AEG Protect 5.31 User manual

Operating Instructions
8000020680 BAL, en
Uninterruptible
Power Supply UPS
Protect 5.31/xxx-480-220-120
10 kVA - 120 kVA
AEG Power Supply Systems GmbH
Department: PSS TED
Name: Schenuit/Bögge
Revision: 02
Date: 09.05.2008

Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA
Page 2 of 56 8000020680 BAL, en
Notes on these Operating Instructions
Duty to provide information
These operating instructions must be read carefully by all persons
working with or on the UPS prior to installation and initial start-up.
These operating instructions are a composite part of the UPS.
The owner of this unit is obliged to communicate the full content of
these operating instructions to all personnel transporting or starting
the UPS or performing maintenance or any other work on this unit.
Validity
These operating instructions comply with the current technical
specifications of the UPS at the time of publication. The contents do
not constitute a subject matter of the contract, but serve for
information purposes only.
AEG Power Supply Systems GmbH reserves the right to make
modifications with regard to the content and technical data in these
operating instructions without prior notice. AEG Power Supply
Systems GmbH cannot be held liable for any inaccuracies or
inapplicable information in these operating instructions, as no
obligation to continuously update the data and maintain their validity
has been entered into.
Warranty
Our goods and services are subject to the general conditions of
supply for products of the electrical industry, and our general sales
conditions. We reserve the right to alter any specifications given in
these operating instructions, especially with regard to technical data,
operation, dimensions and weights. Claims in connection with
supplied goods must be submitted within one week of receipt, along
with the packing slip. Subsequent claims cannot be considered.
AEG Power Supply Systems GmbH will rescind all obligations such
as warranty agreements, service contracts, etc. entered into by AEG
Power Supply Systems GmbH or its representatives without prior
notice if maintenance and repair work is carried out using anything
other than original AEG Power Supply Systems GmbH spare parts or
spare parts purchased from AEG Power Supply Systems GmbH.
Handling
These operating instructions for the UPS are structured so that all
work necessary for start-up, maintenance and repair of the unit can
be performed by qualified personnel.
Illustrations are provided to clarify and facilitate certain steps.
If danger to personnel and equipment cannot be ruled out in the case
of certain work, it is highlighted accordingly by pictograms explained
in Chapter 1, Safety Regulations.

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Abbreviations
The following abbreviations are used in these instructions:
DOU = Graphical Display and Operation Unit
SBS = Static Bypass Switch
REC = Rectifier
INV = Inverter
Hotline
Do you have any suggestions for improving these operating
instructions?
Do you have any questions on any of the subjects dealt with in these
operating instructions?
Our service department is available on the hotline number given
below:
AEG Power Supply Systems GmbH
Emil-Siepmann-Straße 32
D-59581 Warstein
Germany
[phone]
FAX: [phone]
E-mail: [email protected]
http://www.aegpss.de
Copyright
No part of these operating instructions may be transmitted,
reproduced and/or copied by any electronic or mechanical means
without the express prior written permission of AEG Power Supply
Systems GmbH.
©Copyright AEG Power Supply Systems GmbH 2007. All rights
reserved.

