ABB MegaFlex UL S1 Series User manual

—
UPS USER MANUAL
MegaFlex
1000 to 1600 kW UL S1
—
MegaFlex
1000 to 1600 kW UL S1

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
Model
MegaFlex 1000 – 1100 – 1200 – 1500 – 1600 kW UL S1
Issued by
ABB Product Document Department – Quartino - CH
Approved by
ABB R&D Department – Riazzino - CH
Date of issue
07/15/2020
File name
ABB_UPS_USM_MGF_SUL_1M0_1M60_1US_REV-A
Revision
REV-A
Document number 4NWD005509
Article number
4NWP106809R0001
Up
-dating
Revision
Concern Date
Copyright © 2020 by ABB Power Protection SA
All rights reserved.
The information contained in this publication is intended solely for the purposes indicated.
The present publication and any other documentation supplied with the UPS system is not to be reproduced,
either in part or in its entirety, without the prior written consent of ABB.
The illustrations and plans describing the equipment are intended as general reference only and are not
necessarily complete in every detail.
The content of this publication may be subject to modification without prior notice.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
Dear Customer,
We thank you for selecting our products and are pleased
to count you amongst our very valued customers at ABB.
We trust that the use of the MegaFlex 1000 to 1600
Uninterruptible Power Supply System, developed and
produced to the highest standards of quality, will give
you complete satisfaction.
Please read carefully the User Manual
, which contains all
the necessary information and describes all you need to
know about the use of the UPS.
Thank you for choosing ABB!
Start-up and commissioning!
An ABB Global Services Field Engineer must perform start-up and commissioning of the UPS.
Please contact ABB Service Center at least two weeks prior to schedule start-
up and
commissioning at 1-800-292-3739.
Distributed in the USA by
ABB Service Center
ABB Power Protection SA
Via Luserte Sud 9
CH – 6572 Quartino
Switzerland
ABB
Smart Power - Power Protection
5900 Eastport Blvd.
Richmond, VA 23231-4453
Phone: [phone]
http://new.abb.com/ups
To get important information on all
equipment warranties, please
contact the ABB Service Center or
request service follow-
up or by
scanning the QR code.
http://new.abb.com/ups/service
-ups

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
Preface
Congratulations on your choice of a MegaFlex 1000 to 1600 Uninterruptible Power Supply (UPS).
It will keep you away from any trouble due to
unexpected power problems.
This User
Manual
describes the function of the UPS module, the purpose and location of the switches, the
meaning of the system events related to the front panel indication and provides procedures for starting and
stopping the equipment.
Please refer to the accompanying
Installation Guide
, which describes how to prepare the installation site, and
it provides weight, dimensions and procedures for moving, installing and connecting the UPS.
While every care has been taken to ensure the completeness and accuracy of this manua
l, ABB
assumes no
responsibility or liability for any losses or damages resulting from the use of the information contained in this
document.
Note!
MegaFlex 1000 to 1600 is a Category C3 UPS Product (according to IEC 62040-2).
This is a
product for commercial and industrial application in the second environment −
installation restrictions or additional measures may be needed to prevent disturbances.
We recommend that this manual be kept next to the UPS for future references.
If any problems are encountered with the procedures contained in this manual, please contact your ABB
Service Center before you proceed.
This document shall not be copied or reproduced without the permission of
ABB.
Due to technical improvements, some of the information contained in this manual may be changed without
notice.
Safety instructions
Carefully read the safety instructions contained on the following page before the installation, start
-
up and
maintenance of the UPS, options and
Battery.
Pay attention to the rectangular boxes included in the text:
They contain important information and w
arning concerning electrical connections and personnel safety.
