Alpha Outback Energy Tri Power X33 HIP 800 KVA User manual

Tri Power X33 HIP 800 KVA
USER MANUAL

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Work gloves
Use: always
Helmet
Use: When there are suspended loads
Protective clothing
Use: always
Protective eyewear
Use: always
Accident prevention footwear
Use: always
No maintenance operations must be carried out on the device without wearing the Personal Protective
Equipment (PPE) described below.
Personnel involved in the installation or maintenance of the equipment must not wear clothes with wide
sleeves or laces, belts, bracelets or other items that may be dangerous, especially if they are metallic.
Long hair must be tied in such a way as to ensure that it is not a hazard.
The following signs show the protective equipment that should be worn. The various items of PPE must
be selected and sized according to the nature of the hazard (particularly electrical) posed by the
equipment.
Protective equipment to be worn
Thank you for choosing our product.
Symbols used in the manual
In this manual, some operations are shown by graphic symbols to alert the reader to the dangerous nature of the
operations:
Possibility of serious injury or substantial damage to the device, unless
adequate precautionary countermeasures are taken.
This symbol indicates some important information which must be read with
care.
It is recommended to read this part of the manual.
Alpha and Outback is highly specialized in the development and production of uninterruptible power supplies
(UPS). The UPSs of this series are high quality products, carefully designed and manufactured to
ensure optimum performance.

Emergency interventions
The professional figure responsible for accessing the equipment for ordinary maintenance purposes is defined with
the term operator.
This definition covers personnel that know the operating and maintenance procedures for the equipment, and that
have been:
1. trained to operate in accordance with the safety standards relating to the dangers that may arise where
electrical voltage is present;
2. trained to use Personal Protective Equipment and to carry out basic first aid.
The professional figure responsible for the installation and start-up of the equipment, and for any extraordinary
maintenance, is defined with the term specialized technician.
This definition covers personnel that, in addition to the requirements listed above for a general operator, must also:
1. have been suitably trained by the manufacturers or their representative.
2. be aware of installation, assembly, repair and service procedures, and have a specific technical qualification.
3. must have a background of technical training, or specific training relating to the procedures for the safe use
and maintenance of the equipment.
The following information is of a general nature.
First aid interventions
Company regulations and traditional procedures should be followed for any first aid intervention that may be
required.
Firefighting measures
1. Do not use water to put out a fire, but only fire extinguishers that are suitable for
use with electrical and electronic equipment.
2. If exposed to heat or fire, some products may release toxic fumes into the
atmosphere. Always use a respirator when extinguishing a fire.
Definition of “operator” and “specialized technician”
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General Precautions
This manual contains detailed instructions for the use, installation and start-up of the TRI POWER X33
HIP . Read the manual carefully before installation. For information on using the TRI POWER X33 HIP ,
the manual should be kept close at hand and consulted before carrying out any operation on the device.
This device has been designed and manufactured in accordance with the standards for the product, for
normal use and for all uses that may reasonably be expected. It may under no circumstances be used for
any purposes other than those envisaged, or in any other ways than those described in this manual. Any
interventions should be carried out in accordance with the criteria and the time-frames described in this
manual.
Precautions and Safety Regulations
Refer to the “Safety and Compliance Manual” supplied with the UPS (0MNA141_NE).
Environmental Protection
In the development of its products, the company devotes abundant resources to analysing the
environmental aspects.
All our products pursue the objectives defined in the environmental management system developed by
the company in compliance with applicable standards.
No hazardous materials such as CFCs, HCFCs or asbestos are used in this product.
When evaluating packaging, the choice of material has been made favouring recyclable materials.
For correct disposal, please separate and identify the type of material of which the packaging is made in the table
below. Dispose of all material in compliance with applicable standards in the country in which the product is used.
Description
Material
Pallet
Wood (FOR)
Package box
Corrugated cardboard
(PAP)
Protective bag
High density
polyethylene (PE-HD)
Bubble wrap
Low density
polyethylene (PE-HD)
Disposing of the product
The UPS contain electronic cards and batteries which are considered TOXIC and HAZARDOUS waste. When the
product reaches the end of its operating life, dispose of it in accordance with applicable local legislation.
Disposing of the product correctly contributes to respecting the environment and personal health.
The reproduction of any part of this manual, in whole or in part, is forbidden without the prior consent of the
manufacturer. In order to make improvements, Alpha and Outback reserves the right to modify the product described
at any moment and without notice.