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Table of Contents
Notes on these Operating Instructions ...........................................2
1 Safety Regulations.................................................................6
1.1 Important Instructions and Explanations..................................6
1.2 Accident Prevention Regulations.............................................6
1.3 Danger during Maintenance and Repair Work.........................7
1.4 Fire Protection..........................................................................7
1.5 Qualified Personnel..................................................................7
1.6 Safety Awareness....................................................................8
1.7 Application ...............................................................................8
1.8 Liability.....................................................................................9
1.9 Directives .................................................................................9
2 Technical Data......................................................................10
3 General Information.............................................................11
3.1 Technology ............................................................................11
3.2 Operating Elements of the UPS.............................................13
4 Transport, Storage and Installation....................................14
4.1 Packing ..................................................................................14
4.2 Crane Transport.....................................................................14
4.3 Transporting the Unit using a Forklift or Lowlift Truck............15
4.4 Site Requirements..................................................................16
4.5 Floor Mounting.......................................................................17
4.6 Storage ..................................................................................18
5 Function................................................................................18
5.1 Operating Modes ...................................................................18
5.1.1 Operation with Mains Power Supply......................................18
5.1.2 Operation with Faulty Mains Supply.......................................19
5.1.3 Operation with a Faulty Inverter.............................................20
5.1.4 Operation with Manual Bypass ..............................................20
5.2 Function of the Circuit Breakers.............................................21
5.3 Static Bypass Switch (SBS)...................................................22
5.4 Charging the Battery..............................................................23
5.5 Manual Characteristic Curve Switchover...............................23
5.6 Battery Tests..........................................................................23
5.6.1 Capacity Check......................................................................24
5.6.2 Capacity Test.........................................................................25
6 Connection ...........................................................................26
6.1 Inputs and Outputs.................................................................26
6.2 Connection of the Mains, Load and Battery Cables...............27
6.3 Connection of the Control and Signal Lines...........................28
6.4 Connection Cross Sections and Fuse Protection...................29
7 Start-Up.................................................................................30
7.1 Preparing Start-up of the UPS (Individual Unit) .....................30
7.2 Starting up the UPS (Individual Unit) .....................................31

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8 Operation..............................................................................32
8.1 Disconnecting the UPS (Individual Unit)................................32
8.1.1 Restarting after Disconnection (Individual Unit).....................33
8.2 Shutting Down the UPS .........................................................33
8.3 Emergency Shutdown............................................................34
8.4 UPS Fuses.............................................................................34
9 Graphical Display and Operation Unit ...............................35
9.1 General Information ...............................................................35
9.1.1 Signalling ...............................................................................35
9.1.2 Keyboard Operation...............................................................36
9.2 Start-Up..................................................................................38
9.3 Menu Structure.......................................................................38
9.3.1 Menu Tree..............................................................................38
9.3.2 Main Menu .............................................................................39
9.3.3 Operating Display...................................................................39
9.3.4 Status/Measured Values........................................................40
9.3.5 Blocking .................................................................................41
9.3.6 Fault History...........................................................................41
9.3.7 Settings..................................................................................41
9.3.8 Information.............................................................................41
9.3.9 Service...................................................................................41
9.3.10 Help........................................................................................42
10 Annex....................................................................................43
10.1 Battery Handling using the Graphical DOU............................43
10.1.1 Charging the Battery..............................................................43
10.1.2 Battery Data...........................................................................44
10.1.3 Battery Tests..........................................................................45
10.1.4 Possible Battery Tests ...........................................................46
11 Interfaces..............................................................................47
11.1 Remote Signalling..................................................................47
11.2 Serial Interface.......................................................................48
12 Maintenance and Repairs....................................................49
12.1 Diagnostic Functions..............................................................49
12.2 Repairs...................................................................................49
12.2.1 Fault Table.............................................................................50
12.2.2 Removing and Installing the Fan............................................51
12.3 Maintenance ..........................................................................51
12.3.1 Visual Checks ........................................................................52
12.3.2 Functional Test ......................................................................52
12.3.3 Checking the Battery..............................................................53
13 Spare Parts and Customer Service....................................54
14 Annex....................................................................................55

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1 Safety Regulations
1.1 Important Instructions and Explanations
The instructions for operation and maintenance, as well as the
following safety regulations must be complied with to ensure the
safety of personnel as well as the continued availability of the unit.
All personnel installing/dismantling, starting up, operating or servicing
the units must be familiar with and observe these safety regulations.
Only trained and qualified personnel may perform the work described,
using tools, equipment, test equipment and materials intended for the
purpose and in perfect working condition.
Important instructions are highlighted by "CAUTION:",
"ATTENTION:", "NOTE:" and indented text.
CAUTION:
This symbol identifies all working and operational procedures
requiring absolute compliance to avoid any danger to persons.
ATTENTION:
This symbol identifies all working and operational procedures
requiring absolute compliance to prevent any damage, irreparable
or otherwise, to the UPS or its components.
i
NOTE:
This symbol identifies technical requirements and additional
information requiring the operator's attention.
This document includes brief instructions which describe the function
and start-up of the UPS.
These instructions must be glued to the free area on the inside of the
unit door.
1.2 Accident Prevention Regulations
Compliance with the accident prevention regulations valid in the
respective country of use and the general safety regulations in
accordance with IEC 364 is mandatory.
The following safety instructions must be observed prior to any work
on the UPS:
•Disconnect the unit from the power supply.
•Secure against reclosing.
•Verify that the unit is disconnected from the power supply.
•Earth and short circuit the unit.
•Provide protection by covers or barriers for any
neighbouring live parts.

