AEC IST6-US User manual

UPS 30-300kVA User Manual
Preface
I
Preface
Usage
The manual contains information on installing, using, operation and maintenance of
the AEC IST6-US UPS. Please carefully read this manual prior to installation.
Users
Technical Support Engineer
Maintenance Engineer
Note
Our company is providing a full range of technical support and services. Customer
can contact our local office or customer service center for help.
The manual will update irregularly, due to the product upgrading or other reasons.
Unless otherwise agreed，the manual is only used as guide for users and any
statements or information contained in this manual make no warranty expressed or
implied.

II UPS 30-300kVA User Manual
Contents
Contents
Preface............................................................................................................................................... I
Contents ............................................................................................................................................ II
Safety Precautions............................................................................................................................ V
1 Overview .................................................................................................................................. 9
1.1 Product Description .................................................................................................. 9
1.2 System conceptual diagram ...................................................................................... 9
1.3 Power unit conceptual diagram ................................................................................ 9
1.4 Working Modes ........................................................................................................ 9
1.4.1 Normal mode .................................................................................................. 10
1.4.2 Battery Mode .................................................................................................. 10
1.4.3 Bypass Mode .................................................................................................. 11
1.4.4 Maintenance Mode (Manual Bypass) ............................................................. 11
1.4.5 ECO Mode ..................................................................................................... 12
1.4.6 Auto-restart Mode .......................................................................................... 12
1.4.7 Frequency Converter Mode ............................................................................12
1.5 UPS Structure ......................................................................................................... 13
1.5.1 UPS Congure ration ...................................................................................... 13
1.5.2 UPS Structure .................................................................................................13
2 Installation............................................................................................................................... 16
2.1 Location ................................................................................................................. 16
2.1.1 Installation Environment ................................................................................ 16
2.1.2 Site Selection .................................................................................................. 16
2.1.3 Weight and Dimensions .................................................................................. 16
2.2 Unloading and Unpacking ...................................................................................... 19
2.2.1 Moving and Unpacking of the Cabinet .......................................................... 19
2.3 Positioning ............................................................................................................. 22
2.3.1 Positioning Cabinet ........................................................................................ 22
2.4 Battery .................................................................................................................... 23
2.5 Cable Entry ............................................................................................................. 24
2.6 Power Cables .......................................................................................................... 27
2.6.1 Specications .................................................................................................. 27
2.6.2 Specications for Power Cables Terminal ..................................................... 27
2.6.3 Circuit Breaker ............................................................................................... 28
2.6.4 Connecting Power Cables .............................................................................. 29
2.7 Control and Communication Cables ...................................................................... 31
2.7.1 Dry Contact Interface .....................................................................................32
2.7.2 Communication Interface ............................................................................... 37
3 Operator Control and Display Panel .......................................................................................38

UPS 30-300kVA User Manual
Contents
III
3.1 UPS operator panel ................................................................................................ 38
3.1.1 LEDIndicator .................................................................................................. 38
3.1.2 Control and Operation Keys ........................................................................... 39
3.1.3 LCD touch Screen .......................................................................................... 40
3.2 Main Menu ............................................................................................................. 41
3.2.1 Cabinet ........................................................................................................... 41
3.2.2 Power unit ...................................................................................................... 43
3.2.3 Setting ............................................................................................................ 45
3.2.4 Log ................................................................................................................. 47
3.2.5 Operate ........................................................................................................... 54
3.2.6 Scope .............................................................................................................. 56
4 Operations ...............................................................................................................................57
4.1 UPS Start-up ........................................................................................................... 57
4.1.1 Start in Normal Mode ..................................................................................... 57
4.1.2 Start from Battery ........................................................................................... 58
4.2 Procedure for Switching between Operation Modes .............................................. 59
4.2.1 Switching the UPS into Battery Mode from Normal Mode ........................... 59
4.2.2 Switching the UPS from Normal Mode into Bypass Mode ........................... 59
4.2.3 Switching the UPS into Normal Mode from Bypass Mode ........................... 60
4.2.4 Switching the UPS from Normal Mode into Maintenance Bypass Mode ......60
4.2.5 Switching the UPS into Normal Mode from Maintenance Bypass Mode ......61
4.3 Battery Manual .......................................................................................................61
4.4 EPO ........................................................................................................................ 63
4.5 Installation of Parallel Operation System ............................................................... 64
5 Maintenance............................................................................................................................ 66
5.1 Precautions ............................................................................................................. 66
5.2 Instruction for Maintaining Power unit .................................................................. 66
5.3 Instruction for Maintaining monitor unit and bypass unit ...................................... 66
5.3.1 Maintaining monitor unit and bypass unit for 60kVA-120kVA ..................... 66
5.3.2 Maintaining monitor unit and bypass unit for 150kVA and 200kVA .............. 67
5.3.3 Maintaining monitor unit and bypass unit for 400kVA and 500kVA .............. 67
5.4 Battery Setting ........................................................................................................ 67
5.4.1 Setting of Battery Type ................................................................................... 68
5.4.2 Setting of Battery Number ............................................................................. 68
5.4.3 Battery Capacity Setting..................................................................................69
5.4.4 Float and Boost Charge Setting ...................................................................... 69
5.4.5 EOD Voltage Setting ...................................................................................... 69
5.4.6 Charging Current Percent Limit ..................................................................... 69
5.4.7 Battery Temperature Compensate .................................................................. 70