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Contents
1. Preliminary operations .......................................................................................................................................... 7
1.1 Removing the packaging and positioning the device ......................................................................................... 7
1.2 Storage ............................................................................................................................................................... 7
1.3 Handling.............................................................................................................................................................. 7
2. Installation environment ....................................................................................................................................... 8
2.1 Ambient conditions: ............................................................................................................................................ 8
2.2 Dimensions of the premises ............................................................................................................................... 8
2.3 Cooling of the premises ...................................................................................................................................... 9
2.4 Air change for battery premises ......................................................................................................................... 9
3. TRI POWER X33 HIP IN SINGLE CONFIGURATION ......................................................................................... 10
3.1 Set-up of the electrical system ......................................................................................................................... 10
3.1.1 Input ............................................................................................................................................................... 10
3.1.2 Selectivity ....................................................................................................................................................... 11
3.1.3 Battery ............................................................................................................................................................ 12
3.1.4 neutral conductor ........................................................................................................................................... 12
3.1.5 Differential (RCD) ........................................................................................................................................... 13
3.1.6 Backfeed protection ....................................................................................................................................... 14
3.1.7 Emergency power off device (EPO) .............................................................................................................. 14
3.2 Mains, load and battery connections ................................................................................................................ 15
3.3 Connection of signals and remote commands ................................................................................................. 17
3.3.1 EPO connector (emergency power off control).............................................................................................. 17
3.3.2 REMOTE COMMANDS AND ALARMS ......................................................................................................... 17
3.3.3 RS232 ............................................................................................................................................................ 18
3.3.4 Parallel (optional) ........................................................................................................................................... 19
3.3.5 SLOTS 2-1 ..................................................................................................................................................... 19
3.3.6 REMOTE ALARMS (2 optional cards) ........................................................................................................... 19
3.3.7 MODEM (optional) ......................................................................................................................................... 19
3.3.8 MULTI I / O (optional) .................................................................................................................................. 20
3.3.9 REMOTE PANEL (OPTIONAL) ..................................................................................................................... 20
3.3.10 Dual Bus System – UGS (optional). .............................................................................................................. 20
3.3.11 SWOUT and SWMB aux - External temperature sensor (optional). .............................................................. 21
3.4 Start-up procedure ............................................................................................................................................ 24
3.4.1 Battery operation check ................................................................................................................................. 25
3.5 Operating modes .............................................................................................................................................. 26
3.5.1 On - line - factory setting ................................................................................................................................ 26
3.5.2 Standby-on / Smart active .............................................................................................................................. 26
3.5.3 Standby-off (with mains present the load is not powered) ............................................................................. 27
3.5.4 Stabilizer (operation in on-line mode without battery) ................................................................................... 27
3.5.5 Frequency converter (from 50 to 60Hz or vice versa) ................................................................................... 27
3.6 Personalizations ............................................................................................................................................... 28
3.7 Procedure to transfer the load from UPS onto maintenance bypass. .............................................................. 28
3.8 UPS and load shutdown ................................................................................................................................... 29
3.9 Block diagram ................................................................................................................................................... 30
3.10 Components of the block diagrams .................................................................................................................. 31
4. TRI POWER X33 HIP IN PARALLEL CONFIGURATION ................................................................................... 34
4.1 Introduction ....................................................................................................................................................... 34
4.2 Electrical system set-up .................................................................................................................................... 35
4.2.1 Input ............................................................................................................................................................... 35
4.2.2 Differential ...................................................................................................................................................... 35
4.2.3 Emergency power off device (EPO) .............................................................................................................. 35
4.2.4 External maintenance bypass ........................................................................................................................ 36
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4.3 Mains, load and battery connections. ............................................................................................................... 37
4.3.1 UPS AC input / output power connection ...................................................................................................... 37
4.3.2 Power connections battery side ..................................................................................................................... 38
4.4 Connection of signals ....................................................................................................................................... 39
4.5 Start-up procedure ............................................................................................................................................ 41
4.6 Operating modes .............................................................................................................................................. 42
4.7 bypass for maintenance ................................................................................................................................... 44
5. Maintenance ......................................................................................................................................................... 48
6. General characteristics ....................................................................................................................................... 50
7. Appendix A - remote commands and alarms card ........................................................................................... 52
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1. Preliminary operations
1.1 Removing the packaging and positioning the device
On delivery, the packaging must be inspected to ensure that it is whole and that it has not been crushed or dented.
Check in particular that neither of the two impact resistant devices on the packaging is red; if one of them is red,
follow the instructions on the packaging.
The essential details of the device are provided on the shipping document. The marking, weight and dimensions of
the various items making up the packing list are shown.
Check the state of the device by means of a visual inspection of both the inside and the outside. Any dents seen
mean that it has suffered knocks during shipping, which could compromise the normal operation of the device.
1.2 Storage
In the following situations:
installation not immediately after delivery;
de-installation and storage while awaiting relocation,
place the device in covered premises that are protected from direct contact with atmospheric agents and dust. The
following environmental values are those allowed in the storage area:
Temperature: -25 ÷ + 60 °C
Relative humidity: 30 ÷ 95 % max.
For the installation of a battery cabinet, if provided with the uninterruptible power supply, follow the
instructions given in the specific manual.
The list of material provided may vary depending on the order specifications. As a general rule, the packaging should
include the following: this manual, the installation drawing, the warranty and eventual accessories.
