo, scollegare e isolare tutte le fonti di
alimentazione.
Attenzione! L’installazione deve essere eseguita esclusivamente da un
installatore qualificato.
LT
Įspėjimas: Pavojinga įtampa!
Žr. naudojimo instrukcijas.
Atjunkite ir laikinai užblokuokite maitinimą prieš dirbdami su šiuo įrenginiu.
Dėmesio! Įrengti gali tik asmuo, turintis elektrotechniko patirties.
AR
! :
 .

! .
BG
Предупреждение: Опасно напрежение!
Вижте инструкциите за работа.
Изключете и блокирайте захранването преди да работите с устройството.
Внимание! Да се монтира само от експерт електротехник.
LV
Brīdinājums: Bīstams spriegums!
Skatiet darba norādījumus.
Pirms sākat darbu ar šo ierīci, atvienojiet un bloķējiet strāvas padevi.
Uzmanību! Uzstādīšanu drīkst veikt tikai persona ar zināšanām par
elektrotehniku.
CS
Varování: Nebezpečné napětí!
Viz návod k obsluze.
Před zahájením prací na tomto zařízení odpojte a uzamkněte napájení.
Pozor! Toto zařízení smí instalovat pouze osoba s elektrotechnickou
odborností.
NL
Waarschuwing: Gevaarlijke spanning!
Raadpleeg de bedieningsinstructies.
Koppel dit apparaat los van de stroomvoorziening voordat u werkzaamheden
uitvoert.
Let op! Installatie mag alleen worden uitgevoerd door een monteur met
elektrotechnische expertise.
DA
Advarsel: Farlig elektrisk spænding!
Se betjeningsvejledningen.
Frakobl enheden, og afbryd strømforsyningen, før du arbejder med denne
enhed.
Giv agt! Installation må kun foretages af personer med elektroteknisk
ekspertise.
NO
Advarsel: Farlig spenning!
Se i bruksanvisningen.
Koble fra og steng av strømmen før du arbeider på denne enheten.
Forsiktig! Montering skal kun utføres av kvalifiserte personer med
elektrokompetanse.
DE
Warnung: Gefährliche Spannung!
Siehe Bedienungsanleitung.
Vor dem Arbeiten Gerät ausschalten und von der Spannungsversorgung
trennen.
Achtung! Installation nur durch elektrotechnische Fachkraft.
PL
Ostrzeżenie: Niebezpieczne napięcie!
Patrz: instrukcja obsługi.
Przed rozpoczęciem wykonywania pracy z tym urządzeniem odłącz i zablokuj
zasilanie.
Uwaga! Montaż może wykonywać wyłącznie osoba posiadająca doświadczenie
elektrotechniczne.
EL
Προειδοποίηση: Επικίνδυνη τάση!
Ανατρέξτε στις οδηγίες λειτουργίας.
Αποσυνδέστε και απομονώστε την παροχή ισχύος προτού ξε κινήσετε τις
εργασίες σε αυτήν τη συσκευή.
Προσοχή! Η εγκατάσταση πρέπει να γίνεται μόνο από αδειούχο ηλεκτρολόγο
εγκαταστάτη.
PT
Aviso: Tensão perigosa!
Consulte as instruções de operação.
Desconecte e desligue a energia elétrica antes de trabalhar nesse dispositivo.
Atenção! A instalação deve ser feita apenas por uma pessoa com
especialidade eletrotécnica.
EN
Warning: Hazardous voltage!
Refer to installation instructions.
Disconnect and lock out power before working on this device.
Attention! Installation by person with electrotechnical expertise only.
RO
Avertisment: Tensiune electrică periculoasă!
Consultați instrucțiunile de utilizare.
Deconectați și închideți sursa de energie înainte de a lucra cu acest
dispozitiv.
Atenție! Instalare
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6PCS100 UPS-I User Manual
ES
Advertencia: ¡Tensión peligrosa!
Consulte las instrucciones de funcionamiento.
Antes de trabajar con este dispositivo, desconecte y bloquee la corriente.
¡Atención! La instalación debe ser realizada únicamente por un técnico
electricista.
RU
Внимание: Опасное электрическое напряжение!
Обратитесь к инструкциям по эксплуатации.
Отключите питание и обесточьте устройство перед началом работ.
Внимание! Установка должна выполняться только специалистом по
электротехническим работам.
ET
Hoiatus: Elektrilöögi oht!
Lisateavet vaadake kasutusjuhendist.
Enne selle seadmega töötamist ühendage lahti ja lukustage toide.
Tähelepanu! Seadet tohib paigaldada ainult elektrotehnilise kogemusega isik.
