AEG Protect 2.33 2.0 User manual

USER MANUAL
EN
Protect
2.33 2.0
Uninterruptible
Power Supply UPS

2
CONTENTS
1. Introduction ....................................................................................... 5
1.1. Using this manual .............................................................................................5
1.1.1. Symbols and conventions used ....................................................................6
1.1.2. For more information and help ..............................................................7
1.1.3. Safety and instructions ............................................................................7
2. Quality and standard guarantee ....................................................... 8
2.1. Management declaration ................................................................................8
2.2. Standards ..........................................................................................................9
2.3. Environmental protection ................................................................................9
3. Presentation ..................................................................................... 10
3.1. Views ...............................................................................................................10
3.1.1. Views of the equipment ........................................................................10
3.1.2 Corresponding legends for the equipment views ....................................13
3.2. Structure .........................................................................................................15
3.2.1. Structural schema ..................................................................................15
3.3. Operating principle ........................................................................................15
3.3.1. Normal operation ..............................................................................16
3.3.2. Operation with mains failure ............................................................16
3.3.3. Operation with inverter not active ...................................................16
3.3.4. Operation in manual bypass ...........................................................17
3.4. Parallel operation ...........................................................................................17
4. Installation ........................................................................................ 19
4.1. Important safety instructions .........................................................................19
4.1.1. Battery safety instructions .....................................................................20
4.1.2. Cabinet access .......................................................................................21
4.2. Set up and installation ....................................................................................23
4.2.1. Unpacking and content checking .........................................................23
4.2.2. Storage ...................................................................................................24
4.2.3. Transportation to site ............................................................................24
4.2.4. Location ..................................................................................................25

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4.3. Connection .....................................................................................................26
4.3.1. To the mains connection, terminals (X1 to X4) ....................................26
4.3.2. Connection of the output, terminals (X6 to X9) ..................................28
4.3.3. UPS connection to each battery pack in cabinet,
terminals (X11, X12, X23 and X47, X48, X49) ......................................29
4.3.4. Connection main protective earthing terminal ( )
and protective earth bonding terminal ( ) ........................................30
4.3.5. Interface relay contacts, connector (X32) .............................................30
4.3.6. COM-interface RS232 and RS485, connector (X31) ...........................31
4.3.7. EPO terminals (X50) ..............................................................................33
4.3.8 Parallel BUS connection (X36)................................................................33
5. Operation ......................................................................................... 35
5.1. Start up ...........................................................................................................35
5.1.1. Control before start up .........................................................................35
5.1.2. Start up procedure ................................................................................35
5.2. Complete UPS shutdown ..............................................................................37
5.3. Emergency power off (EPO) operation ........................................................38
5.4. Bypass manual switch (Maintenance) ............................................................38
5.4.1. Principle of operation ............................................................................38
5.4.2. Transfer to maintenance bypass ...........................................................38
5.4.3. Transfer to normal operation ................................................................39
6. Control panel and display description ............................................ 41
6.1. Control panel parts ........................................................................................41
6.1.1. Touch Screen ..........................................................................................41
6.2. Basic functions of keyboard from synoptic ...................................................41
6.2.1. Messages menus and classification in submenus ..................................43
6.2.2. Menu structure ......................................................................................44
6.3. Screen description ..........................................................................................45
6.3.1. Main level (screen menu 0.0) ................................................................45
6.3.2. UPS status control (screen menu 1.0) ...................................................46

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6.3.3.
‘‘MEASURES” level (screen menu 2.0) ....................................................48
6.3.4. ‘‘SETTINGS” level (screen menu 3.0) .................................................... 51
6.3.5. ‘‘ALARMS” level (screen menu 4.0) ......................................................56
6.3.6. ‘‘DATA LOGGER” level (screen menu 5.0) ..........................................69
7. Maintenance, warranty and service ................................................ 71
7.1. Basic maintenance guide ...............................................................................71
7.1.1. Battery fuses ..........................................................................................71
7.1.2. Batteries .................................................................................................71
7.1.3. Cooling Fan ............................................................................................72
7.1.4. Capacitors ..............................................................................................72
7.2. Warranty conditions .......................................................................................72
8. Annexes ........................................................................................... 73
8.1. General technical Specification .....................................................................73
8.2 Safety Instructions ...........................................................................................76