1.3 Handling
The equipment must only be handled by adequately trained personnel. It can be unloaded from the vehicle and put
into place by lifting the box or the wooden deck to which the equipment is secured with a fork-lift truck. A transpallet
or fork-lift truck should be used for the permanent positioning of the equipment, in accordance with the instructions
provided below.
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1 Insert the forks of the fork-lift truck in the lower part of the device, from the front or back, and ensure that they
stick out about 30 cm on the other side.
If a transpallet is used, raise the device only as much as is strictly necessary.
2 Secure the device to the transpallet or fork-lift before moving it.
Risk of overturning
In order to avoid the risk of the device overturning, ensure that it is firmly secured to the transpallet or
fork- lift truck by means of appropriate ropes before moving it.
When being moved the cabinet should be handled with care; knocks or drops can damage it. Once in position,
remove the packaging carefully in order not to scratch the device.
The packaging should be removed as follows:
1. Cut the bands
2. Slide away the carton from above.
3. Remove the screws securing the cabinet to the wooden base.
4. If using a transpallet, remove the device from the pallet and set it on the floor, using the same precautions as
set out in the section on Handling.
2. Installation environment
The TRI POWER X33 HIP and the battery cabinet have been designed for indoor installation. The choice of
premises for installation should comply with the points set out below.
2.1 Ambient conditions:
ensure that the floor can support the weight of the UPS and of any battery cabinet that may be used;
avoid dusty environments;
avoid narrow environments that could hinder normal maintenance operations;
avoid placing the device in areas exposed to direct sunlight or heat;
ensure that the ambient temperature conforms to the following:
minimum operating temperature: 0 °C
maximum temperature for 8 hours a day: + 40°C
average temperature for 24 hours: + 35°C
max relative humidty: 95 % without condensation
Max installation height: 1000 m at rated power
(-1% power for every 100 m above 1000 m) max 4000 m
2.2 Dimensions of the premises
For the mechanical dimensions of the cabinets, refer to the “INSTALLATION DRAWINGS” supplied with the UPS
and with the battery cabinet, if present. These drawings provide the following data:
the position of the holes in the base to secure the device to the floor, if applicable;
the view of the floor support for the sizing of a structure to raise the cabinet, if applicable;
the position of cable entry;
the position of the fans on the top of the UPS, for the positioning of a structure to convey the warm air
discharged by the equipment outside the premises, if applicable;
the input, output and battery cables section;
the power dissipated by the equipment (kW).
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2.3 Cooling of the premises
The recommended operating temperature for the lifetime of the UPS and of the batteries is between 20 and 25°C.
The lifespan of the battery depends on the operating temperature; with an operating temperature of between 20°C
and 30°C, the lifespan of the batteries is halved. A heat dissipation system is required to keep the temperature of the
premises housing the equipment within the field 20÷25°C.
The heat dissipation needed for the correct operation of the UPS is brought
about by the air current made by the fans located inside the UPS (forced
convection) and by the air around the side panels (natural convection).
In order to ensure proper air circulation, and therefore the correct operation of
the UPS, measures must be taken during installation to avoid any obstructions
to the free circulation of air. These include the following:
ensure a distance of at least 60 centimetres from the ceiling, so as not
to hinder air extraction,
leave a free space of at least one metre at the front of the equipment
to ensure both the circulation of the air and installation and
maintenance operations;
With natural convection the thermal load is dissipated to the outside
through the walls; thus a cabinet placed against a wall or in a hollow
dissipates less heat than one located in a free environment.
The following rule must be observed:
leave at least one of the three side walls free: right, left or back.
the side strips must not be mounted for installations where cabinets are placed side by side.
2.4 Air change for battery premises
The room in which the battery box is installed must be provided ventilated so as to keep the concentration of
hydrogen generated during charging within safe limits. The room should preferably be ventilated naturally; if it cannot
be, forced ventilation may be employed. Standard EN 50272-2 regarding air exchange provides that the minimum
aperture must satisfy the following equation:
A = 28 x Q = 28 x 0.05 x n x Igas x C10 (1/10³) [cm²]
where: A = surface free of air input/output opening; Q = air flow to be exhausted [m³/h];
n = number of battery elements; C10 = battery capacity in 10 hours [Ah];
Igas = gas producing current [mA//Ah]
according to the standard:
Igas = 1 in backup charging for VRLA type batteries (*); Igas = 8 in fast charging for VRLA type batteries (*)
(*) for open vessel or nickel batteries, contact the battery manufacture for details.
example calculation
Type of battery: VRLA; Number of elements: 240 (40 mono-blocks)
Capacity: 120Ah; Igas (**): 8 (fast charging)
A = 28 x Q = 28 x 0.05 x n x Igas x C10=28 x 0.05 x 240 x 8 x 120 x 1/10³ = 322 cm2
(**) to increase the safety margin, we take the fast charging condition, well aware that the battery mostly runs in
backup charging mode. Using the backup charging value for Igas would result in a value of one eighth of the above.
The air intake/outlet must be located so as to be most favourable to circulation, e.g.:
openings on opposing walls;
with a minimum distance of 2 m if both on the same wall.
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