Parallel System secured with “RPA – Redundant Parallel Architecture”
When included in the text, this symbol refers to operation needed only for the RPA
Parallel System.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
Table of content Page
1Safety rules..................................................................................................................................................................6
1.1 Safety symbols and warnings............................................................................................................................................................................ 8
1.2 Cyber security ....................................................................................................................................................................................................... 9
2Layout ........................................................................................................................................................................10
2.1 Layout MegaFlex 1000 to 1600 ....................................................................................................................................................................... 10
3Introduction .............................................................................................................................................................. 11
4Description ................................................................................................................................................................ 12
4.1 Block diagram and main elements ..................................................................................................................................................................13
4.2 Operation modes ............................................................................................................................................................................................... 14
4.2.1 Normal VFI Operation Mode (Voltage Frequency Independent) ..............................................................................................................................14
4.2.2 eBoost™ Operation Mode (option) ................................................................................................................................................................................14
4.2.3 Utility Failure Operation ...................................................................................................................................................................................................15
4.2.4 Utility Recovery Operation ...............................................................................................................................................................................................15
4.2.5 Automatic Bypass ..............................................................................................................................................................................................................16
4.3 RPA Parallel System operation .........................................................................................................................................................................17
4.3.1 Introduction to the RPA Parallel System........................................................................................................................................................................17
4.3.2 Features of RPA Parallel System .....................................................................................................................................................................................18
4.3.3 System control....................................................................................................................................................................................................................18
4.3.4 Synchronization..................................................................................................................................................................................................................18
4.3.5 Load sharing........................................................................................................................................................................................................................18
4.4 Service and technical support ......................................................................................................................................................................... 19
4.5 Warranty............................................................................................................................................................................................................... 19
4.6 Recycling instructions.......................................................................................................................................................................................20
5Control Panel ............................................................................................................................................................. 21
5.1 Control Panel........................................................................................................................................................................................................21
6LCD screen ................................................................................................................................................................. 22
6.1 Home screen........................................................................................................................................................................................................ 22
6.1.1 Description of the selection keys....................................................................................................................................................................................23
6.1.2 Description of the signaling LEDs ................................................................................................................................................................................. 24
6.2 Measures .............................................................................................................................................................................................................. 27
6.3 Events ....................................................................................................................................................................................................................31
6.3.1 Events (alarms and messages)....................................................................................................................................................................................... 33
6.3.2 Alarms list ........................................................................................................................................................................................................................... 33
6.3.3 Messages list.......................................................................................................................................................................................................................37
6.4 Setup.....................................................................................................................................................................................................................40
6.5 Commands...........................................................................................................................................................................................................44
6.6 RPA Parallel System............................................................................................................................................................................................49
7Operation...................................................................................................................................................................52
7.1 Procedures for single MegaFlex 1000 to 1600............................................................................................................................................. 53
7.1.1 Initial start-up of the MegaFlex 1000 to 1600 ............................................................................................................................................................. 53
7.1.2 Complete UPS shut-down ................................................................................................................................................................................................57
7.1.3 Restore to normal operation after “System shutdown” with Load not supplied ................................................................................................ 58
7.1.4 Restore to normal operation after “EPO - Emergency Power Off” with Load not supplied .............................................................................. 59
7.2 Procedures single MegaFlex 1000 to 1600 functioning as Frequency Converter................................................................................60
7.2.1 Initial Start-up of the MegaFlex 1000 to 1600 as frequency converter..................................................................................................................60
7.2.2 Complete shut-down of the MegaFlex 1000 to 1600 as frequency converter...................................................................................................... 64
7.2.3 Restore to normal operation after “System shutdown” with Load not supplied ................................................................................................ 65
7.2.4 Restore to normal operation after “EPO - Emergency Power Off” with Load not supplied .............................................................................. 66
7.3 Procedures for MegaFlex 1000 to 1600 RPA Parallel System ................................................................................................................... 67
7.3.1 MegaFlex 1000 to 1600 RPA Parallel System start-up ............................................................................................................................................... 67
7.3.2 Separate a UPS unit from the RPA Parallel System (System Redundancy) ............................................................................................................72
7.3.3 Reconnect a UPS unit to RPA Parallel System.............................................................................................................................................................. 74
7.3.4 Complete RPA Parallel System shut-down................................................................................................................................................................... 76
7.3.5 Restore to normal operation after “System shutdown” with Load not supplied .................................................................................................77
7.3.6 Restore to normal operation after “EPO - Emergency Power Off” with Load not supplied .............................................................................. 79
8Options ...................................................................................................................................................................... 81
8.1 Connectivity options ......................................................................................................................................................................................... 81
8.2 Options in UPS cabinet ..................................................................................................................................................................................... 81
9Maintenance ..............................................................................................................................................................82
9.1 Maintenance........................................................................................................................................................................................................82
9.1.1 Service check...................................................................................................................................................................................................................... 82
9.1.2 Fans and ventilation ......................................................................................................................................................................................................... 82
9.1.3 Other components with limited lifetime...................................................................................................................................................................... 82
9.1.4 Battery ................................................................................................................................................................................................................................. 83
9.1.5 UPS room conditions and temperature........................................................................................................................................................................ 83
9.1.6 Preventive maintenance program ................................................................................................................................................................................. 83
10 Notes ..........................................................................................................................................................................84
10.1 Notes Form..........................................................................................................................................................................................................84

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1Safety rules
Save these instructions!