SK
Výstraha: Nebezpečné napätie!
Pozrite si návod na použitie.
Pred začatím prác na tomto zariadení odpojte a zablokujte napájanie.
Pozor! Inštaláciu smie vykonávať len osoba s odbornými znalosťami v oblasti
elektrotechniky.
FI
Varoitus: Vaarallinen jännite!
Katso käyttöohje.
Katkaise virta ja estä virran kytkeminen lukituksella ennen töiden aloittamista.
Huomio! Asennuksen saa suorittaa vain henkilö, jolla on kokemusta
sähkötekniikasta.
SL
Opozorilo: Nevarna napetost!
Glejte navodila za uporabo.
Pred delom na tej napravi izklopite in zaklenite električno napajanje.
Pozor! Namestitev sme izvesti samo elektrotehnični strokovnjak.
FR
Avertissement: Tension dangereuse!
Consultez les consignes d’utilisation.
Débranchez et verrouillez l’alimentation électrique avant d’entreprendre des
travaux sur cet appareil.
Attention! L’installation doit être effectuée uniquement par une personne
ayant une expertise en électrotechnique.
SV
Varning: Livsfarlig spänning!
Se i bruksanvisningen.
Frånkoppla och blockera anläggning eller en anläggningsdel innan arbeite
utförs.
Obs! Får endast installeras av behörig elektriker.
HR
Upozorenje: Opasan napon!
Pogledajte upute za uporabu.
Odspojite i isključite struju prije rada na ovom uređaju.
Pažnja! Ugradnja je dopuštena samo osobama stručnim u području
elektrotehnike.
TR
Uyarı: Tehlikeli gerilim!
Çalışma talimatlarına bakın.
Bu cihaz üzerinde çalışmadan önce elektriği kesin ve kilitleyin.
Dikkat! Yalnızca elektroteknik uzmanlığa sahip kişiler tarafından kurulabilir.
HU
Figyelmeztetés: Veszélyes feszültség!
Lásd a használati utasítást.
Válassza le és zárja ki az áramellátást, mielőtt a berendezésen dolgozni kezd.
Figyelem! Az üzembe helyezést csak elektrotechnikai szakértelemmel
rendelkező személy végezheti el.
ZH
警告：高压危险!
请参见操作手册
操作本设备前请断开并锁定电源。
注意！安装仅限专业电工人员。

PCS100 UPS-I User Manual 7
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Safety Notices
This manual contains important information regarding the operation of the ABB PCS100 UPS-I Industrial
Uninterruptable Power Supply and provides technical and operational guidance for operators. The following
safety instructions are to be observed.
This manual does not provide sufficient information for safe service of the PCS100 UPS-I. For
such service information refer to appropriate manual.
This manual does not provide sufficient information for safe service of the PCS100 AVC-40. For
such service information refer to appropriate manual.
CAUTION –Trained Operators
All operations on the PCS100 UPS-I must only be carried out by a trained Operator familiar with
the contents of this manual. Hazardous conditions could arise from incorrect adjustment.
DANGER –Hazardous Voltages
An Operator must not open doors or panels marked as containing hazardous voltages. Many
parts in this product, including printed circuit boards operate at lethal voltages. DO NOT
TOUCH components or connections that have voltage present
DANGER –Arc Flash
Shorted terminals can cause arc flash resulting in severe burns, severe eye injury, blindness
or death. Use insulated tools and do not short any terminals. Wear appropriate personal
protective equipment.
DANGER –Stored Charge
Stored charge is present after the device is switched off. When the PCS100 UPS-I is powered
down lethal voltages (+/- 375 Vdc) will remain in the energy storage element and the
complete PCS100 UPS-I should be considered live.
DANGER –Potential Material Hazard of Batteries and Ultracapacitors
Under normal operation batteries and Ultracapacitors do not pose a risk to safety, however
incorrect operating or handing, or physical damage could result in hazardous conditions. See
the links and QR codes in this User Manual to the appropriate Material Safety Data Sheets.
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8PCS100 UPS-I User Manual
DANGER –Protective Covers
Normal operation of this product requires any protective covers to be in place and doors secured
closed.
DANGER –Personal Protection Equipment
Ensure safety glasses are worn while working if any part of the unit could be energized.
Ensure appropriate safety footwear is worn if inserting or removing modules or components
from the product.