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1.3 Danger during Maintenance and Repair Work
CAUTION:
The voltage applied to the UPS can be fatal. Prior to start-up
and/or maintenance work always disconnect the UPS from the
power supply and secure the unit against reclosing. The
capacitors must be discharged. Free-standing and movable
components can protrude into the work area and cause injuries.
ATTENTION:
Considerable damage can be caused to equipment if unsuitable
spare parts are used during repair work, if work is carried out by
unauthorised personnel, or the safety regulations are not
observed.
i
NOTE:
Only trained and qualified personnel (refer to Chapter 1.5) may
work on or around the UPS while strictly observing the safety
regulations.
1.4 Fire Protection
Structure of fireproof enclosures (EN 60950)
If uninterruptible power supply units are installed in rooms with
inflammable floors (e.g. textile, wood, PVC) or in computer centres,
the floor plate must always be installed. The assembler is responsible
for proper installation.
CAUTION:
If smoke is detected or a fire breaks out, immediately disconnect
the UPS from the power supply and inform the maintenance
personnel.
1.5 Qualified Personnel
The UPS may only be transported, installed, connected, started,
serviced and operated by qualified personnel who are familiar with
the pertinent safety and installation regulations. All work performed
must be inspected by responsible experts.
The qualified personnel must be authorised by the responsible safety
officer of the installation to perform the work required.
Qualified personnel is defined as personnel
•having completed training and gained experience in the
respective field,
•familiar with the pertinent standards, rules and regulations and
accident prevention regulations,
•having received instruction on the mode of operation and
operating conditions of the UPS,
•capable of recognising and preventing dangers.
Regulations and definitions for qualified personnel can be found in
DIN 57105/VDE 0105, Part 1.

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1.6 Safety Awareness
The personnel defined in chapter 1.5 are responsible for safety. They
must also ensure that only suitably qualified persons are permitted
access to the UPS or the safety area.
The following points must be observed:
All such working procedures are prohibited which are detrimental to
the safety of persons and the operation of the UPS in any way.
The UPS may only be operated in perfect working condition.
Never remove or render inoperable any safety devices.
All necessary operational measures must be initiated prior to
deactivating any safety device in order to perform maintenance,
repair or any other work on the unit.
Safety awareness also entails informing colleagues of any unsuitable
behaviour and reporting any faults detected to the respective
authority or person.
1.7 Application
The UPS may only be used for uninterrupted power supply in the
described installation position and operating mode while observing
the maximum permissible connection values as specified in these
operating instructions. The unit may only be used for this intended
purpose. It is not permitted to make any unauthorised modifications to
the UPS or to use any spare parts and replacement parts not
approved by AEG Power Supply Systems GmbH or to use the UPS
for any other purpose.
The person responsible for the installation must ensure that
•the safety instructions and operating instructions are readily
available and are complied with,
•the operating conditions and technical data are observed,
•safety devices are used,
•the prescribed maintenance work is performed,
•maintenance personnel is informed without delay or that the UPS
is shut down immediately in the event of abnormal voltages or
noise, high temperatures, vibrations or any similar effects in order
to detect the cause.
These operating instructions contain all information required by
qualified personnel for operation of the UPS. Additional information
and explanations for unqualified persons and for the use of the UPS
in non-industrial applications are not included in these operating
instructions.
The warranty obligations of the manufacturer are only applicable if
these operating instructions are observed and complied with.