IV UPS 30-300kVA User Manual
Contents
5.4.8 Boost Charge Time Limit ............................................................................... 70
5.4.9 Auto Boost Period ...........................................................................................70
5.4.10 Auto maintenance Discharge Period ...............................................................70
5.4.11 Warnings for Battery and Environment Temperature Overheat ......................71
5.5 Replacing Dust Filter (optional) ............................................................................. 71
6 Product Specication ..............................................................................................................72
6.1 Applicable Standards ............................................................................................. 72
6.2 Environmental Characteristics ............................................................................... 72
6.3 Mechanical Characteristic ...................................................................................... 73
6.4 Electrical Characteristics ........................................................................................ 73
6.4.1 Electrical Characteristics (Input Rectier)...................................................... 73
6.4.2 Electrical Characteristics (Intermediate DC Link) ......................................... 74
6.4.3 Electrical Characteristics (Inverter Output) .................................................... 74
6.4.4 Electrical Characteristics (Bypass Mains Input) ............................................ 75
6.5 Eciency ............................................................................................................... 75
6.6 Display and Interface ............................................................................................. 75

UPS 30-300kVA User Manual
Safety Precautions
V
Safety Precautions
This manual contains information concerning the installation and operation of
AEC IST6-US UPS. Please carefully read this manual prior to installation.
The AEC IST6-US UPS cannot be put into operation until it is commissioned by
engineers approved by the manufacturer. Not doing so could result in personnel
safety risk, equipment malfunction and invalidation of warranty.
Safety MessageDefinition
Danger: Serious human injury or even death may be caused, if this requirement is
ignored.
Warning: Human injury or equipment damage may be caused, if this requirement is
ignored.
Attention: Equipment damage, loss of data or poor performance may be caused, if this
requirement is ignored.
Commissioning Engineer: The engineer who installs or operates the equipment should
be well trained in electricity and safety and familiar with the operation, debug, and
maintenance of the equipment.
Warning Label
The warning label indicates the possibility of human injury or equipment damage, and
advises the proper step to avoid the danger. In this manual, there are three types of
warning labels as below.
Labels Description
Danger
Serious human injury or even death may be caused, if this requirement
is ignored.
Warning
Human injury or equipment damage may be caused, if this requirement
is ignored.
Attention
Equipment damage, loss of data or poor performance may be caused, if
this requirement is ignored.
Safety Instruction
Danger
Performed only by commissioning engineers.
This UPS is designed for commercial and industrial
applications only, and is not intended for any use in life-support
devices or system.
Warning
Read all the warning labels carefully before operation, and
follow the instructions.
When the system is running, do not touch the surface with this
label, to avoid any hurt of scald.
ESD sensitive components inside the UPS, anti-ESD measure
should be taken before handling.