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We would like to thank you in advance for the trust you have placed in us by pur-
chasing this product. Read this instruction manual carefully before starting up the
equipment and keep it for any possible future consultation that may be required.
We remain completely at your disposal for any further information or any query
you should wish to make.
Yours sincerely,
AEG Power Solutions
• The equipment here described can cause significant physical damage due to
improper handling. This is why the installation, maintenance and/or fixing of the
equipment described here must be done by our staff or specifically authorised
personnel.
• According to our policy of constant evolution, we reserve the right to modify
the specifications in part or in whole without advance warning.
• All reproduction or third party concession of this manual is prohibited without
the previous written authorization of our firm.
1.1. USING THIS MANUAL
The goal of this manual is to give explanations and procedures for the installation
and operation of the equipment. This manual has to be read carefully before
instaling and operating the equipment. Keep this manual for future consultation.
This equipment has to be installed by qualified staff. With the simple help of this
manual, it can be operated by personnel without specific training.
1. INTRODUCTION

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1.1.1. SYMBOLS AND CONVENTIONS USED
Warning
Carefully read the indicated paragraph and take the stated prevention measures.
Danger of electrical discharge
Pay special attention to it, both in the indication on the equipment and in the
paragraph referred in this user manual.
Main protective earthing terminal
Connect the earth cable coming from the installation to this terminal.
Earth bonding terminal
Connect the earth cable coming from the installation to this terminal.
Notes of information
Additional topics that complement the basic procedures.
Preservation of the environment
The presence of this symbol in the product or in its associated documentation
states that, when its useful life is expired, it will not be disposed with the domestic
refuse. In order to avoid possible harm to the environment, separate this product
from other refuse and recycle it appropriately. Users may contact their provider or
with the relevant local authorities to be informed on how and where they can take
the product to be recycled and/or disposed of correctly.

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1.1.2. FOR MORE INFORMATION AND HELP
For more information and/or help with the version of your specific unit, contact
our Service and Technical Support (S.T.S.).
1.1.3. SAFETY AND INSTRUCTIONS
Together with the equipment and this “user and installation“ manual, information
pertaining to “safety instructions” is provided. These can be found in chapter 8.2
of this manual. Before proceeding to installation or commissioning, check that
both sets of information are available. Please refer to chapter 8.2 carefully. Com-
pliance with “safety instructions” are available for you to understand and observe.
Once read, keep the safety instructions available for future reference.

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2.1. MANAGEMENT DECLARATION
Our goal is the client’s satisfaction, therefore this management has decided to
estab lish a quality and environmental policy, by means of installation a quality and
environmental management system that becomes us capable to comply the
requirements demanded by the standard ISO 9001 and ISO 14001 and by our
clients and concerned parts too.
Likewise, the enterprise management is committed to the development and
improvement of the quality and environmental management system, through:
• The communication to all the company about the importance of satisfaction
both in the client’s requirements and in the legal regulations.
• Publicizing the quality and environmental policy diffusion and meeting the
quality and environment targets.
• To carry out revisions by the management.
• To provide the needed resources.
Quality and environmental officer
The management designated person in charge of the quality and environment
department, who, independent of other responsibilities, has the responsibility and
authority to assure that the processes of the quality and environmental management
systems are established and maintained; to inform the management about the
operation of the quality and environmental management system, including areas for
improvement; and to promote the knowledge of the requirements and environmental
requirements at all levels of the organization.
The following process map represents the interaction among all the processes of
the quality and environmental system:
Fig.1:
CONTINUOUS IMPROVEMENT PROCEDURE / MANAGEMENT REVISION
INTERNAL LOGISTICS PROCESS
MAINTENANCE PROCESS
TRAINING PROCESS
QUALITY MANAGEMENT PROCESS ENVIRONMENT MANAGEMENT PROCESS
R & D PROCESS
COMMERCIAL PROCESS PRODUCTION PROCESS
TECHNICAL OFFICE PROCESS
CLIENTS
CLIENT:
- PRODUCT
- SERVICE
Process map of quality and environmental system.
2. QUALITY AND STANDARD GUARANTEE