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1.8 Liability
No liability is accepted if the UPS is used for applications not intended
by the manufacturer. Any measures necessary for the prevention of
injury or damage to equipment are the responsibility of the owner or
user. In the event of any claims in connection with the UPS, please
contact us immediately quoting:
•Type designation
•Works number
•Reason for claim
•Period of use
•Ambient conditions
•Operating mode
1.9 Directives
The Protect 5. 31/xxx units comply with the currently applicable
DIN and VDE regulations. VBG4 is met on the basis of compliance
with VDE 0106, Part 100.
The requirements of VDE 0100, Part 410, "Functional extra-low
voltage with safe isolation", have been complied with where
applicable.
The CE sign on the unit confirms compliance with the EC outline
directives for 72/23 EEC – Low voltage and for 89/339 EEC –
Electromagnetic compatibility if the installation and start-up
instructions described in these operating instructions are observed.

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2 Technical Data
Please refer to the enclosed technical data sheet for optional and unit-specific setting
values.
Type kVA 10 20 30 40 60 80 100 120
Rated connection voltages
Voltage range in V 3 x 480 V ±15 %
Frequency on rectifier input in Hz 45 - 66
Current consumption at
max. battery charge in A 19 36 54 72 110 147 181 216
Current consumption at trickle
charge in A 13 29 47 57 83 112 139 167
Rectifier output current IAGR
in A 50 95 143 190 280 370 460 550
Intermediate circuit voltage in V
(rated voltage) 216 bei 108 Lead acid cells voltage range 173 bis 260
Output voltage in V, neutral
conductor under full load 120 V optional adjustable from 110 V - 127 V
Output current in A 83 167 250 333 500 667 833 1000
Output frequency in Hz 50 Hz ±1 %
optional 60 Hz ±1 %
THD factor in % at rated load ≤3 %
Overload capacity 1,5 x Inom for 1 minute
1,25 x Inom for 10 minutes
Ishort circuit (max) = 3 x Inom
50 % Load Efficiency in %
Power loss in W
75 % Load Efficiency in %
Power loss in W
100 % Loadt Efficiency in %
Power loss in W
Outer dimensions in mm
without transport eyelets (IP20)
Height
Width
Depth
1810
600
850
1810
900
850
1810
1200
850
1810
1200
850
1810
1200
850
1810
2100
850
1810
2100
850
1810
2100
850
Weight in kg (approx.) 350 520 800 800 780 a/A* a/A* a/A*
Table 1 Technical data of the UPS
75

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3 General Information
One application of Protect 5. 31/xxx systems is to ensure an
uninterruptible power supply to computers, IT systems, process
control systems and their periphery in production and administration
systems.
The Protect 5. 31/xxx range covers a power range of 10 kVA to
80 kVA.
Figure 1 Example model 60 kVA (refer to Chapter 2, Table 1 for dimensions)
1 DOU – display and operation unit
2 Ventilation grids (4x) for each control cabinet
3.1 Technology
Due to the utilisation of electronic high-performance components, the
Protect 5. 31/xxx series is suitable for universal applications and has
a very high degree of operational reliability as well as optimum
efficiency and communication capability with other systems due to
integrated interfaces.
The entire control electronics of the UPS is based on the utilisation of
state-of-the-art microcomputer assemblies. Logical integration and
linking of the various assemblies in the overall system permits
specification of the unit properties by unit-related software parameter
settings.

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The information exchange between the individual modules is carried
out using the CAN bus (Controller Area Network). This CAN bus has
high interference immunity and is frequently used for industrial
applications.
U, N, PE- X4
U, V, W, PE
- X1
- Q1
- T1
- F1
- K7
- Q29
U, N, PE
- X3
L-, L+, PE- X2
Signalling
- A18 DOU
Display
Mains SBS-Mains
Battery Load
Rectifier
Inverter SBS
- T40
optional
optional
Figure 2 Functional principles of the Protect5.xxx/31
The main components of the UPS are (Figure 2):
Rectifier section with:
•Thyristor stack and control unit
•Transformer
•Smoothing device for the batteries
•Interference suppression devices
Inverter section with:
•Inverter stack and control unit
•Interference suppression devices
Static bypass switch (SBS) with:
•Thyristor stack and control unit
•Interference suppression devices
Figure 2 illustrates the functional principle of the uninterruptible power
supply unit.