This manual contains important instructions for models MegaFlex 1000 to 1600 that should be followed during
installation and maintenance of the UPS and Battery.
General
- Move the UPS in an upright position in its original package to the final destination room.
To lift the cabinets, use a forklift or lifting belts with spreader bars.
- Check for sufficient floor and elevator loading capacity.
- Check the integrity of the UPS equipment carefully.
If you notice visible damage, do not install or start the UPS.
Contact your ABB Service Center immediately.
- WARNING! RISK OF ELECTRICAL SHOCK!
Do not remove covers, there are no user serviceable parts inside.
- After switching off takes 5 minutes for the DC capacitors to discharge because a lethally high voltage remains
at the terminals of the electrolytic capacitors.
- UPS’s and Battery system require a 12 months periodic maintenance to operate reliably and safely.
This should be performed by qualified service personnel. The UPS contains its own energy source (Battery).
- The field-wiring outlets may be electrically live, even when the UPS is disconnected from the Utility.
- Dangerous voltages may be present during Battery operation.
- The Battery must be disconnected during maintenance or service work.
- This UPS contains potentially hazardous voltages.
- Be aware that the Inverter can restart automatically after the Utility voltage is restored.
- End user must follow applicable regional occupational safety codes/regulations during installation, operation
and equipment maintenance. This may require additional field marking or labelling defining appropriate level
of PPE (Personal Protection Equipment) to reduce the risk of Arc-flash related injuries.
Contact our ABB Service Center for product specific information.
Installation
- This UPS must be installed and connected only by trained personnel.
- Verify accurately during Commissioning and Maintenance of the UPS, for the following:
Damaged components, squeezed wires and cables, or not correctly inserted plugs.
- After removing the sidewalls of the UPS, make sure that all earth connections when reassembling, are correctly
reattached.
- This UPS is intended for use in a controlled indoor environment free of conductive contaminants and
protected against animals intrusion.
- WARNING! HIGH LEAKAGE CURRENT TO GROUND:
Ground connection is essential before connecting to AC input!
- Switching OFF the Unit does not isolate the UPS from the Utility.
- Do not install the UPS in an excessively humid environment or near water.
- Avoid spilling liquids on or dropping any foreign object into the UPS.
- The Unit must be placed in a sufficiently ventilated area; the ambient temperature should not exceed 104°F
(40°C).
- Optimal Battery life is obtained if the ambient temperature does not exceed 77°F (25°C).
- It is important that air can move freely around and through the Unit. Do not block the air vents.
- Avoid locations in direct sunlight or near heat sources.
Storage
- Store the UPS in a dry location; storage temperature must be within -13°F (-25°C) to 131°F (+55°C).
- The optimal temperature for Battery storage is 68°F (20°C) to 77°F (25°C) and shall never exceed the range -4°F
(-20°C) to 104°F (40°C).
- If the Unit is stored for a period exceeding 3 months, the Battery must be recharged periodically (time
depending on storage temperature).
Battery
- The Battery-voltage is dangerous for person’s safety.
- When replacing the Battery, use the same number, voltage (V) and capacity (Ah).
- Proper disposal or recycling of the Battery is required.
Refer to your local codes for disposal requirements.
- Never dispose of Battery in a fire: they may explode.
- Do not open or mutilate Battery: their contents (electrolyte) may be extremely toxic.
If exposed to electrolyte, wash immediately with plenty of water.
- Avoid charging in a sealed container.
- Never short-circuit the Batteries.
When working with Batteries, remove watches, rings or other metal objects and only use insulated tools.
- In case of air shipment, the cables +/- going to the Battery fuses/terminals shall be disconnected and isolated.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
Safety instructions when working with Battery
Danger!
External Battery must be installed and connected to the UPS by Qualified Service Personnel.
Installation Personnel must read this entire section before handling the UPS and Battery.
Full voltage and current are always present at the Battery terminals.
The Battery used in this system can provide dangerous voltages, extremely high currents and a risk of electric
shock.
If the terminals are shorted together or to ground they may cause severe injury.