VI UPS 30-300kVA User Manual
Safety Precautions
Move & Install
Danger
Keep the equipment away from heat source or air outlets.
In case of re, use dry powder extinguisher only, any liquid
extinguisher can result in electric shock.
Warning
Do not start the system if any damage or abnormal parts
founded.
Contacting the UPS with wet material or hands may be subject
to electric shock.
Attention
Use proper facilities to handle and install the UPS. Shielding
shoes, protective clothes and other protective facilities are
necessary to avoid injury.
During positioning, keep the UPS way from shock or vibration.
Install the UPS in proper environment, more detail in section
3.3.
Debug& Operate
Danger
Make sure the grounding cable is well connected before
connecting the power cables, the grounding cable and neutral
cable must be in accordance with the local and national codes
practice.
Before moving or re-connecting the cables, make sure to cut
o all the input power sources, and wait for at least 10 minutes
for internal discharge. Use a multi-meter to measure the voltage
on terminals and ensure the voltage is lower than 36V before
operation.
Risk of Voltage Backfeed.Beforeworking on the circuits,
isolatethe Uninterruptible Power Supply (UPS), and then
checkfor Hazardous Voltage betweenall terminals
including the protective earth.
Attention
The earth leakage current of load will be carried by RCCB or
RCD.
Initial check and inspection should be performed after long
time storing of UPS.
Maintenance&Replacement
Danger
All the equipment maintenance and servicing procedures
involving internal access need special tools and should be
carried out only by trained personnel. The components that can
only be accessed by opening the protective cover with tools
cannot be maintained by user.
This UPS full complies with “IEC62040-1-1-General and
safety requirements for use in operator access area UPS”.
Dangerous voltages are present within the battery box.
However, the risk of contact with these high voltages is
minimized for non-service personnel. Since the component
with dangerous voltage can only be touched by opening the
protective cover with a tool, the possibility of touching high

UPS 30-300kVA User Manual
Safety Precautions
VII
voltage component is minimized. No risk exists to any
personnel when operating the equipment in the normal manner,
following the recommended operating procedures in this
manual.
Riskof Fire.TO REDUCE THE RISK OF RIFE,
REPLACE FUSESWITH THE SAME TYPE AND
RATINGS. DISCONNECT OUTPUT AND ALL INPUT
SOURCESOF POWER FROM THIS EQUIPMENT
BEFORE SERVICING.
Battery Safety
Danger
All the battery maintenance and servicing procedures involving
internal access need special tools or keys and should be carried
out only by trained personnel.
WHEN CONNECTED TOGETHER, THE BATTERY
TERMINAL VOLTAGE WILL EXCEED 400Vdc AND IS
POTENTIALLY LEATHAL.
Battery manufacturers supply details of the necessary
precautions to be observed when working on, or in the vicinity
of, a large bank of battery cells. These precautions should be
followed implicitly at all times. Particular attention should be
paid to the recommendations concerning local environmental
conditions and the provision of protective clothing, rst aid and
re-Figure ting facilities.
Ambient temperature is a major factor in determining the battery
capacity and life. The nominal operating temperature of battery
is 20°C. Operating above this temperature will reduce the
battery life. Periodically change the battery according to the
battery user manuals to ensure the back-up time of UPS.
Replace the batteries only with the same type and the same
number, or it may cause explosion or poor performance.
When connecting the battery, follow the precautions for
high-voltage operation before accepting and using the battery,
check the appearance the battery. If the package is damaged, or
the battery terminal is dirty, corroded or rusted or the shell is
broken, deformed or has leakage, replace it with new product.
Otherwise, battery capacity reduction, electric leakage or re
may be caused.
Before operating the battery, remove the nger ring, watch,
necklace, bracelet and any other metal jewelry
Wear rubber gloves.
Eye protection should be worn to prevent injury from
accidental electrical arcs.
Only use tools (e.g. wrench) with insulated handles.
The batteries are very heavy. Please handle and lift the
battery with proper method to prevent any human injury or
damage to the battery terminal.
Do not decompose, modify or damage the battery.
Otherwise, battery short circuit, leakage or even human
injury may be caused.

VIII UPS 30-300kVA User Manual
Safety Precautions
The battery contains sulfuric acid. In normal operation, all
the sulfuric acid is attached to the separation board and
plate in the battery. However, when the battery case is
broken, the acid will leak from the battery. Therefore, be
sure to wear a pair of protective glasses, rubber gloves and
skirt when operating the battery. Otherwise, you may
become blind if acid enters your eyes and your skin may be
damaged by the acid.
At the end of battery life, the battery may have internal
short circuit, drain of electrolytic and erosion of
positive/negative plates. If this condition continues, the
battery may have temperature out of control, swell or leak.
Be sure to replace the battery before these phenomena
happen.
If a battery leaks electrolyte, or is otherwise physically
damaged, it must be replaced, stored in a container resistant
to sulfuric acid and disposed of in accordance with local
regulations.
If electrolyte comes into contact with the skin, the affected
area should be washed immediately with water.
Disposal
Warning Dispose of used battery according to the local instructions

UPS 30-300kVA User Manual
Overview
9
1 Overview
1.1 Product Description
This series AEC IST6-US UPS is an online double-conversion UPS that uses digital signal
processing(DSP) technology. Provide a stable and uninterrupted power supply for the important
load.
1.2 System conceptual diagram
The AEC IST6-US UPS is congured by the following part: Power modules, Bypass & Monitoring
module, and cabinet with manual Bypass switch. One or several battery strings should be installed
to provide backup energy once the utility fails. The UPS structure is shown inFigure 1-1.