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2.2. STANDARDS
The UPS series product is designed, manufactured and certified in
accordance with the standard ISO 9001 of quality management systems.
The marking shows the conformity to the EEC directive (quoted between
brackets) by means of the application of the following standards:
• 2006/95/EC: Low voltage directive.
• 2004/108/EC: Electromagnetic Compatibility directive (EMC)
In accordance with the specifications of the harmonized standards:
• EN-IEC 62040-1: Uninterruptible power supply (UPS). Part 1-1: General and
safety requirements for UPSs used in accessible areas by end users.
• EN-IEC 60950-1: IT equipment. Safety. Part 1: General requirements.
• EN-IEC 62040-2: Uninterruptible power supply (UPS). Part 2: Prescriptions
for Electromagnetic compatibility (EMC).
• EN-IEC 62040-3: Uninterruptible power supply (UPS). Part 3: Methods of
operation specification and test requirements.
The manufacturer’s responsibility is excluded in the event of any modification or
tampering with the product on the customer’s side.
2.3. ENVIRONMENTAL PROTECTION
This product has been designed to respect the environment and has been
manufactured in accordance with the standard ISO 14001.
Equipment recycling at the end of its useful life:
Our company is committed to use the services of authorised institutions and
according to the regulations to safely dispose of the recovered product at the end
of its useful life (contact your distributor).
• Packing: To recycle the packaging, follow the legal regulations in force.
• Batteries: The batteries pose a serious danger for health and the environment.
The disposal of them must be carried out in accordance with the standards
in force.

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3.1. VIEWS
3.1.1. VIEWS OF THE EQUIPMENT
3. PRESENTATION
Fig.2: Cabinet front view for UPS up to
20 kVA with front door closed
Fig.3: Cabinet front view for UPS from
30 to 80 kVA with front door closed
(CL)
(CL)
(PF)
(PF)
(PB)
(PB) (RD) (RD)
(RV)
(RV)
(RV)
(fig. 4)
(fig. 4)

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Fig.4: Control panel view
Fig.6: Cabinet front view for UPS up
to 20 kVA with front door opened
2
3
a
b
c
d
e
1
Fig.5: Communication connectors details
Fig.7: Cabinet front view for UPS up to
30 to 80 kVA with front door opened
*Not available for Protect 2.33 2.0

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Fig.8: No. 1–3 battery cabinet front view
with front door closed
Fig.9: No. 1–3 battery cabinet front view with
front door opened
Fig.10: No. 4 battery cabinet front view with
front door closed
Fig.11: No. 4 battery cabinet front view with
front door opened

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3.1.2 CORRESPONDING LEGENDS FOR THE EQUIPMENT VIEWS
Protection and handling elements (Q):
(Q1a) Input circuit breaker or switch according to power of the equipment
(Q2) Output switch
(Q3) Battery fuse holder switch with 3 fuses (models up to 40 kVA) or switch
(for higher models)
(Q4) Not available for Protect 2.33 2.0
(Q5) Maintenance bypass switch
(Q8) Battery fuse holder switch 3 fuses, located in the battery cabinet
Connecting elements (X):
(X1) Phase input terminal R
(X2) Phase input terminal S
(X3) Phase input terminal T
(X4) Neutral input terminal N
(X5) Main protection earthing terminal ( )
(X6) Phase output terminal U
(X7) Phase output terminal V
(X8) Phase output terminal W
(X9) Neutral output terminal N
(X10) Earth bonding terminal for load or loads and/or battery cabinet ( )
(X11) Battery terminal +
(X12) Battery terminal –
(X23) Battery terminal N
(X31) DB9 connector COM RS232- and RS485 ports
(X32) DB9 connector relay interface
(X36) Connector for connecting cable for parallel use
(X47) Battery terminal + of external batteries cabinet
(X48) Battery terminal – of external batteries cabinet
(X49) Battery terminal N (middle tap) of external batteries cabinet
(X50) Terminals for external EPO

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Keyboard and optical indications control panel (PC):
(LCD) Graphic LCD
(ENT) Key “ENTER”
(ESC) Key “ESC”
() Key up
() Key down
() Key move to right
() Key move to left
(a) Rectifier input voltage OK LED (green)
(b) Output voltage unit from the bypass LED (orange)
(c) Inverter is working LED (green)
(d) Unit working from batteries - mains failure - LED (red)
(e) General alarm. In case of any alarm of the unit LED (red)
Other abbreviations:
(BL) Mechanical block for manual bypass switch (Q5)
(CL) Lock for cabinet front door
(PB) Levelers and immobilizing elements
(PC) Control panel
(PF) Cabinet front door
(PR) Cable routing or wire cones
(RD) Scroll wheel
(RV) Ventilation grille
(SL) Slot for optional intelligent card
(TB) Terminal cover
(TS) Slot cover (SL)
(t1) Screws fixing for terminals cover (TB)
(t2) Screws fixing for mechanical block (BL) for switch (Q5)
(t3) Screws fixing for slot cover (TS)