You must be extremely careful to avoid electric shock and burns caused by contacting Battery terminals or
shorting terminals during Battery installation.
Do not touch uninsulated Battery terminals.
A qualified service person, who is familiar with Battery systems and required precautions, must install and service
the Battery.
The installation must conform to national and local codes.
Keep unauthorized personnel away from the Battery.
The qualified service person must take these precautions:
1Wear protective clothing, such as rubber gloves and boots and protective eye wear.
Battery contain caustic acids and toxic materials and can rupture or leak if mistreated.
Remove rings and metal wristwatches or other metal objects and jewellery.
Do not carry metal objects in your pockets where the objects can fall into the Battery cabinet.
High energy through conductive materials could cause severe burns.
2Tools must have insulated handles and must be insulated so that they will not short Battery terminals.
Do not allow a tool to short between individual or separate Battery terminals or to the cabinet or rack.
Do not lay tools or metal parts on top of the Battery and do not lay them where they could fall onto the
Battery or into the cabinet.
3Disconnect charging source prior to connecting or disconnecting Battery terminals.
Install the Battery as shown on the drawing provided with the Battery.
When connecting cables, never allow a cable to short across a Battery’s terminals, the string of Battery, or to
the cabinet or rack.
4Align the cables on the Battery terminals so that the cable lug will not contact any part of the cabinet or rack,
even if the Battery is moved.
Keep the cable away from any sharp metal edges.
5Install the Battery cables in such a way that the UPS or Battery cabinet doors cannot pinch them.
6Do not connect the Battery terminal to Ground.
If any Battery terminal is inadvertently grounded, remove the source of the ground.
Contacting any part of a grounded Battery can cause a risk of electric shock.
7Determine if Battery is inadvertently grounded. If inadvertently grounded, remove source from ground.
Contact with any part of a grounded Battery can result in electrical shock.
The likelihood of such shock can be reduced if such grounds are removed during installation and
maintenance.
8To reduce the risk of fire or electric shock, install the Battery in a temperature and humidity controlled
indoor area, free of contaminants.
9Battery system chassis ground (earth) must be connected to the UPS chassis ground (earth).
If you use conduits, this ground conductor must be routed in the same conduit as the Battery conductors.
10 Where conductors may be exposed to physical damage, protect the conductors in accordance with all
applicable codes.
11 If you are replacing the Battery or repairing Battery connections, shut OFF the UPS and remove the Battery
fuses.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
1.1 Safety symbols and warnings
Safety warnings
The text of this manual contains some warnings to avoid risk to the persons and to avoid damages to the UPS
system and the supplied critical loads.
The non-observance of the warnings reminding hazardous situations could result in human injury and equipment
damages.
Please pay attention to the meaning of the following warnings and symbols.
Throughout this manual the following symbols are defined:
Warning, if instruction is not followed injury or serious equipment damage may occur!
Caution, internal parts have dangerous voltage present.
Risk of electric shock!
PE (Earth) – GND (Ground)
Protective Grounding terminal:
A
terminal which must be connected to earth ground prior to making any other connection to
the equipment.
A terminal to which or from which an alternating (sine wave) current or voltage may be applied
or supplied.
A terminal to which or from which a direct current or voltage may be applied or supplied.
This symbol indicated the word “phase”.
This symbol indicates the principal ON/OFF switch in the on position.
This symbol indicates the principal ON/OFF switch in the off position.

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1.2 Cyber security
UPS must be protected in a Security Restricted Area.
UPS must be installed in a location/room with mechanical lock.
Limit access to authorized personnel only and it shall stay under
Authorized Personnel Operator to
manage the accesses.
The UPS products are designed to be connected and to communicate information and data via a
network interface through the optional SNMP card, which should be connected to a secure network.
It is custo
mer sole responsibility to provide and continuously ensure a secure connection between
the product and customer network or any other network and to establish and maintain appropriate
measures (such as but not limited to the installation of firewalls, appli
cation of authentication
measures, encryption of data, installation of antivirus programs, etc.) to protect the UPS product,
the network, its system and interfaces against any kind of security breaches, unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
ABB Ltd and its affiliates are not liable for damages and/or losses related to such security
breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information.