 
 







Figure 1-1UPS Conceptual Diagram
1.3 Power unit conceptual diagram
The power unitconceptual diagram is shown asFigure1-2.The Power unit contains a rectier, an
inverter, and a DC/DC converter for charge and discharge of the external batteries.








Figure1-2Power unitconceptual diagram
1.4 Working Modes
The Modular UPS is an on-line, double-conversion UPS that permits operation in the
following modes:
Normal mode
Battery mode
Bypass mode
Maintenance mode (manual bypass)
ECO mode
Auto-restart mode
Frequency Converter mode

Overview
10 UPS 30-300kVA User Manual
1.4.1 Normal mode
The inverter of power modules continuously supply the critical AC load. Therectier/charger
derives power from the AC mains input source and supplies DC power to the inverter while
simultaneously FLOAT or BOOST charging its associated backup battery.



 
 







Figure1-3UPS conceptual diagram in normal mode
Note
Indicates the energy ow direction.
1.4.2 Battery Mode
Upon failure of the AC mains input power, the inverter ofpower unit, which obtain power from the
battery, supply the critical AC load. There is no interruption in power to the critical load upon
failure. After restoration of the AC mains input power, the” Normal mode” operation will continue
automatically without the necessity of user intervention.



 
 







Figure1-4UPS conceptual diagram in Battery mode
Note
With the function of Battery cold start, the UPS may start without utility. See more detail in
section4.1.2.

UPS 30-300kVA User Manual
Overview
11
1.4.3 BypassMode
If the inverter overload capacity is exceeded under Normal mode, or if the inverter becomes
unavailable for any reason, the static transfer switch will perform a transfer of the load from the
inverter to the bypass source, with no interruption in power to the critical AC load. Should the
inverter be asynchronous with the bypass, the static switch will perform a transfer of the load from
the inverter to the bypass with power interruption to the load. This is to avoid large cross currents
due to the paralleling of unsynchronized AC sources. This interruption is programmable but
typically set to be less than 3/4 of an electrical cycle, e.g., less than 15ms (50Hz) or less than
12.5ms (60Hz). The action of transfer/re-transfer can also be done by the command through
monitor.



 
 







Figure1-5UPS conceptual diagram inBypass Mode
1.4.4 Maintenance Mode (Manual Bypass)
A manual bypass switch is available to ensure continuity of supply to the critical load when the
UPS becomes unavailable e.g. during a maintenance procedure.



 
 







Figure1-6UPS conceptual diagram inMaintenance Mode

Overview
12 UPS 30-300kVA User Manual
Danger
During Maintenance mode, dangerous voltages are present on the terminal of input, output
and neutral, even with all the modules and the LCD turned o.
The UPS which without External maintenance switch in Maintenance Mode, dangerous
voltages are present on terminal and internal Copper bar.
1.4.5 ECO Mode
The economy control operation (ECO) mode is an energy-saving mode, In ECO mode,
when the bypass input voltage is within the ECO voltage range, the static bypass turns
on, andthe bypass supplies power, and inverter is standby. When the bypass
inputvoltage is beyond the ECO voltage range, the UPS transfers from bypass mode
to normal mode.



 
 







Figure1-7UPS conceptual diagram inECO Mode
Note
There is a short interruption time (less than 10ms) when transfer from ECO mode to battery mode,
it must be sure that the interruptionhas no eect on loads.
1.4.6 Auto-restart Mode
The battery may become exhausted following an extended AC mains failure. The
inverter shuts down when the battery reaches the End of Discharge Voltage (EOD).
The UPS may be programmed to “System Auto-Start Mode after EOD”. The system
starts after a delay time when the AC main recovers. The mode and the delay time are
programmed by the commissioning engineer.
1.4.7 FrequencyConverter Mode
By setting the UPS to Frequency Converter mode, the UPS could present a stable output of xed
frequency (50 or 60Hz), and the bypass static switch is not available.