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3.2. STRUCTURE
3.2.1. STRUCTURAL SCHEMA
In a single line diagram, figure 12 shows the basic structure of standard
equipment and another one with separate bypass line, for a three phase input
and output configuration. For any other configuration, only the quantity of cables
and terminals at the input, output and bypass will vary. The internal structure of
the equipment will never vary.
Fig.12:
Maintenance line (manual bypass).
Emergency line (static bypass)
 Normal operation
 Mains failure
 Inverter operation not active
(provided that the EPO inactive)
Operation on bypass manual
UPS block diagram with operating flows
3.3. OPERATING PRINCIPLE
Protect 2.33 2.0 is a double conversion system AC/DC, DC/AC with a sine wave
output that gives safe protection in extreme conditions of power supply
(variations in voltage, frequency, electrical noises, blackout and other power
disturbances, etc…). Whatever the kind of load that has to be protected, these
devices are prepared to assure quality and continuity in the electrical supply.
The operation is basically as follows:
• Rectifier, an IGBT three phase rectifier, converts the AC voltage into DC by
absorbing a pure sine wave current (THD < 2,5 %*), and charging batteries at
constant current / voltage.
• The batteries supply the power needed by the inverter in the event of mains
failure.
• The inverter deals with transforming the voltage of the DC bus into AC by
providing a sine wave, alternating output stabilized in voltage and frequency
suitable for supplying the loads connected on the output.
* from 50 % load

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• The basic double conversion structure is complemented by two new functional
blocks, the static bypass commuter switch and the manual bypass commuter
switch.
• The static bypass commuter switch connects the output load directly to the
bypass network in special circumstances such as overloading or overheating and
reconnects it to the inverter when normal conditions are restored.
• The manual bypass commuter switch isolates the UPS from the mains and from
the loads connected on the output, so that maintenance operations may be
performed in the UPS without any need to interrupt the supply to the loads.
3.3.1. NORMAL OPERATION
With the mains present, the rectifier transforms the AC input voltage into DC,
raising the DC voltage to a suitable level for supplying the inverter and to charge
the batteries.
The inverter deals with transforming the voltage of the DC bus into AC, providing
a sine wave alternating output, stabilized in voltage and frequency to supply the
loads connected to the output (Fig.12).
3.3.2. OPERATION WITH MAINS FAILURE
In the event of mains failure or power disturbance occur, the group of batteries
supplies the power needed to supply the inverter.
The inverter continues working normally, independent of the lack of mains, and
the back-up time of the device depends only on the capacity of the group of
batteries (Fig.12).
When the battery voltage reaches the end of back-up time, the control blocks the
output as protection against a deep battery discharge.
When the mains returns and following the first seconds of analysis, the UPS
operates once more as in section “Normal operation”.
3.3.3. OPERATION WITH INVERTER NOT ACTIVE
The inverter is inactive due to the existence of alarm conditions such as overloads,
overheating, end of back-up time, etc. In this case the rectifier continues charging
the batteries to maintain their optimal charge state.
The inverter is also inactive if the unit has not been started up with the keyboard.
In this case, the rectifier will be inactive.

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In all these cases the output voltage of the UPS is supplied by the emergency
bypass line through the static bypass commuter switch (Fig. 12), provided that the
EPO is inactive.
3.3.4. OPERATION IN MANUAL BYPASS
When we wish to perform some maintenance check on the device, it may be
disconnected from the mains without any need to cut the power supply to the
system and affect the critical load. The UPS may be altered, only by technical or
maintenance personnel. For maintenance bypass follow the special instructions
for that purpose (refer chapter 5.4).
3.4. PARALLEL OPERATION
2 UPS’s can be paralleled to one UPS system for redundancy purposes or to
double the maximal load level. Only identical UPS with the same ratings can
be paralleled. Fig.13 shows the single line diagram of a parallel system of
Protect 2.33 2.0 showing the power connections and the control bus cables.
Two UPS running in parallel always do load-sharing. Parallel operation offers
several advantages like higher availability or “modular” adaption of the UPS
system to cover increasing power demands.
The parallel system management is based on a dynamic MASTER-SLAVE principle,
where the first UPS in normal operating mode will become MASTER. It has the
control of the second UPS (SLAVE).
Fig.13: Single line diagram for UPS parallel system