Although ABB
provides functionality testing on the products and updates that we release, you
should institute your own testing program for any product updates or other major system updates
(to include but not limited to code changes, configuration file changes, third p
arty software
updates or patches, hardware change out, etc.) to ensure that the security measures that you have
implemented have not been compromised and system functionality in your environment is as
expected.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
2Layout
2.1 Layout MegaFlex 1000 to 1600
Fig. 2.1-1 MegaFlex 1000 to 1600 - General view
Fig. 2.1-3 Control Panel
Fig. 2.1-2 MegaFlex 1000 to 1600 - General view with open doors
CI Customer Interface
Board
CR Connectivity Rack
J35DSP Serial port RS232
(only for ABB
Service Center)
J35µPSerial port RS232 for
IMV protocol
RPA RPA board
(Redundant Parallel
Architecture) for
Parallel System
(option)
SNMP 3-ph SNMP/WEB
plug-in adapter
(option)
XA Terminal block (see
Installation Guide /
Section 4.11)
MGF_UL_1000-1600_UPS_ABB_02
MGF_UL_1000-1600_S1_UPS_04
12
XA
RPA
J35µP
SNMP
CR
CI
J35DSP
EPO
EPO
+-Q1 UVR

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
3Introduction
The MegaFlex 1000 to 1600 Uninterruptible Power Supply (UPS) provides the energy supply for critical loads
which need a reliable, continuous free from voltage disturbances and frequency fluctuations supply.
In case the power provided by the Utility Fails, or exceeds the permitted tolerances, the power to supply the Load
is provided by the Battery for the specified time at the rated Load (or longer at a reduced Load) or until the Utility
power returns.
MegaFlex 1000 to 1600 is a truly VFI double conversion Uninterruptible Power Supply (UPS),
equipped with automatic bypass, where the Load is normally supplied by the Inverter.
If the Inverter is not able to supply the required Output Voltage, or when overload or short
-
circuit on the output occur, the Load is instantly transferred to the Utility via the Automatic
Bypass.
The UPS automatically returns to normal mode when the failure condition is restored.
MegaFlex 1000 to 1600 can be configured, if chosen, for the eBoost™ Operation Mode
(Option
- High efficiency: up to 99.0% / Fast power transfer: <2ms) permitting maximum energy saving.
Key features of the MegaFlex 1000 to 1600
More Critical equipment supported
Rated at 1 Power Factor, MegaFlex 1000 to 1600 delivers more real power than other UPS in the market.
With today’s trend toward power factor corrected loads, MegaFlex 1000 to 1600 can support more total Load
than any other UPS available, allowing you to support a greater number of today’s enterprise computing Power
Factor Corrected (PFC) equipment.
High Efficiency
Thanks to type Advanced Neutral Point Clamped three level IGBT technology, MegaFlex 1000 to 1600 guarantees a
high overall performance.
Intelligent Energy Management (IEM) combined with RPA, results in the most cost efficient and reliable UPS
solution in the industry.
Fully digital
Digital Signal Processor (DSP), Flash memory and Advanced Neutral Point Clamped are the technology corner
stones of a new age of power quality and power reliability.
RPA™ - Redundant Parallel Architecture™ Parallel System
ABB provides a unique technology called Redundant Parallel Architecture™ (RPA™) that can parallel
Uninterruptible Power Supply (UPS) modules with true redundancy.
With RPA™, there is no need for external electronics or switches to control the UPS modules in the parallel system.
One of the UPS modules in the system arbitrarily takes a leadership role, while the other UPS modules have access
to all control parameters.
If one UPS fails to operate, the load is automatically redistributed among the others.
If the lead UPS fails to operate then a different UPS automatically takes on the leadership role.
The RPA™ systems are designed to have no single points of failure, ensuring the highest level of power protection
for critical loads.
Extremely flexible
Tailor made power protection to meet your individual installation requirements; MegaFlex 1000 to 1600 offers
various options like EMC filter and our comprehensive software for mission control and data protection to cover
all your application needs.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
4Description
Fig. 4-1 MegaFlex 1000 to 1600
MegaFlex 1000 to 1600 is one
of
the best performing and most
reliable three-
phase UPS
systems providing critical power
protection for a wide range of
applications.
Every MegaFlex 1000 to 1600
system operates in VFI mode
(Voltage Frequency
Independent) yielding the
maximum levels of
power
reliability for all mission-
critical
processes.
With proven technology the MegaFlex 1000 to 1600 UPS provides top class reliability and performance.
With Back-feed Protection and compliance to EMC standards the MegaFlex 1000 to 1600 complies to current
standards.
