AEG Protect C.R User manual

OPERATING INSTRUCTIONS UPS
PROTECT C.
R
PROTECT C. 1000 R (S)
PROTECT C. 2000 R (S)
PROTECT C. 3000 R (S)
PROTECT C. 6000 R

Thank you for purchasing the PROTECT C.R. from AEG
Power Solutions.
Safety information and operating instructions are
included in this manual. To ensure correct use of the
UPS, please read this manual thoroughly before
operating it. Save this manual properly.
2

1 Notes on these Operating
Instructions
Duty to Provide Information
These operating instructions will help you to install and
operate the Uninterruptible Power Supply (UPS) PROTECT
C. 1000 R(S), PROTECT C. 2000 R(S), PROTECT C. 3000 R (S)
or PROTECT C. 6000 R as well as the associated external
battery units PROTECT C. 1000 R BP, PROTECT C. 2030 R BP
or PROTECT C. 6000 R BP, – all referred to as PROTECT C.R
in this document – safely and properly, and for its intended
purpose. These operating instructions contain important
information necessary to avoid dangers during operation.
Please read these instructions carefully prior to
commissioning!
These operating instructions are a composite part of the
PROTECT C.R.
The owner of this unit is obliged to communicate the full
content of these operating instructions to all personnel
transporting or starting the PROTECT C.R or performing
maintenance or any other work on the unit.
Validity
These operating instructions comply with the current technical
specifications of the PROTECT C.R at the time of delivery.
The contents do not constitute a subject matter of the
contract, but serve for information purposes only.
Warranty and Liability
We reserve the right to alter any specifications given in these
operating instructions, especially with regard to technical data
and operation, prior to start-up or as a result of service work.
Claims in connection with supplied goods must be submitted
within one week of receipt, along with the packing slip.
Subsequent claims cannot be considered.
3