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The rectifier (REC) supplies the inverter and the battery with
DC voltage. The inverter (INV) converts this DC voltage into a
1-phase AC voltage.
In the event of a mains fault (such as a power failure), the power
supply to the load is maintained from the battery without any
interruption.
The supply reliability is further increased by the static bypass
switch (SBS), which in the event of an INV fault switches the
SBS circuit over to the load circuit without any interruption.
3.2 Operating Elements of the UPS
12
1
2
3
7, 8
9
10
6
11
X1 X2 X3 X4
OFF
5
4
Figure 3 Arrangement of the operating elements, components and individual PCBs
with open door
1 Fans
2 Optional PCBs on the control unit pivot plate
3 Remote signalling (master board and expansion board)
4 CAN-COM controller (CCC)
5 Terminal strip X12 (remote signals and options)
6 Q29, manual bypass switch
7, 8 Ventilation grids
9 Terminals for rectifier and SBS circuits, battery and loads
10 Q1, load interrupter switch for the rectifier circuit
11 Internal fuses for control unit and fan (A91)
12 DOU display and operation unit

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4 Transport, Storage and Installation
4.1 Packing
The UPS units are packed at the works to withstand both rail and
road transport. The housing is fixed to the transport pallet using four
bolts. The unit is packed in plastic film to prevent any damage to the
surface paint and protect the unit against moisture.
i
NOTE:
To prevent damage only remove the protective film from the UPS
immediately prior to installation.
The four fixing bolts on the base frame can then be removed using a
spanner.
4.2 Crane Transport
CAUTION:
Do not walk under suspended loads!
Always wear protective clothing such as a helmet, safety shoes
and work gloves!
Transport the unit with due care and observe the safety
regulations!
ATTENTION:
Only transport the UPS in an upright position!
Never tilt or cant it, avoid displacing the centre of gravity!
Figure 4 Transporting by crane

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The length of the ropes is calculated so that an angle of 45° is given
between the rope and the top edge of the cabinet (DIN 580). The
minimum load capacity of each rope must be ≥0.5 times the weight
of the cabinet (DIN 580). The weight of each UPS can be found in
Table 1, Chapter 2. One rope must be used for each transport eyelet.
Proceed as follows to transport the unit by crane (Figure 4):
•Insert and tighten the four transport eyelets (not supplied) in the
threaded bores provided on top of the cabinet.
•Hook in the four ropes.
•Carefully lift the UPS and transport it to its intended location.
•Lower the UPS carefully without jolting it.
•Remove the ropes and transport eyelets.
4.3 Transporting the Unit using a Forklift or Lowlift Truck
ATTENTION:
Prior to transport with a forklift or lowlift truck, always ensure that
the transport devices used for the UPS are designed for the
respective weight (refer to Table 1, Chapter 2).
i
NOTE:
Transport with a forklift or lowlift truck should be avoided
whenever possible, especially on construction sites and/or uneven
ground.
Always transport by crane when possible!
Fixing bolts for ventilation grids
Figure 5 Ventilation grid

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Preparation:
Leave the UPS on the transport pallet.
Transport with lowlift truck Transport with forklift truck
Figure 6 Transport with lowlift and forklift truck
ATTENTION:
Observe the centre of gravity of the unit!
The lifting arms must be
- sufficiently long and
- sufficiently far apart.
Transport the unit as follows:
•Insert the lifting arms between the transport pallet and the UPS.
•Carefully lift the UPS and transport it to its intended location.
•Lower the UPS carefully without jolting it.
•Retract the forklift or lowlift truck.
•Refit the ventilation grids on the UPS using the corresponding
fixing bolts.
4.4 Site Requirements
Suitable floor surfaces for installation of the UPS are:
•Double floors
•Above cable ducts or
•directly on a level surface.
Ensure that the weight of the UPS units does not exceed the
maximum floor bearing capacity (refer to Table 1, Chapter 2).
The site must also meet the following requirements:
•be free of conductive dust,
•be free of corrosive or acid fumes,
•the intake air temperature of the unit must not exceed 35 °C, and
•the air vents of the UPS must not be obstructed by any
constructional features or other measures.
UPS units are suitable for installation in confined spaces. Ensure that
a min. space of 1000 mm is provided in front of the unit to ensure an
escape route, and a space of 400 mm above the unit to guarantee
unobstructed air venting.