Reliability can be further increased by paralleling up to six UPS units utilizing ABB’s unique RPA™ technology
(Redundant Parallel Architecture).
With RPA every UPS is controlled in a true peer-to-peer configuration with redundancy in all critical elements and
functions, eliminating all single points of failure.
The decentralized bypass offers great flexibility to up or down grade the system in case future needs might
change.
MegaFlex 1000 to 1600, best in class efficiency
•High efficiency in double conversion mode up to 96.0/96.3% and eBoost™ operation mode up to 99.0%.
•High efficiency at partial and reduced loads for cost benefits in operating conditions.
•Higher efficiency at partial load in RPA Systems with adaptive capacity control.
•MegaFlex 1000 to 1600 products designed in compliance with UL 1779 standard, C3 level for immunity, i.e. can
withstand possible disturbances and noise without affecting standard operating conditions.
•Advanced User Interface with touch screen display guided menu.
•Reduced energy consumption costs.
•Reduced size and costs of the air conditioning system.
•Compact design, saving installation space.
Note!
Through their complete life cycle, all ABB UPS Systems
are fully supported by service teams which
provide world-class, 24x7 preventive and corrective services, training and application expertise.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
4.1 Block diagram and main elements
Fig. 4.1-1 Block Diagram MegaFlex 1000 to 1600
The MegaFlex 1000 to 1600 system can be divided into the following main elements:
Control System
MegaFlex 1000 to 1600 is designed with microprocessor-controlled signal processing circuits.
The interface between the operator and the unit is provided by the monitoring system on the front panel.
This monitoring system consists of an active mimic diagram, a keyboard and a backlit display.
Rectifier
The Active IGBT Rectifier converts the 3-phase utility voltage into a controlled and regulated DC-voltage,
supplying the Inverter and to charge the Battery through the Battery-charger.
Thanks to modulation strategy applied to IGBT Bridge, the rectifier provides clean input power in terms of low
THDi and unity power factor.
Inverter
The Inverter converts the DC voltage into a three-phase AC-voltage with constant amplitude and frequency, which
is completely independent and isolated from the AC-input voltage.
Automatic Bypass
The Automatic Bypass consists of a static semiconductor-switch (SSM: Static Switch Module), used to provide an
uninterrupted transfer of the Load from Inverter to Utility.
Back-feed Protection
MegaFlex 1000 to 1600 UPS is equipped with an automatic system for the protection against voltage back
feeding towards Utility, through the Bypass (UL 1778 and CSA C22.2 no. 107.3).
This protection works automatically by opening contactor K6 (in series with the thyristors of the static switch).
Battery
The Battery supplies the DC power to the Inverter when the Utility is out of acceptable tolerances.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
4.2 Operation modes
This section describes the different possible operation modes of the UPS explaining the function of the main
modules of the UPS.
4.2.1 Normal VFI Operation Mode (Voltage Frequency Independent)
Under normal conditions the Load is
permanently powered by the Inverter with
constant amplitude and frequency
.
The Rectifier, powered by the Utility, supplies
the Inverter and the
Battery-charger keeps the
Battery
fully charged.
The
Inverter converts the DC voltage in a new
AC sine wave voltage with constant amplitude
and frequency independently from the input
Utility Power.
Fig. 4.2.1-1 Block diagram normal operation mode
4.2.2 eBoost™ Operation Mode (option)
eBoost
™
e
High efficiency (up to 99.0%)
Boost
Fast power transfer (< 2ms)
When the
eBoost™ Operation Mode is
selected, and the
Utility Power is available, the
Load
is normally powered through the
Automatic Bypass
.
When the
Utility Voltage is detected out of the
prescribed tolerances, the
Load is
automatically transferred to the Inverter.
Fig. 4.2.2-1 Energy flow in eBoost™ Operation Mode
When the
Utility recovers, the Load returns to the Automatic Bypass
after a variable time defined by the control
unit.
The
eBoost™ Operation Mode can be used for single units or the RPA Parallel System, for up to 6 UPS modules,
with
all units individually able to supply power through a redundant communication bus.
The
eBoost™ Operation Mode can be configured directly by the user for higher efficiency, considering the Utility
reliability and criticality of the
Load.
The selection bet
ween the two operation modes “VFI mode and eBoost™ Operation Mode
”, or switching
between operation modes at required time, can be done through the UPS
Control Panel (see
Section 6.4 /
eBoost).