PCS100 UPS-I User Manual 9
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Contents
About This Document.........................................................................................................................................................2
Introduction.............................................................................................................................................................................................................. 2
The Company............................................................................................................................................................................................................ 2
Quality Control ......................................................................................................................................................................................................... 2
For More Information ............................................................................................................................................................................................. 2
Document Information........................................................................................................................................................................................... 3
This Document ......................................................................................................................................................................................................... 3
Usage.......................................................................................................................................................................................................................... 3
Who Should Read This Manual?............................................................................................................................................................................ 3
Prerequisites............................................................................................................................................................................................................. 3
Hardware Revision................................................................................................................................................................................................... 4
Software Revision.................................................................................................................................................................................................... 4
Safety ............................................................................................................................................................................5
Safety Instructions.................................................................................................................................................................................................. 5
Safety Notices ...........................................................................................................................................................................................................7
1Overview .................................................................................................................................................................... 13
1.1. User Benefits.....................................................................................................................................................................................................13
1.2. Features.............................................................................................................................................................................................................13
1.3. PCS100 UPS-I Advantages Compared to Alternative Solutions.............................................................................................................13
1.4. Applications and Industries ......................................................................................................................................................................... 14
1.5. PCS100 Power Protection Portfolio............................................................................................................................................................ 14
2Functional Description............................................................................................................................................. 15
2.1 How it works..................................................................................................................................................................................................15
2.2 Single Line Diagram.....................................................................................................................................................................................15
2.3 Operation...................................................................................................................................................................................................... 16
2.3.1 Utility Voltage within Limits ................................................................................................................................................................................... 16
2.3.2 Utility Disturbance Occurs .......................................................................................................................................................................................17
2.3.3 Utility Voltage Returns ..............................................................................................................................................................................................17
2.3.4 Voltage Operating Range ........................................................................................................................................................................................ 18
2.3.5 Fail-Safe Bypass Operation..................................................................................................................................................................................... 18
2.4 Typical Applications.................................................................................................................................................................................... 19
3Model Definition .......................................................................................................................................................20
3.1 Type Code .....................................................................................................................................................................................................20
3.1.1 Rated Voltage.............................................................................................................................................................................................................20
3.1.2 Rated Frequency........................................................................................................................................................................................................20
3.1.3 Number of Inverter Modules ...................................................................................................................................................................................20
3.1.4 Termination Side .......................................................................................................................................................................................................20
3.1.5 Energy Storage ..........................................................................................................................................................................................................20
3.1.6 Options........................................................................................................................................................................................................................ 21
3.2 Rating label....................................................................................................................................................................................................21
3.3 PCS100 UPS-I Model Range....................................................................................................................................................................... 22
4Technical Specification ............................................................................................................................................25
4.1 Utility –Input................................................................................................................................................................................................ 25
4.2 Load –Output .............................................................................................................................................................................................. 26
4.3 Inverter Supply............................................................................................................................................................................................. 26
4.4 Fail-Safe Bypass........................................................................................................................................................................................... 27
4.5 Coupling Transformer................................................................................................................................................................................ 27
4.6 Energy Storage - Ultracapacitors ............................................................................................................................................................ 27
4.7 Energy Storage - Batteries........................................................................................................................................................................ 28
4.8 Event Recording........................................................................................................................................................................................... 28
4.9 Environmental.............................................................................................................................................................................................. 28
4.10 Enclosure....................................................................................................................................................................................................... 29
4.11 User Interface............................................................................................................................................................................................... 29
4.12 Serial Comms ............................................................................................................................................................................................... 29
4.13 Standards and Certifications ................................................................................................................................................................... 29
5Subassemblies ..........................................................................................................................................................30
5.1 Utility Disconnect.........................................................................................................................................................................................31
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10 PCS100 UPS-I User Manual
5.1.1 900 A Utility Disconnect.......................................................................................................................................................................................... 31
5.1.2 2200 A and 4200 A Utility Disconnect ................................................................................................................................................................... 32
5.1.3 Coupling Transformer Enclosure ...........................................................................................................................................................................33
5.1.4 Coupling Transformer .............................................................................................................................................................................................. 33
5.1.5 Float Charger .............................................................................................................................................................................................................34
5.1.6 Inverter Enclosure .....................................................................................................................................................................................................34
5.1.7 PCS100 Inverter .........................................................................................................................................................................................................35
5.1.8 Auxiliary Master Module...........................................................................................................................................................................................36
5.1.9 Auxiliary Slave Module ..............................................................................................................................................................................................36
5.1.10 Fail-Safe Bypass.........................................................................................................................................................................................................36
5.1.11 Intergrated Fail-Safe Bypass...................................................................................................................................................................................36