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ATTENTION:
The waste heat of the UPS must be dissipated!
The ventilation of the battery compartments must be carried out in
accordance with DIN/VDE 0510, Part 2. The following general rule is
applicable for ventilation requirements (for lead-acid batteries):
Q = 0.05 x n x I / 2
with: Q = air volume in m3/h
n = number of lead-acid cells
I = amperage
The ambient temperature in the battery compartment should not
exceed 20 °C, as the service life of the batteries is otherwise
considerably reduced.
4.5 Floor Mounting
Four holes are provided in the base frame of the UPS for the fixing
bolts. The spacing and diameter of the bores can be found in the
table below.
Before securing the UPS to the floor, ensure that it is vertically
aligned, and compensate for any unevenness (e.g. using metal
wedges).
Type rating
in kVA 10 20 30/40 60 80/100/120
Cubicle 1 Cubicle 2
a in mm 450 750 1050 1050 750 1050
b in mm 600 900 1200 1200 900 1200
Figure 7 Dimensions for floor mounting
"A"
Load introduction area
Detail "A":
75
5
0
50 2
5
ø20
2
5
7
5
0
ø20
Wall
b
8
5
0
a

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4.6 Storage
UPS units may only be stored for a maximum period of six months in
the original packaging in dry, ventilated rooms with a permanent roof.
The permissible ambient temperature range is between -35 °C and
+70 °C with a relative humidity of ≤85%.
If the unit is stored for longer than six months, conventional
desiccants must be added and the UPS units must be sealed in
airtight plastic film.
Please refer to the respective manufacturer's instructions for storage
instructions for the batteries.
5 Function
5.1 Operating Modes
Four different operating modes are possible:
•Operation with mains power supply
•Operation with faulty mains supply
•Operation with defective inverter, and
•operation with manual bypass.
5.1.1 Operation with Mains Power Supply
~
_
~
_
Q29
Mains Secured
busbar
Loads
SBS
circuit
Q29
Q29 option
Figure 8 Power circuit with mains supply
The rectifier is powered from the mains and converts the AC voltage
statically into a stabilised DC voltage. This DC voltage serves for
charging and automatic trickle charging of the connected battery,
which is always charged as a result.
The inverter converts this secured DC voltage into a stabilised
sinusoidal AC voltage and powers the connected loads.

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5.1.2 Operation with Faulty Mains Supply
~
_
~
_
Q29
Mains Secured
busbar
Loads
SBS
circuit
Q29
Q29 option
Figure 9 Power circuit with a faulty mains supply
The mains does not sufficiently maintain the supply of the rectifier of
the UPS system. In this case, power is supplied to the inverter from
the charged battery without interruption. The power supply to the
loads is therefore also ensured in the event of a mains failure.
The standby time is limited by the extent to which the batteries are
discharged and is primarily determined by the battery capacity.
The inverter only switches off when the battery voltage drops below
the permissible value.
When the voltage and frequency are within the tolerance range once
more after the mains supply has been restored, the rectifier switches
back on automatically. It then resumes the voltage supply to the
inverter and the charging of the battery.

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5.1.3 Operation with a Faulty Inverter
~
_
~
_
Q29
Mains Secured
busbar
Loads
SBS
circuit
Q29
Q29 option
Figure 10 Power circuit with a faulty inverter
If an inverter is defective, power is supplied to the loads by the
SBS circuit.
The SBS is an electronic switching device between the load and the
mains. The synchronisation unit in the SBS ensures that the
frequency and phases of the inverter voltage are synchronised with
the mains.
5.1.4 Operation with Manual Bypass
~
_
~
_
Q29
Mains Secured
busbar
Loads
SBS
circuit
Q29
Q29 option
Figure 11 Power circuit with manual bypass
The manual bypass enables maintenance and service personnel to
perform work on the UPS without having to switch off the load circuit.
ATTENTION:
The manual bypass switch Q29 may only be actuated when the
inverter is switched off.
In the event of a mains supply failure in manual bypass mode, the
load supply fails.