Note!
The eBoost™ Operation Mode is available only if enabled at the factory by an
ABB Service
Technician.

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MegaFlex 1000 to 1600 UPS User Manual / REV-A
4.2.3 Utility Failure Operation
When the
Utility
is no longer within acceptable
tolerances, the
Battery
will provide the DC power to the
Inverter
.
The
Inverter
will maintain continuous AC power to the
Load
until the Battery Voltage
reaches the lower limit of
the
Inverter operation capability.
During the discharge, the LCD screen displays the
estimated time the
Battery can support the critical load.
Prior to the
Battery completely discharging, the "stop
operation
" alarm (shut-
down imminent) warns the
operator that the
Battery
is almost discharged and the
UPS is about to shut-down.
Fig. 4.2.3-1 Block diagram Utility Failure operation
In case of RPA Parallel System
With a Parallel System for
Power Capacity (see Section 4.3)
•
With the Bypass Utility power available, a “Battery low” warning on any unit will cause the Load
to be
transferred to Utility (after a selectable time delay).
•
With Bypass Utility power not available, a “Battery low” warning on any unit will start the “stop operation
”
timer (adjustable).
The Load will shut down at the end of the “stop operation” time period.
With a Parallel System for
Redundancy (RPA - see Section 4.3)
•
When
a Battery low warning occurs on a unit not necessary to support the present Load, this unit will shut
down after a timeout period (selectable).
The Load is shared between the other units.
•
As the warning occurs on one unit necessary to support the present Load, the system starts the "
stop
operation" timeout (selectable).
The Load will shut down at the end of the “stop operation” time period.
4.2.4 Utility Recovery Operation
As soon as the AC input power recovers, the Rectifier will
start automatically
, supplying DC power to the Inverter
and recharging the
Battery.
If the
Inverter was previously shut-
down due to low
Battery
, the Load will be initially powered by Utility
throug
h the Automatic Bypass.
When the
Battery
is recharged enough to ensure a
minimum time of operation with the present load, the
Inverter
will start automatically and the Load
will be
transferred back to the Inverter.
Fig. 4.2.4-1 Block diagram Utility recovery operation
In case of RPA Parallel System
When the AC input power recovers,
the Rectifiers will start-up sequentially, according to their number in the
RPA
Parallel System
. This minimizes the initial inrush current.
The
Inverters will start-up automatically, but only when the Battery
has been sufficiently recharged for a
minimum runtime
with the present Load.
When enough Inverters to supply the
Load have been restarted, the Load
will be transferred from the Automatic
Bypa
ss back to the Inverter output.

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4.2.5 Automatic Bypass
In normal operation, the
Load
is supplied by
the
Inverter.
When the control system detects a fault in the
Inverter
, an overload condition or a short-
circuit condition, the
Automatic Bypass will
transfer the critical
Load to the Utility without
interruption.
When the
Inverter recovers, or the overload or
short
-circuit condition is corrected, the Load
will be automatically transferred back to the
Inverter.
Fig. 4.2.5-1 Block diagram Automatic Bypass
If the UPS is unable to return to normal mode following an automatic transfer to
Bypass mode
, an alarm
condition will be initiated.
In case of RPA Parallel System
Each unit has its own internal
Static Bypass.
These units are continuously exchanging information, enabling all of the internal Bypass circuits in a
n
RPA Parallel
System
to operate simultaneously.
If the
Inverter of a unit fails, its Bypass circuit remains available to the RPA Parallel System.
It is excluded only if the unit is separated from the common bus by opening its “
Q1 – External UPS Output
Circuit
Breaker”
.

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4.3 RPA Parallel System operation
4.3.1 Introduction to the RPA Parallel System
Fig. 4.3.1-1 Block diagram RPA Parallel System operation
Two or more equal power Units can be paralleled to increase the output power (Paralleling for Capacity) or to
improve the overall reliability of an UPS system (Paralleling for Redundancy).
The outputs of Parallel Units are connected to a common power bus, and in normal operation the Units connected
on the Parallel Bus share the Load equally.
The modular concept of MegaFlex 1000 to 1600 allows parallel operation of up to 6 Units, without using
paralleling switchgear, external bypass circuits or common control circuitry (see Fig. 4.3.1-1).
Parallel Units for Power Capacity
Several Units can be paralleled in order to achieve output power greater than the maximum power of a Single
Unit.