The warranty does not apply to damage caused by non-
compliance with these instructions (such damage also
includes damaging the warranty seal). AEG will accept no
liability for consequential damage. AEG reserves the right to
rescind all obligations such as warranty agreements, service
contracts, etc. entered into by AEG and its representatives
without prior notification in the event of maintenance and
repair work being carried out with anything other than original
AEG spare parts or spare parts purchased by AEG.
Handling
PROTECT C.R is designed and constructed so that all
necessary steps for start-up and operation can be performed
without any internal manipulation of the unit. Maintenance
and repair work may only be performed by trained and
qualified personnel.
Illustrations are provided to clarify and facilitate certain steps.
If danger to personnel and the unit cannot be ruled out in the
case of certain work, it is highlighted accordingly by
pictograms explained in chapter 3.
Hotline
If you still have questions after having read these operating
instructions, please contact your dealer or our "Hotline":
Tel.: ++49 (0)180 5 234 787
Fax: ++49 (0)180 5 234 789
Internet: www.aegpartnernet.com
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.
© Copyright AEG 2009. All rights reserved.
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Table of Contents
1Notes on these Operating Instructions ............................ 3
2General Information ......................................................... 7
2.1 Technology ............................................................... 7
2.2 System Description................................................... 8
3Safety............................................................................... 9
3.1 General Safety Instructions ...................................... 9
3.2 Safety Instructions for PROTECT C.R .................... 9
3.3 CE-Certificate ......................................................... 13
3.4 Technical Data........................................................ 15
4Set-Up and Operation.................................................... 22
4.1 Unpacking and Inspection ...................................... 22
4.2 Point of Installation ................................................. 23
4.3 Overview: Connections, Operating /Display Elements .. 24
4.3.1 Front view ........................................................ 24
4.3.2 Rear view......................................................... 24
4.3.3 Display............................................................. 26
5Commissioning .............................................................. 27
5.1 Mechanical Set-Up ................................................. 27
5.1.1 Set-Up in a 19" Rack ....................................... 27
5.2 External Battery Expansions .................................. 28
5.2.1 Electrical Start-Up ........................................... 29
5.3 Operating Statuses................................................. 32
5.3.1 Normal Operation ............................................ 32
5.3.2 Battery Operation / Autonomy Operation ........ 33
5.3.3 Bypass Operation............................................ 34
5.3.4 Unit Overload................................................... 35
5.4 Interfaces and communication................................ 36
5.4.1 Data line protection RJ11 and RJ45
(modem / telephone / fax / network) ................ 36
5.4.2 Computer interfaces RS232 ............................ 36
5.4.3 Communication Slot ........................................ 36
5.4.4 Shutdown and UPS management software .... 37
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6Signalling and Error Correction ......................................38
6.1 Signalling.................................................................38
6.2 Fault Diagnosis / Fault Rectification........................40
6.2.1 Error Messages................................................40
7Maintenance...................................................................42
7.1 Charging the Battery ...............................................42
7.2 Maintenance.. Fehler! Textmarke nicht definiert.42
7.2.1 Visual Check....................................................43
7.2.2 Checking the Battery .......................................43
7.2.3 Fan Checking...................................................43
8Storage, Dismantling and Disposal................................44
8.1 Storage....................................................................44
8.2 Dismantling .............................................................44
8.3 Disposal ..................................................................44
9Glossary .........................................................................45
9.1 Technical terms.......................................................45
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2 General Information
2.1 Technology
i
PROTECT C.R is an Uninterruptible Power
Supply (UPS) for essential loads such as PCs,
workstations, servers, network components,
telecommunication equipment and similar
devices. It consists of:
Mains filter with overvoltage protection (appliance
protection/class D) and mains energy backfeed protection
Rectifier section with PFC logic (power factor correction unit)
Separate battery charger with switch mode power supply
technology
Sealed, maintenance-free battery system (2kVA externally)
as energy storage medium with DC/DC converter unit
IGBT inverter for continuous supply of connected loads
with sinusoidal AC voltage
Automatic bypass as additional passive redundancy
Microprocessor controlled control unit
View of the PROTECT C.R components
Inverte
r
Batter
y
s
y
stem
Load
Automatic
bypass
Mains
~
~
Battery
char
g
e
r
~
PFC
CPU
control unit
RS232
SNMP
DC/DC booste
r
Mains
filter
Filter
Rectifier
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2.2 System Description
The UPS is connected between the public utility's mains and
the loads to be protected.
The power section of the rectifier converts the mains voltage
to DC voltage for supplying the inverter. The circuit
technology used (PFC) enables sinusoidal current
consumption and therefore operation with little system
disturbance. A separate, second rectifier (charging REC set
up using switch mode power supply technology) is
responsible for charging or trickle-charging the battery
connected in the intermediate circuit. The configuration of this
charging REC means the harmonic content of the charging
current for the battery is almost zero, so the service life of the
battery is increased even more. The inverter is responsible
for converting the DC voltage into a sinusoidal output voltage.
A microprocessor-controlled control system based on pulse-
width modulation (PWM) in conjunction with an extremely
quickly pulsating IGBT power semiconductors of the inverter
guarantee that the voltage system on the protected busbar is
of the highest quality and availability.
In the event of mains faults (e.g. current failures), the voltage
continues to be supplied from the inverter to the load without
any interruption. From this point onwards, the inverter draws
its power from the battery instead of the rectifier. No switching
operations are necessary; this means there is no interruption
in the supply to the load.
For safety reasons (as required by German standards, VDE),
the mains input in the unit will be disconnected by a two-pole
switch in the event of a mains failure. Energy backfeed to the
mains and voltage supply to the pins of the mains connector
are thus reliably avoided.
The automatic bypass serves to increase the reliability of the
supply further. It switches the public mains directly through to
the load if there is an inverter malfunction. As a result, the
automatic bypass represents an extra passive redundancy for
the load.
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3 Safety
3.1 General Safety Instructions
Read these operating instructions prior to start-up of the
PROTECT C.R UPS and its external battery modules (special
accessories), and observe the safety instructions!
Only use the unit if it is in a technically perfect condition and
always in accordance with its intended purpose, while being
aware of safety and danger aspects, and in accordance with
the operating instructions! Immediately eliminate any faults
that could be detrimental to safety.
The following pictograms are used in these operating
instructions to identify dangers and important information:
Danger!
Identifies risk of fatal injury to the operator.
Attention!
Identifies risk of injury and risk of damage to the
unit and parts of the unit.
i
Information!
Useful and important hints for the operation of the
UPS and its external battery modules (special
accessories).
3.2 Safety Instructions for PROTECT C.R
This chapter contains important instructions for the
PROTECT C.R UPS and its external battery modules (special
accessories). These must be followed during assembly,
operation and maintenance of the uninterruptible power
supply and the battery systems (internal and, if appropriate,
external as well).
9