UPS 30-300kVA User Manual
Overview
13
1.5 UPS Structure
1.5.1 UPS Congure ration
The UPS congure ration is provided in Table 1-1.
Table 1-1 UPS ConFigureuration
Item Components Quantity/ pcs Remark
30kVA
60kVA
Circuit Breaker 4 factory installed
Bypass &
Monitoring unit 1 factory installed
90kVA
120KVA
150KVA
180KVA
Manual Bypass
Breaker 1 factory installed
Bypass &
Monitoring unit 1 factory installed
210kVA
240kVA
270kVA
300kVA
Circuit Breaker 4 factory installed
Bypass unit 1 factory installed
Monitoring unit 1 factory installed
30kVA
Power unit Power unit 1~10 factory installed
1.5.2 UPSStructure
The UPS structure is shown in(d) 210kVA~300kVA UPS structure
Figure1-8.
(a) 30~60kVAUPS structure

Overview
14 UPS 30-300kVA User Manual
LCD
Power unit
Monitor and bypass unit
Manual
bypass
(b) 90kVA~120kVAUPS structure
(c) 150kVA ~180kVA UPS structure

UPS 30-300kVA User Manual
Overview
15
(d) 210kVA~300kVA UPS structure
Figure1-8UPS structure

Installation
16 UPS 30-300kVA User Manual
2 Installation
2.1 Location
As each site has its requirements, theinstallationinstructions in this section areto act as a guide for
the general procedures and practices that should be observed by the installingengineer.
2.1.1 Installation Environment
The UPS is intended for indoor installation and uses forced convection cooling by internal fans.
Please make sure there is enough space for the UPS ventilation and cooling.
Keep the UPS far away from water，heat and inammable and explosive, corrosivematerial. Avoid
installing the UPS in the environment with direct sunlight, dust, volatile gases, corrosive material
and high salinity.
Avoid installing the UPS in the environment with conductive dirt.
The operating environmenttemperaturefor battery is 20℃-25℃. Operating above25℃will
reduce the battery life, and operation below 20℃will reduce the battery capacity.
The battery will generate a little amount of hydrogen and oxygen at the end of charging; ensure
the fresh air volume of thebattery installation environment must meet EN50272-2001
requirements.
If external batteries are to be used, the battery circuit breakers (or fuses) must be mounted as close
as possible tothe batteries, and the connecting cables should be as short as possible.
2.1.2 Site Selection
Ensure the ground or installation platform can bear the weight of the UPS cabinet,batteries and
battery rack.
Attention
The UPS cabinet，battery can battery rack are suitable for mounting on concrete or other
non-combustible surface on
No vibration and less than 5 degree inclinationhorizontally.
The equipment should be stored in a room so as to protect it againstexcessivehumidity and heat
sources.
The battery needs to be stored in dry and cool place with good ventilation. The most suitable
storage temperature is 20 ºC to 25ºC.
2.1.3 Weight and Dimensions
The size of three views for the UPS cabinet is shown inFigure2-2.
Attention
Ensure there is at least 0.8m before the front of the cabinet so as to easily maintain the power
module with the front door fully open and at least 0.5m behind for ventilation and cooling. The
room reserved for the cabinet is shown inFigure2-1.

UPS 30-300kVA User Manual
Installation
17
≥500
≥500
≥800
Figure2-1 Room reserved for the cabinet (Unit: mm)
(a) Dimensions of 30~60KVA (unit: mm)

Installation
18 UPS 30-300kVA User Manual
(b) Dimensions of 90KVA~120kVA (unit: mm)
(c) Dimensions of 150KVA~180kVA (unit: mm)

UPS 30-300kVA User Manual
Installation
19
(d) Dimensions of 210KVA ~300kVA (unit: mm)
Figure2-2Dimensions
Ensure that the oor or installation support can bear the weight of the UPS, batteries, and battery
racks. The weight of batteries and battery racks depends on the site requirements. The weight for
the UPS cabinet is shown in Table 2-1.
Table 2-1 weight for the UPS
Capacity Weight
30KVA 165 Kg
60KVA 210 Kg
90KVA 305 Kg
120KVA 350 Kg
150KVA 445 Kg
180KVA 490 Kg
210KVA 765 Kg
240KVA 810 Kg
270KVA 855 Kg
300KVA 900 Kg
2.2 Unloading and Unpacking
2.2.1 Moving and Unpacking of the Cabinet
The steps to move and unpack the cabinet are as follows：

Installation
20 UPS 30-300kVA User Manual
1) Check if any damages to the packing. (If any, contact to the carrier)
2) Transport the equipment to the designated site by forklift, as shown inFigure2-3.
Figure2-3Transport to the designated site
3) Open the top plate of the steel-edged wooden case with slotted awl and pier,followed by
sideboards (seeFigure2-4).
Figure2-4Disassemble the case
4) Remove the protective foam around the cabinet.