The maximum total power shared between the Paralleled Units is equal to the total installed nominal power.
In the event of a failure of one Unit, the power supplied by the UPS system becomes insufficient and the Load will
be transferred to the Utility Bypass source.
Parallel Units for Redundancy
The nominal power rating of the n out of n+1 Redundant Paralleled Modules must be equal to or higher than the
required Load power.
The Load will be equally shared by the n+1 Units connected on the output bus.
Should one of the n+1 Paralleled Units trip Off-line, the remaining (n) Modules will supply the Load, maintaining
conditioned power to the critical Load.
From this result higher reliability and security for the Load plus a higher MTBF (Mean Time Between Failures).

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4.3.2 Features of RPA Parallel System
MegaFlex 1000 to 1600 RPA Parallel System is designed to provide a complete Redundant Parallel Architecture
and is free from common equipment.
Not only the Inverters but also the Bypass functions are redundant.
When one UPS needs maintenance or service, the Load is powered by the other Units.
The redundant communication bus to which all Units are connected keeps each Unit informed about the status of
all the other Units.
The Control Panel located on each Unit allows controlling and monitoring the status of this Unit.
4.3.3 System control
A High-Speed Redundant and Serial Communication Bus guarantees the exchange of data and thus the
communication between the CPU's of each Unit
Each Module controls is own function and operational status and communicates with all other Modules, in order
to act or react if necessary, adapting to the new conditions.
4.3.4 Synchronization
All Units are identical, but one Unit is arbitrarily selected as the reference and all the other Units synchronize to
this Unit, which in turn synchronizes to the Utility Bypass voltage, as long as the latter is within tolerances.
In case of reference failure, another Unit in the RPA Parallel System is automatically chosen to take over the
reference role.
The Bypass Input for all the Units of the RPA Parallel System must be supplied from the same AC source (no phase
shift allowed between them).
4.3.5 Load sharing
On each Unit of the RPA Parallel System, Inverter Output Voltage and Current are measured and applied to a Load
sharing bus.
An eventual difference between the Units is therefore automatically equalized.
Note!
As indicated in this manual, the “Q1 - External UPS Output Circuit Breaker” with dedicated Auxiliary
Contact to be connected to the UPS is required. See Section 4.11.2 of the Installation Guide.
It is strongly recommended that no Transformers, Automatic Circuit Breakers or Fuses should be
installed between the Units Output and the Load Common Bus Bars, except the “Q1 -
External UPS
Output Circuit Breaker” as mentioned above.

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4.4 Service and technical support
For any request of technical support please contact your local
ABB
Service Center
.
Your ABB Service Center
(see page 3)
Fig. 4.4-1 Identification label
The requested data permitting to identify your
UPS are marked on the identification label
fixed
on the front of the cabinet, behind the lower
front door.
For fast and efficient technical support please
mention the data marked on the
identification
label.
4.5 Warranty
ABB, operating through its authorized agents, warrants that the standard products will be free of defects in
materials and workmanship for a period as per contract specifications.
Note!
This warranty does not
cover failures of the product which result from incorrect installation,
misuse, alterations by persons other than authorized agents, or abnormal working conditions.
MGF_UL_1000-1 600_UPS Label identi fication_ABB_01
12
EPO
EPO
+
-
Q1 K3
Made in Switzerland
Output Power:
Input:
Input Frequency:
Output:
Output Power:
Output Frequency:
kVA
V; 3W+PE
Hz
Input Current: AOutput Current:
UPS
Serial No.
MegaFlex UL
kVA
V; 3W+PE
Hz
A
Production
Date

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4.6 Recycling instructions
Note!
This product has been designed to respect the
environment, using materials and components
respecting eco-design rules.
It does not contain CFCs (Carbon Fluor Clorid) or HCFCs (Halogen Carbon Fluor Clorid).
Packing material recycling!
ABB, in compliance with environment protection, uses only environmentally friendly material
at
the end of its service life, must be recovered conforming to the local applicable regulations.
UPS packing materials must be recycled in compliance with all applicable regulations.
Recycling at the end of service life!
ABB, in compliance with environment protection recommends to the User
that the UPS
equipment, at the end of its service life, must be recovered conforming to the local applicable
regulations.
Battery disposal!
Leads contained in the B
atteries is a dangerous substance for the environment, therefore it
must be correctly recycled by specialized companies.