5.1.12 Optional Fail-Safe Bypass........................................................................................................................................................................................36
6Energy Storage..........................................................................................................................................................38
6.1 Ultracapacitor Energy Storage.................................................................................................................................................................38
6.1.1 Utracapacitor Monitor Board..................................................................................................................................................................................40
6.1.2 Ultracapacitor Energy Storage User Interface ....................................................................................................................................................40
6.1.2.1 Status Lamps.............................................................................................................................................................................................. 41
6.1.2.2 Mimic Panel.................................................................................................................................................................................................42
6.1.2.3 Status LEDs.................................................................................................................................................................................................43
6.1.3 Ultracapacitor Energy Storage Autonomy Time.................................................................................................................................................44
6.1.4 Calculation of Autonomy Time ...............................................................................................................................................................................46
6.2 Battery Energy Storage..............................................................................................................................................................................48
6.2.1 Models without Batteries ........................................................................................................................................................................................49
6.2.2 Calculation of Autonomy Period at Specific Load Levels..................................................................................................................................49
7User Interface............................................................................................................................................................50
7.1 Graphic Display Module .............................................................................................................................................................................50
7.1.1 Navigation Panel........................................................................................................................................................................................................52
7.1.2 Status Page ................................................................................................................................................................................................................53
7.1.3 Status Bar ...................................................................................................................................................................................................................54
7.1.4 Event Log Page .......................................................................................................................................................................................................... 57
7.1.4.1 Interpreting the Event Log ...................................................................................................................................................................... 57
7.1.4.2 Additional Event Information..................................................................................................................................................................59
7.1.5 Product Page..............................................................................................................................................................................................................60
7.1.6 Menu Page .................................................................................................................................................................................................................. 61
7.1.7 Summary Page ........................................................................................................................................................................................................... 61
7.2 Utility Disconnect Status LEDs................................................................................................................................................................. 62
7.3 PCS100 Inverter Display Boards...............................................................................................................................................................64
8Operating PCS100 UPS-I ..........................................................................................................................................66
8.1 Starting and Stopping PCS100 UPS-I......................................................................................................................................................66
8.1.1 GDM Control...............................................................................................................................................................................................................66
8.1.2 Remote Control..........................................................................................................................................................................................................68
8.1.3 Start/Stop Configuration........................................................................................................................................................................................68
9advanced functional descriptions ..........................................................................................................................69
9.1 Voltage Event Detection............................................................................................................................................................................69
9.1.1 RMS detection............................................................................................................................................................................................................70
9.1.2 Transient detection ..................................................................................................................................................................................................70
9.1.3 Frequency detection..................................................................................................................................................................................................71
9.2 Transfer Description....................................................................................................................................................................................71
9.3 Redundancy .................................................................................................................................................................................................. 72
9.4 Energy Storage Description...................................................................................................................................................................... 73
9.4.1 PCS100 Inverter fast charging ................................................................................................................................................................................ 73
9.4.2 Float Charger ............................................................................................................................................................................................................. 73
9.5 Generator Walk-In........................................................................................................................................................................................ 74
9.6 Fan Control Service..................................................................................................................................................................................... 75
9.7 Neutral Current............................................................................................................................................................................................ 76
10 Parameters ................................................................................................................................................................ 77
10.1 Parameter Setting (Menu Page)................................................................................................................................................................77
10.1.1 Menu Navigation ....................................................................................................................................................................................................... 77
10.1.2 Parameter Access Control .......................................................................................................................................................................................78
10.1.2.1 Operator menu...........................................................................................................................................................................................78
10.1.2.2 Tech menu...................................................................................................................................................................................................78
10.2 Parameter Index .......................................................................................................................................................................................... 79
10.3 Parameter Listing........................................................................................................................................................................................80
10.3.1 Menu 000 General .....................................................................................................................................................................................................80
10.3.2 Menu 000 Electrical Settings ..................................................................................................................................................................................82
10.3.3 Menu 200 Name Settings ........................................................................................................................................................................................84
10.3.4 Menu 300 Product Revision.....................................................................................................................................................................................85
10.3.5 Menu 400 GDM Services ..........................................................................................................................................................................................86
10.3.6 Menu 500 UPS Settings............................................................................................................................................................................................87
10.3.7 Menu 600 Tests .........................................................................................................................................................................................................90
10.3.8 Menu 700 Charger Settings.....................................................................................................................................................................................92
10.3.9 Menu 800 Status-Currents ......................................................................................................................................................................................93
10.3.10 Menu 900 Commissioning.......................................................................................................................................................................................94
10.3.11 Menu GDM A00 Display ............................................................................................................................................................................................95
10.3.12 Menu GDM B00 Network Settings .........................................................................................................................................................................96

PCS100 UPS-I User Manual 11
10.3.13 Menu GDM C00 Network Status.............................................................................................................................................................................97
10.3.14 Menu GDM D00 Product Revision ..........................................................................................................................................................................97
11 Event Codes and descriptions.................................................................................................................................98
12 Remote Monitoring................................................................................................................................................. 114
12.1 Cybersecurity ..............................................................................................................................................................................................115
