Always “On” UPS M4101 User manual

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14
Borealis Series
Three Phase ELI System
8 KW – 48 KW
Installation Manual

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 i

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 ii
NOTE
The instructions contained in this manual are not intended to cover all of the
details or variations in equipment, or to provide for every possible contingency
to be met in connection with installation, operation, or maintenance. Should
further information be desired or should particular problems arise which are not
covered sufficiently for the purchaser’s purposes, the matter should be referred
directly to Always On.
Any electrical or mechanical modifications to this equipment, without prior
written consent of Always On, will void all warranties and may void UL/cUL
listing. Unauthorized modifications may also result in personal injury, death,
and damage to the equipment.
Dear Customer,
Thank you for selecting our emergency lighting inverter (ELI). We are pleased
to include you as one of our valued Always On customers!
We are confident that this emergency lighting inverter system, developed and
manufactured in our ISO 9001 certified facilities, will provide the quality and
satisfaction you demand.
Please read this installation manual carefully as it contains the necessary
information required to install the ELI properly.
Thank you for choosing Always On.

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 iii
Preface
Congratulations on your choice of our emergency lighting inverter (ELI).
This equipment has been manufactured and tested using methods and procedures equivalent to
UL 924.
This manual describes the recommended procedures for installing the ELI.
While every effort has been made to ensure the completeness and accuracy of this manual,
Always On assumes no responsibility or liability for any losses or damages resulting from the
use of the information contained in this document.
WARNING: This manual is intended to provide installation instructions only.
The information contained in this manual is to be used as a guideline and
recommendation only. Only qualified personnel should perform installation
and maintenance. Factory authorized personnel shall inspect installation
prior to start up and commissioning to validate warranty. Failure to follow
this directive will void the warranty.
We recommend that this manual be kept with the ELI for future reference. If any problems are
encountered with the procedures contained in this manual, please contact our Service Centre
before proceeding.
This document may not be copied or reproduced without the explicit written permission of
Always On.
Due to technical advancements and improvements, some of the information contained in this
manual may be changed or modified without prior notice.

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 iv
Symbols
The following symbols are used through out this manual.
Warning Information
This symbol alerts you to important information.
Electrical Hazard
This symbol indicates an electrical hazard may be present.
Electrical Symbols
Protective grounding terminal; a terminal that must be connected to ground prior to
making any other connection to the equipment.
A terminal to/from which an alternating current or voltage may be applied/supplied.
A terminal to/from which a direct current or voltage may be applied/supplied.
This symbol indicates the word “phase”.

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 v
Safety Instructions
READ AND FOLLOW ALL SAFETY INSTRUCTIONS.
SAVE THESE INSTRUCTIONS.
This manual contains important safety instructions that should be followed during installation
and maintenance of the ELI system and optional packages. Before the installation process
begins, we recommend that the installer read through the safety precautions, operators manual
and the option installation instructions, taking all necessary safety precautions to protect
themselves and the equipment being installed.
GENERAL
-Move the ELI in an upright position, in its original packaging, to its final destination.
-To lift the cabinets, use a forklift or lifting belts with spreader bars.
-Check for sufficient floor and elevator loading capacity.
-Check the integrity of the ELI equipment carefully.
-If visible damage is evident, do not attempt to install or start the ELI. Contact the transport
delivery company immediately, file a claim with the transport company and inform Always
On directly.
-Do not use outdoors.
-The use of accessory equipment not recommended by Always On may cause an unsafe
condition
-WARNING! RISK OF ELECTRICAL SHOCK: use extreme caution when removing covers.
-All maintenance and service work should be performed by qualified and trained service
personnel. The ELI may contain its own energy source, (batteries) which can be dangerous
to the untrained person. This ELI contains potentially hazardous voltages
-The field-wiring terminals may be electrically live, even when the ELI is not connected to the
utility.
-Use caution when servicing batteries. A battery can present a risk of electrical shock, burn
from high short-current. Battery acid can cause burns to skin and eyes. If acid is spilled on
skin or in eyes, flush with fresh water and contact physician immediately.
-When replacing batteries use the same number and type (sealed-cell lead acid).
-Proper disposal of batteries is required. Refer to your local codes for disposal requirements.
-Dangerous voltages may be present during battery operation. The batteries must be
disconnected during maintenance or service work. (Open battery breaker or fuses)
-Be aware that the inverter can restart automatically after the utility voltage is restored.
-Do not use this equipment for other than intended use.