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There are two operation modes possible:
• Redundant system: As long as both UPS do not exceed the level of 50 % load
one UPS is able to take over the full load if one of the UPS in the system fails.
After the failed UPS was repaired it can be restarted and will recover the redun-
dancy condition. In case of more than 50 % load per UPS the system will gener-
ate an alarm. In case one UPS fails at more than 50 % load per UPS the second
UPS will take over and will run into overload. It will supply the load according to
the UPS overload capability. After that condition both UPS will switch to bypass.
• Parallel system for power enhancement: Paralleling two UPS will double the
maximum power. There will be no alarm “Redundancy lost”.

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• Refer to the safety instructions.
• Ensure that the data on the rating plate of the UPS match those required for
installation.
• Any incorrect connection or handling may cause damage to the UPS and/or
the loads connected to it. Read these instructions carefully and follow the steps
indicated in the correct order.
• This UPS must be installed by qualified staff and is usable by personal with no
specific training. All staff using this equipment should become familiar with the
contents of this of this “Manual”.
• Should a power increase be required in the future through parallel switching,
consider that larger cable diameters may be required. Likewise, the additional
installation of an external manual bypass switch for each device is
recommended.
4.1. IMPORTANT SAFETY INSTRUCTIONS
As this is a device with class I protection against electric shocks, it is essential to
install a protective earth conductor (connect earth (( ) ). Connect the conductor to
the terminal (X5), before connecting the power supply to the UPS input.
All connections in the device, including those for control (interface, remote
control, ...), will be performed with the switches at rest and without any mains
feed present (UPS power line cut off “Off”).
It must never be forgotten that the UPS is a generator of electrical power, users
must take all necessary precautions against direct or indirect contact.
Warning labels should be placed on all primary power switches installed in places
away from the device to alert the electrical maintenance personnel of the presence
of a UPS in the circuit. The label should contain the following or an equivalent text:
Before working on this circuit:
• Isolate Uninterruptible Power System (UPS).
• Then check for hazardous voltage between all terminals including the
protective earth.
Risk of voltage feedback
4. INSTALLATION

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Once the power supply is connected to the input of the UPS (with static bypass
included or with an independent static bypass line), although the inverter is “Off”
(shut-down), it does not mean that no output voltage is available at the output
terminals.
To do this, it is required to switch (Q1a), (Q4) and (Q2) to position “Off”. It is
possible that the UPS might be supplying output voltage from the manual bypass,
so this must be considered for the purpose of safety. If the output power supply of
the UPS has to be interrupted in this situation, deactivate the switch (Q5).
In devices with battery terminals, precautions must be taken as they are not
electrically insulated from the alternating input line, and there might be dangerous
voltage between the battery terminals and the ground.
4.1.1. BATTERY SAFETY INSTRUCTIONS
The manipulation and connection of the batteries shall be only be carried out and
supervised by personnel with battery knowledge.
For units requested without batteries, the acquisition, installation and connection
of the batteries will always be done by the customer and it is under his
responsibility. The relevant information on the batteries (number, capacity and
voltage) are indicated in the battery label pasted beside the nameplate of the
equipment. Strictly respect this data, the battery polarity connection and the
circuit diagram provided with this documentation.
The battery supply can involve the risk of electric shock and can produce high short
circuit current. Observe the following preventive measures before manipulating any
terminal block identified in the labeling as “Battery”:
• Disconnect the corresponding protection elements.
• When connecting a battery cabinet to the equipment, respect the cable’s
polarity and color (red-positive; black-negative) indicated in the manual and
in the corresponding labeling.
• Wear rubber gloves and shoes.
• Use tools with insulated handles.
• Removes watches, rings or other metal objects.
• Do not place metal tools or objects on the batteries.
• Never manipulate directly with your hands or through conducting objects, do
not short the battery terminal block or the battery enclosure.
• Never short the battery terminals as it involves a high risk. It may result in
damage to the equipment and batteries.