12.1.1 Cybersecurity Disclaimer ........................................................................................................................................................................................115
12.1.2 List of User/System accounts in ABB delivery ...................................................................................................................................................115
12.2 Remote Web Pages ....................................................................................................................................................................................115
12.2.1 Connecting the Network Connection.................................................................................................................................................................. 116
12.2.2 Configuring the Network Connection..................................................................................................................................................................117
12.2.3 Connecting to Remote Web Pages .......................................................................................................................................................................117
12.2.4 Viewing and Downloading Event Log...................................................................................................................................................................117
12.2.5 Service Page ............................................................................................................................................................................................................. 118
12.2.5.1 Download Service Information. ............................................................................................................................................................ 118
12.2.5.2 Update the Product Firmware .............................................................................................................................................................. 118
12.2.5.3 Make a change to an internal parameter............................................................................................................................................ 118
12.3 Modbus TCP ................................................................................................................................................................................................119
12.3.2 Supported Functions.............................................................................................................................................................................................. 119
12.3.3 Performance............................................................................................................................................................................................................. 119
12.3.4 Modbus TCP User Parameters.............................................................................................................................................................................. 119
12.3.5 Modbus TCP Error Codes....................................................................................................................................................................................... 122
13 Wiring....................................................................................................................................................................... 123
13.1 Power Connections....................................................................................................................................................................................123
13.1.1 900 A Utility Disconnect ........................................................................................................................................................................................ 123
13.1.2 2200 A and 4200 A Utility Disconnect ................................................................................................................................................................. 123
13.2 Control Connections................................................................................................................................................................................. 124
13.2.1 Digital Inputs and Outputs.................................................................................................................................................................................... 124
13.2.2 Emergency Power Off (EPO) ................................................................................................................................................................................. 125
13.2.3 Relay Outputs........................................................................................................................................................................................................... 125
14 Maintenance ............................................................................................................................................................126
14.1 Maintenance Schedule ............................................................................................................................................................................. 126
14.2 Repairs......................................................................................................................................................................................................... 128
15 Dimensions and Layouts........................................................................................................................................ 129
15.1 Dimensions and Weights......................................................................................................................................................................... 129
15.2 Individual Enclosures –Plan View .......................................................................................................................................................... 130
15.3 Individual Enclosures –Elevations......................................................................................................................................................... 130
15.4 Clearances....................................................................................................................................................................................................131
15.5 Layout Plans ................................................................................................................................................................................................131
16 Protection Requirements....................................................................................................................................... 132
16.1 Input Circuit Protection ............................................................................................................................................................................132
16.2 Short Circuit Protection............................................................................................................................................................................132
16.3 Input Overload Protection –Utility Disconnect...................................................................................................................................132
16.4 Arc Fault Protection...................................................................................................................................................................................132
16.4.1 Arc Fault and Standards......................................................................................................................................................................................... 132
16.4.2 Arc Fault Protection Recommendation............................................................................................................................................................... 133
16.4.2.1 MCCBs........................................................................................................................................................................................................ 133
16.4.2.2 ACBs ........................................................................................................................................................................................................... 133
16.4.2.3 Fuses .......................................................................................................................................................................................................... 133
16.5 Personal protective equipment...............................................................................................................................................................133
17 Installation Requirements .....................................................................................................................................134
17.1 Maintenance Bypass................................................................................................................................................................................. 134
17.2 Floor Requirements .................................................................................................................................................................................. 134
17.3 Electromagnetic Compatibility (EMC).................................................................................................................................................. 134
17.4 Location....................................................................................................................................................................................................... 134
17.5 Phase Rotation........................................................................................................................................................................................... 134
17.6 Power Systems .......................................................................................................................................................................................... 134
17.7 Harmonics................................................................................................................................................................................................... 134
17.8 Load Imbalance.......................................................................................................................................................................................... 135
17.9 Supply transformer................................................................................................................................................................................... 135
18 Service and technical support ............................................................................................................................... 136
ABB Power Conditioning provide global service and support of installation and commissioning of PCS100 products ............. 136
18.1 Comprehensive Global Services Portfolio............................................................................................................................................ 136
18.2 Custom Tailored Service Contracts....................................................................................................................................................... 136
18.3 Life Cycle Management............................................................................................................................................................................ 136
18.4 Training ....................................................................................................................................................................................................... 136
18.5 Engineering And Technical Support...................................................................................................................................................... 136
19 Appendices ..............................................................................................................................................................138
19.1 General Disclaimer .................................................................................................................................................................................... 138

12 PCS100 UPS-I User Manual
19.2 Recycling Information .............................................................................................................................................................................. 138
19.3 Waste Electrical and Electronic Equipment Information (WEEE) ................................................................................................... 138
19.4 Glossary....................................................................................................................................................................................................... 138
19.5 Open-Source Software............................................................................................................................................................................. 139
19.6 Detailed Single-Line Diagram.................................................................................................................................................................140
19.7 Torque settings and Bolt order...............................................................................................................................................................141
20 Appendices ..............................................................................................................................................................142

PCS100 UPS-I User Manual 13
—
1OVERVIEW
The ABB PCS100 UPS-I is a high performance high efficiency UPS system that ensures protection from power
quality events, enabling continuous power supply to modern industrial processes.