The UPS carries high voltage. Danger! The unit
may only be opened by trained and qualified
personnel. Repairs may only be carried out by
qualified customer service staff!
The output may be live, even if the UPS is not
connected to the mains, since the UPS has its
own internal power supply (battery)!
For health and safety reasons, the unit must be
earthed correctly!
PROTECT C.R may only be operated with or connected to a
220 V / 230 V / 240 V mains with protective grounding using a
CE marked mains connection cable with PE conductor
(included in the delivery) that has been tested in accordance
with national standards.
Danger! Risk of burning!
The battery has powerful short-circuit
currents. Incorrect connection or isolation faults
can lead to melting of the plug connections,
sparking potential and severe burns!
The unit has a warning signal that sounds when
the battery voltage of PROTECT C.R is
exhausted or when the UPS is not working in its
normal mode (see also chapter 6.1).
Observe the following safety instructions to
ensure permanent operational safety of and safe
work with the UPS and the battery modules
(special accessories):
Do not dismantle the UPS!
(The UPS does not contain any parts that require regular
maintenance. Bear in mind that the warranty will be
invalidated if the unit is opened!)
Do not install the unit in direct sunshine or in close
proximity of heaters!
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The unit is designed to be installed inside in heated
rooms. Never install the housing in the vicinity of water or
in an excessively damp environment!
Condensation may occur if the UPS is brought from a
cold environment into the room where it is to be installed.
The UPS must be absolutely dry prior to start-up. As a
result, leave it to acclimatise for at least two hours.
Never connect the mains input to the UPS output, and
vice versa!
Ensure that no fluids or foreign bodies can penetrate the
housing!
Do not block the air vents of the unit! Keep children away
from the unit and ensure that objects are never inserted
through the air vents!
Do not connect household appliances such as hairdryers to
the UPS! Also take care when working with motor loads. It is
essential to avoid back-feeding the inverter, e.g. if the load is
intermittently operated in regenerative mode.
The mains connection should be near the unit and easily
accessible to facilitate disconnecting the AC input or
pulling out the plug!
During operation, do not disconnect the mains connection
cable from the UPS or from the socket outlet in the building
(shockproof socket), otherwise the protective grounding of the
UPS and all the loads connected to it will be cancelled.
Danger! Electric shocks!
Even after the mains voltage has been
disconnected, the components within the UPS
remain connected to the battery and can thus
cause electric shocks. It is therefore imperative to
disconnect the battery circuit before carrying out
any maintenance or repair work!
If it is necessary to replace the battery or carry
out maintenance work, this must be done by or
under the supervision of a specialist familiar with
batteries and the necessary safety precautions!
Only authorised persons are allowed in the
vicinity of the batteries!
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When replacing the batteries, the following must be observed:
Only ever use identical maintenance-free sealed lead
batteries with the same data as the original batteries.
Danger! Explosive!
Never throw batteries into open fire.
Never open or damage batteries. (Electrolyte
may leak out and damage skin and eyes. It may
be toxic!)
Batteries can cause electric shocks and high
short-circuit currents.
Take the following safety precautions when working with the
batteries:
Take off watches, rings and other metallic objects!
Always use tools with insulated handles!
i
Do not switch loads on and off using the UPS
main switch. Do not use multiple outlet adapters
with a central on/off switch, in order to avoid
peak inrush currents.
Switch OFF the UPS using its main switch “OFF” if you do not
intend to use it for some time. PROTECT C.R must be
switched off every evening if the electricity supply in your
company is switched off every night. Otherwise, the battery
will be discharged (assumed power failure). Frequent and
complete discharging of the battery leads to a shorter service
life of the battery and should therefore be avoided!
For personal safety reasons, never switch on the
main switch when the mains connector of
PROTECT C.R is disconnected!
12