To supply continuous power during utility events the PCS100 UPS-I uses a modular energy storage and inverter
system.
The energy storage is either batteries or Ultracapacitors with the choice of technology dependent on the
autonomy required.
Battery systems can deliver autonomy up to several minutes.
Ultracapacitors provide seconds of autonomy (ride through time) for short power quality events, which are the
most common problems encountered.
Ultracapacitors have extremely high power density and long lifetime resulting in a very compact and low
maintenance solution.
Harsh electrical environments are often found in modern industry. The PCS100 UPS-I uses a robust high speed
power electronic disconnect switch to disconnect the utility from the load.
The modular inverter construction and fail-safe electromechanical bypass provides the highest system
availability.
Coupled with the small footprint and easy serviceability, this low maintenance, high efficiency industrial UPS is
the solution for all power protection applications.
1.1. User Benefits
–Robust fail-safe modular industrial design
–Long lifetime energy storage
–Small footprint
–Highest efficiency and availability
–Low maintenance requirements
–Easy serviceability
1.2. Features
–Very high efficiency (99% typical)
–Designed specifically for industrial loads (motors, drives, transformers, production tools)
–Modular design providing high reliability and typically 30 minutes MTTR (mean time to repair)
–Very high fault current capacity
–Advanced Ultracapacitor or high discharge rate battery storage
–Generator walk-in algorithm for a controlled transfer of the load to backup generators
–Ratings from 150 kVA to 3000 kVA and voltages 208 Vac to 480 Vac
1.3. PCS100 UPS-I Advantages Compared to Alternative Solutions
–Robust with high availability
oDesigned for harsh electrical environments
oModular design
–Lowest cost of ownership
oHighest efficiency
oLong lifetime energy storage
–Small footprint
oUltracapacitor or battery storage options

14 PCS100 UPS-I User Manual
1.4. Applications and Industries
ABB’s PCS100 UPS-I is the ideal solution for protecting loads in factories and manufacturing plants across a wide
range of industries including:
–IT
–Commerce
–Semiconductor
–Automotive
–Pharmaceutical
–Chemical
–Textile
For example, the PCS100 UPS-I is used to protect:
–Data center HVAC and servers
–Semiconductor fabrication, test and assembly lines
–Machining centers, CNC machines
–Printing machines
–Carbon fiber manufacturing
–High-speed packaging lines
–Plastic film manufacturing
1.5. PCS100 Power Protection Portfolio
The PCS100 UPS-I is part of the PCS100 Power Protection portfolio, as shown below. Each product is tailored to
address specific power quality problems:
PCS100 AVC
Active Voltage Conditioner
PCS100 UPS-I
Industrial UPS
PCS100 RPC
Reactive Power Conditioner
Utility sag and surge correction
Load voltage regulation
Utility deep sag and surge correction
Utility outage protection
Load created sag correction
Power Factor correction
Harmonic mitigation
Unbalance correction
Table 1-1: PCS100 Power Protection portfolio

PCS100 UPS-I User Manual 15
—
2FUNCTIONAL DESCRIPTION
2.1 How it works
When the utility voltage is normal, the load is supported directly by the utility.
When a sag, surge or outage occurs, the PCS100 UPS-I immediately transfers the load onto its inverter. Power is
provided by battery or Ultracapacitor energy storage.
Batteries are typically used to bridge start-up time for generator backup systems where critical applications may
be subject to longer supply outages.
Ultracapacitors are ideal for protecting the load from sags and short-term outages or to bridge the switching
time to another feeder.
Power supply before
PCS100 UPS-I
Power Quality Event
Occurs
Power supply after
PCS100 UPS-I
Power Quality Event
Corrected
Figure 2-1: PCS100 UPS-I concept
2.2 Single Line Diagram
The ABB PCS100 UPS-I is a robust single conversion UPS providing continuous current flow to the load during
transfer due to the revolutionary high speed Utility Disconnect and fast PCS100 Inverter technology. The modular
inverter construction and robust Fail-Safe Bypass provides the highest efficiency and system availability. The
single conversion design with Coupling Transformer enables simple, low footprint construction with wide range
of operation voltages, galvanic isolation of DC Energy Storage system and robustness for industrial loads.

16 PCS100 UPS-I User Manual
3-Phase
Utility
Supply
Maintenance Bypass
3-Phase
Protected
Load
Coupling
Transformer
Inverter
Circuit
Breaker
DC
Circuit
Breaker
PCS100 UPS-I
Fail-Safe Bypass
(optional)
Utility Voltage PCS100 UPS-I
supplied voltage Output Voltage
Utility
Disconnect
Input
Circuit
Breaker
Energy
storage
Batteries
or
Ultracapacitors
Figure 2-2: PCS100 UPS-I Single line diagram
2.3 Operation
The following diagrams show how the PCS100 UPS-I behaves when a utility disturbance occurs, and what
happens when the Fail-Safe Bypass is operating.
Note: The following diagrams show a Fail-Safe Bypass. In some PCS100 UPS-I models the Fail-Safe
Bypass is integrated and for other models it is optional.
2.3.1 Utility Voltage within Limits
The power to the load is supplied from the utility (Online mode). Inverters are idling and maintain synchronization
with the utility voltage to allow instant operation in the case of a utility disturbance. A Float Charger (not shown)
maintains the state of charge of the battery or Ultracapacitor storage.
Energy Storage
Batteries
or
Ultracapacitors
Utility Disconnect
SCRs ON
Inverter
OFF
Fail-Safe Bypass
OPEN
Utility
Load
PCS100 UPS-I Voltage
Utility Voltage
Coupling
Transformer
Output Voltage
Legend
Energy Flow
Utility Voltage
PCS100 UPS-I Voltage
Figure 2-3: PCS100 UPS-I energy flow in case of utility supply within limits

PCS100 UPS-I User Manual 17
2.3.2 Utility Disturbance Occurs
When the utility voltage deviates from user defined limits, due to voltage sags, surges, under-voltages, over-
voltages or outage, the PCS100 UPS-I inverters begin supplying power to the load (Discharge mode). At the same
time the utility is disconnected, isolating the PCS100 UPS-I output and load from the utility. ABB’s own inverter
commutation technique is used to ensure the Utility Disconnect SCR’s are commutated off as fast as possible,
minimizing any disturbance to the load.
Legend
Energy Flow
Utility Voltage
PCS100 UPS-I Voltage
Utility Disconnect
SCRs OFF
Inverter
ON
Fail-Safe Bypass
OPEN
Utility
Loa
d
Coupling
Transformer
Utility Voltage
PCS100 UPS-I Voltage
Output
Voltage
Energy Storage
Batteries
or
Ultracapacitors
Figure 2-4: PCS100 UPS-I energy flow in case of utility supply disturbance
2.3.3 Utility Voltage Returns
When the voltage returns within user defined limits the PCS100 UPS-I synchronizes with the utility voltage then
closes the Utility Disconnect. If required the PCS100 UPS-I can softly transfer the load from the inverter to the
utility or generator using the generator walk-in function. Once the load is transferred, power to the load is again
supplied by the utility. The PCS100 UPS-I energy storage is then rapidly recharged by the inverters.
Legend
Energy Flow
Utility Voltage
PCS100 UPS-I Voltage
Utility Disconnect
SCRs ON
Inverter
ON
Fail-Safe Bypass
OPEN
Utility
PCS100 UPS-I Voltage
Utility Voltage
Coupling
Transformer
Load Output Voltage
Energy Storage
Batteries
or
Ultracapacitors
Figure 2-5: PCS100 UPS-I energy flow in case of charging
For detailed information on Energy Storage charging refer to section 9.4.

18 PCS100 UPS-I User Manual
2.3.4 Voltage Operating Range
Figure 2-6 shows typical voltage operating range with Ultracapacitor Energy Storage (1.0 Power Factor when
new). For exact autonomy time at different load levels refer to the graph in section 6.1.3 which also includes aging
impact on Ultracapacitor Energy Storage.
0%
20%
40%
60%
80%
100%
120%
140%
0 1 2 3 4 5 6 7 8
PCS100 UPS-I On Line
PCS100 UPS-I Discharging
PCS100 UPS-I Discharging
100%
Load
75%
Load 50% Load
Utility Voltage
Typical Ride Through Time (seconds)
Adjustable
Surge Treshold
Adjustable
Sag Treshold
Figure 2-6: PCS100 UPS-I voltage operating range example
For detailed information on voltage detection and transfer performance refer to section 9.