3.3 CE-Certificate
13

14

3.4 Technical Data
Type power
PROTECT C. 1000 R (S) 1000 VA (cos = 0.7 lag.)
700 W
PROTECT C. 2000 R (S) 2000 VA (cos = 0.7 lag.)
1400 W
PROTECT C. 3000 R (S) 3000 VA (cos = 0.7 lag.)
2100 W
PROTECT C. 6000 R 6000 VA (cos = 0.7 lag.)
4200 W
UPS Input
Rated input voltage 220 / 230 / 240 Vac
Voltage tolerance range
C. 1000 R (S) – C. 3000 R (S) 160 Vac – 300 Vac ± 5 Vac
Bypass 80 Vac – 264 Vac
C. 6000 R 176 Vac – 276 Vac ± 3 %
Bypass 176 Vac – 261 %
Nominal frequency 50 Hz / 60 Hz
(automatic detection)
Frequency tolerance range ± 4 Hz
Curr. consumption (full load)
PROTECT C. 1000 R (S) 7 A
PROTECT C. 2000 R 10 A
PROTECT C. 2000 R S 12 A
PROTECT C. 3000 R (S) 16 A
PROTECT C. 6000 R 31 A
Input power factor
C. 1000 R(S) – C. 3000 R(S) ≥0.96
C. 6000 R ≥0.98
Connection
C. 1000 R(S) – C. 3000 R(S) non-heating
appliance connector
C. 6000 R Terminal block
15

Overvoltage RJ11 (phone, fax, modem)
dataline protection RJ45 (Ethernet 10/100 MBit/s)
UPS Output
Rated output voltage
C. 1000 R(S) – C. 3000 R(S) 220 / 230 / 240 Vac ± 2 %
C. 6000 R 220 / 230 / 240 Vac ± 1 %
(configuration via software
“CompuWatch”)
Nominal frequency
C. 1000 R(S) – C. 3000 R(S) 50 Hz / 60 Hz ± 0.2 %
C. 6000 R 50 Hz / 60 Hz ± 0.1 %
(depending on mains)
Voltage waveform Pure sine wave
Harmonic distortion:
≤4 % THD (linear load)
≤7 % THD (non-linear load)
Connection Non-heating appliance connectors
Current Crest Ratio 3:1
Overload behaviour in battery mode
C. 1000 R(S) – C. 3000 R(S) up to 105 % ± 5 % continuous;
> 105 % ± 5 % – < 150 % ± 5 %
for 25 s;
150 % ± 5 % for 200 ms
C. 6000 R up to 105% continuous;
> 105 % for 10 s
Overload behaviour with existing mains
C. 1000 R(S) – C. 3000 R(S) up to 105 % ± 5 % continuous;
> 105 % ± 5 % – < 150% ± 5 %
for 30 s;
150 % ± 5 % for 300 ms
Then automatic inverter to
Bypass in < 4 ms (switches
back when overload damps =
Load < 90 %))
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C. 6000 R up to 105 % continuous;
> 105 % – < 130 % for 10 min;
130 % for 1 s
Then automatic inverter to
Bypass in 0 ms (switches
back when overload damps
= Load < 90 %)
Short circuit behavior 3 x INfor 140 ms
Battery
Autonomy time (full load with internal battery)
PROTECT C. 1000 R 6 min.
PROTECT C. 2000 R,
C. 3000 R and C. 6000 R at least one battery module
required
Autonomy time with external optional battery expansions
(only for PROTECT C. – models):
Autonomy time (full load)
Coupled
battery modules C.1000 R C. 2000 R C. 3000 R C. 6000 R
1 37 min. 10 min. 5 min. 8 min.
2 75 min. 30 min. 17 min. 25 min.
3 - 50 min. 30 min. 45 min.
4 - 75 min. 48 min. 60 min.
5 - 90 min. 60 min. 70 min.
Rated direct voltage (intermediate circuit)
PROTECT C. 1000 R (S) 36 V
PROTECT C. 2000 R (S) 96 V
PROTECT C. 3000 R (S) 96 V
PROTECT C. 6000 R 240 V
Battery charging current
PROTECT C. 1000 R 1 A
PROTECT C. 1000 R S 7 A
PROTECT C. 2000 R 1 A
17