2.3.5 Fail-Safe Bypass Operation
In an expected or unexpected PCS100 UPS-I shutdown, load current will be transferred to the Fail-Safe Bypass
(where fitted). This provides an additional level of security by placing a mechanical contact in parallel with the
Utility Disconnect.
Legend
Energy Flow
Utility Voltage
PCS100 UPS-I Voltage
Utility Disconnect
SCRs ON
Inverter
OFF
Fail-Safe Bypass
CLOSED
Utility
Load
PCS100 UPS-I Voltage
Utility Voltage
Coupling
Transformer
Output Voltage
Energy Storage
Batteries
or
Ultracapacitors
Figure 2-7: PCS100 UPS-I energy flow in case of bypass operation

PCS100 UPS-I User Manual 19
2.4 Typical Applications
The PCS100 UPS-I may be applied to provide protection in low voltage systems. The following diagrams show
typical applications providing protection to an entire factory and sensitive electronic loads within that factory.
CAUTION
The PCS100 UPS-I is designed for use in TN power systems. For any other type of power
distribution system please refer to ABB document 2UCD120000E017, or contact the ABB factory for
information. See Figure 19-1 for typical connection details.
Figure 2-8 shows a typical PCS100 UPS-I installation where the PCS100 UPS-I is used to protect the complete
factory. The PCS100 UPS-I is installed between the incoming breaker and the factory LV distribution system.
Protected
Loads
PCS100 UPS-I Low Voltage
Switchgear
Distribution
Transformer
Main
Circuit
Breaker
Utility
Supply
Figure 2-8: PCS100 UPS-I installation protecting the complete factory
Figure 2-9 shows typical PCS100 UPS-I installation where the PCS100 UPS-I is used to protect a specific load. The
PCS100 UPS-I is installed within the LV distribution system, i.e. on the feeder supplying the specific load to be
protected.
Low Voltage
Switchgear
Distribution
Transformer
Main
Circuit
Breaker
Utility
Supply Protected Load
PCS100 UPS-I
Figure 2-9: PCS100 UPS-I installation protecting a specific load
ABB recommends that a maintenance bypass (not supplied with the PCS100 UPS-I) is fitted. The maintenance
bypass allows maintenance to be performed on the PCS100 UPS-I without disruption to the load.
Distribution
Transformer
Main
Circuit
Breaker
Utility
Supply Protected
Load
PCS100 UPS-I
Maintenance Bypass
Figure 2-10: PCS100 UPS-I with maintenance bypass

20 PCS100 UPS-I User Manual
—
3MODEL DEFINITION
3.1 Type Code
The PCS100 UPS-I type code is
given in the product tables. The
type code is a unique code for
the specific model PCS100 UPS-I
and specifies all the
components that are used to
construct the model. From the
base code given in the product
tables options can be added to
the type code. These options
are called plus (+) codes.
The following diagram outlines
the structure of the type code:
PCS100-12 480/60 10 - - - R-EB05 FS2
+
PCS100 UPS-I
Rated Voltage & Rate Frequency
Number of Inverter modules
Termination Side (Front View)
Energy storage type & quantity
Options (plus codes)
Figure 3-1: PCS100 UPS-I type code
3.1.1 Rated Voltage
This is the rated maximum voltage of the PCS100 UPS-I. Options are 480V, 400V and 220V. Other operating
voltages (i.e. 380V) are achieved by software settings.
3.1.2 Rated Frequency
Options are 50 Hz and 60 Hz. 400 V models are only available at 50 Hz.
3.1.3 Number of Inverter Modules
The number of inverter modules needed depends on the load kVA. Each inverter module can deliver 150 kVA at the
rated voltage. Table 3-2 provides the allowable number of modules that can be employed.
Note: Operation at lower than the rated voltage results in less kVA per module. Consult the rating tables in the
UPS-I Technical Catalogue (document number 2UCD120000E002) for more information.
3.1.4 Termination Side
The location of the power terminals when viewed from the front of the PCS100 UPS-I. For 900 A and lower current
systems the termination is always on the Left (L). For > 900A systems the termination is always on the Right (R).
3.1.5 Energy Storage
Energy storage can be Ultracapacitors (EC) or Batteries (EB). The following number indicates the quantity of
strings of energy storage. For Ultracapacitors one string provides 300 kW of backup power. For batteries one
string provides 240 kW of backup power. The number of strings required depends on the load kW rating.