PROTECT C. 2000 R S 9.6 A
PROTECT C. 3000 R 1 A
PROTECT C. 3000 R S 9.6 A
PROTECT C. 6000 R 2 A
Recharge time PROTECT C. – models
(to 90% of rated capacity)
Coupled
battery modules C. 1000 R C. 2000 R C. 3000 R C. 6000 R
Integr. battery 5 h - - -
1 24 h 5 h 5 h 5 h
2 40 h 14 h 14 h 14 h
3 - 24 h 24 h 24 h
4 - 32 h 32 h 32 h
5 - 40 h 40 h 40 h
Type Sealed, maintenance-free
PROTECT C. 1000 R 12 V 7.2 Ah x 3
PROTECT C. 1000 R BP 12 V 7.2 Ah x 3 x 2
PROTECT C. 2030 R BP 12 V 7.2 Ah x 8
PROTECT C. 6000 R BP 12 V 7.2 Ah x 20
Comment for “S” versions UPS with increased battery
charger for charging external
battery systems (no integrated
battery)
Communication
Ports RS232 SUB-D (9-pin)
additional: communication slot
for expansion (z.B. AS/400 /
SNMP, ...)
Shutdown Software on CD “CompuWatch” for all popular
operating systems like
Windows, Linux, Mac, Unix,
FreeBSD, Novell, Sun
18

General Data
Classification VFI SS 211 to IEC 62040–3
Double conversion technology
Overall efficiency (full load)
PROTECT C. 1000 R (S) ≥85 %
PROTECT C. 2000 R (S) ≥85 %
PROTECT C. 3000 R (S) ≥88 %
PROTECT C. 6000 R > 88 %
Noise level (1m distance)
PROTECT C. 1000 R (S) < 45 dB (A)
PROTECT C. 2000 R (S) < 50 dB (A)
PROTECT C. 3000 R (S) < 50 dB (A)
PROTECT C. 6000 R < 55 dB (A)
Type of cooling Forced cooling
by variable speed fans
Operating temperature range 0°C to +40°C
Recommendation +15°C to
+25°C (due to battery
system)
Storage temperature range 0°C to +40°C
Relative humidity < 95%, non-condensing
Max. site altitude up to 1000 m at full load
If the UPS is installed or used
in a place where the altitude
is above than 1000m, the
output:
Altitude (m) 1000 1500 2000 2500 3000
Derating
Power 100% 95% 90% 85% 80%
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Outlets
PROTECT C. 1000 R (S) 4 x IEC 320-10A
PROTECT C. 2000 R (S) 4 x IEC 320-10A
PROTECT C. 3000 R (S) 1 x IEC 320-10A
+ 1 x IEC 320-16A
PROTECT C. 6000 R 4 x IEC 320-10A
+ connection via terminal block
Equipment colour Black line
Weights:
PROTECT C. 1000 R 16.5 kg
PROTECT C. 1000 R S 9.5 kg
PROTECT C. 1000 R BP 19 kg
PROTECT C. 2000 R 10 kg
PROTECT C. 2000 R S 11 kg
PROTECT C. 3000 R 11 kg
PROTECT C. 3000 R S 12 kg
PROTECT C. 2030 R BP 29 kg
PROTECT C. 6000 R 18 kg
PROTECT C. 6000 R BP 64 kg
Dimensions W x H x D:
PROTECT C. 1000 R (S) 482.6 mm x 88 mm x 450 mm
PROTECT C. 1000 R BP 482.6 mm x 88 mm x 450 mm
PROTECT C. 2000 R (S) 482.6 mm x 88 mm x 450 mm
PROTECT C. 3000 R (S) 482.6 mm x 88 mm x 450 mm
PROTECT C. 2030 R BP 482.6 mm x 88 mm x 450 mm
PROTECT C. 6000 R 482.6 mm x 132 mm x 600 mm
PROTECT C. 6000 R BP 482.6 mm x 132 mm x 600 mm
20