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 vi
INSTALLATION
-This ELI is intended for use in a controlled indoor environment free of conductive
contaminants and protected against any type of intrusion.
-Do not install the ELI in an excessively humid environment or near water.
-Avoid spilling liquids and/or dropping any foreign object(s) onto the ELI.
-The unit must be placed in a sufficiently ventilated area; the ambient temperature should not
exceed 40°C (104°F).
-Optimal battery life is obtained if the ambient temperature does not exceed 25°C (77°F).
-HIGH GROUND LEAKAGE CURRENT: ground connection completed before connecting the
AC voltage wires on the input!
-Switching OFF the ELI does not isolate the ELI from the utility as the utility supply is still
HOT at the input terminal strip. Supply breaker needs to be opened.
-It is important that air can move freely around and through the unit. Do not block the air
vents.
-Avoid locations in direct sunlight or near heat sources (gas or electric heaters).
STORAGE
-Store the ELI in a dry location free of contaminants;
-Storage temperature must be within -25°C (-13°F) to 55°C (131°F).
- If the unit is stored for a period exceeding 3 months, the batteries must be recharged
periodically (time depending on storage temperature).
WARNING!
LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT IS
APPARENTLY NOT OPERATING. OBSERVE ALL CAUTIONS AND WARNINGS IN THIS
MANUAL. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. REFER
UNIT TO QUALIFIED SERVICE PERSONNEL IF MAINTENANCE IS REQUIRED. NO ONE
SHOULD WORK ON THIS EQUIPMENT UNLESS THEY ARE FULLY QUALIFIED TO DO SO.
AN INSTALLER SHOULD NEVER WORK ALONE.
WARNING!
WHEN REMOVING POWER FROM THE ELI, ALLOW FIVE MINUTES FOR CAPACITORS
TO DISCHARGE BEFORE WORKING ON THE EQUIPMENT.
CAUTION!
This equipment complies with the requirements in Part 15 of FCC rules for a Class A
computing device. Operation of this equipment in a residential area may cause
interference to radio and TV reception, requiring the operator to take whatever steps
necessary to correct the interference.
CAUTION!
Do not put option control wiring in the same conduit as the ELI input or output power
cables.

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 vii
THIS SAFETY NOTICE IS ADDRESSED TO THE ALWAYS ON
CUSTOMER ENGINEERS WHO PERFORM MAINTENANCE OF THE
UNINTERRUPTIBLE POWER SUPPLY (ELI) SYSTEMS.
Electrical Safety
•Maintenance work to be performed by a factory trained customer engineers, or qualified
personnel. Extremely dangerous voltage levels can exist within the ELI system. Extreme
caution must be used.
•Ensure system is in maintenance bypass mode or external wrap-around bypass mode
before work is started.
•This manual is designed as an aid tool in diagnosing problems that may arise. Always
On does not assume responsibility if information causes injuries.
•Apart from the front door, do not open any other part of the ELI without consulting the
factory first. Before removing the protection screens, be sure that the unit is completely
powered off.
•Be aware that dangerous voltage can be supplied by the internal battery or electrolytic
capacitors.
•When system is in bypass mode and all fuses have been opened dangerous voltages
may exist within the ELI system. Use extreme caution when exchanging boards and
working inside the unit.
READ AND FOLLOW ALL SAFETY INSTRUCTIONS.
SAVE THESE INSTRUCTIONS.

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 viii
TABLE OF CONTENTS
1. Introduction..................................................................................................................................1
1.1. Overview.....................................................................................................................1
1.2. Features......................................................................................................................1
1.3. Definitions..................................................................................................................2
2. Handling ........................................................................................................................................3
2.1. Transport....................................................................................................................3
2.2. Delivery.......................................................................................................................3
2.3. Storage........................................................................................................................3
2.4. Unpacking..................................................................................................................4
3. Physical Topology......................................................................................................................5
4. Installation ....................................................................................................................................8
4.1. Site & Environmental Conditions........................................................................8
4.2. Cable Selection.......................................................................................................10
4.3. Terminal Strip Connections................................................................................11
4.4. Skirting Installation ...............................................................................................12
5. ELI AND BBU WIRING DIAGRAMS.......................................................................................13
6. INTERFACE CONNECTIONS..................................................................................................18
6.1. Dry Contacts............................................................................................................18
6.2. Software for PC Monitoring.................................................................................19
6.3. Emergency Power off Connection.....................................................................19
6.4. DB9 Connectors.....................................................................................................19
6.5. Web Monitoring Module (SNMP Module).........................................................19
6.6. Emergency Lighting Notification.......................................................................20
7. Battery Backup Units (BBU)...................................................................................................22
7.1. Run Time Charts.....................................................................................................24
7.2. BBU Configurations ..............................................................................................26
8. Technical Specifications.........................................................................................................28
9. Contact Information..................................................................................................................32

**WARNING: ONLY AUTHORIZED FACTORY TRAINED PERSONNEL ARE PERMITTED TO COMMISSION, START UP OR OPERATE THE INVERTER SYSTEM (ELI).
WARRANTY IS VOID IF UNAUTHORIZED PERSONNEL COMMISSION OR START UP THE INVERTER.
M4101_Borealis_8-48Kw_Installation_Manual V1.0 2012-06-14 1
1. Introduction
Congratulations on your choice of the Borealis On-Line Emergency Lighting Inverter (ELI). This
ELI features the latest top of the line microprocessor technology and IGBT transistors and
provides clean, highly regulated and pulse width modulated (PWM) true sine wave power.
1.1. Overview
This ELI is designed for installation between your AC power supply (utility or generator)
and your lighting equipment. It provides power to your equipment during major power
events such as blackouts and brownouts, over-voltage and under-voltage conditions.
The ELI provides a consistent supply of regulated AC power during these power events,
allowing you to ensure safety and lighting for the period required.
1.2. Features
This ELI provides full time self-diagnostics as well as two levels of audible alarms when
the unit is operating in battery mode. Along with the current mode of operation, the LCD
screen displays critical system information including:
•Percent Load
•Remaining battery capacity, battery voltage
•Input voltage,
•Output voltage,
•Input frequency,
•Output frequency and
•Internal ELI temperature.
A manual test switch has been incorporated into the input/test breaker that makes
testing a simple procedure. The internal bypass switch allows maintenance on the ELI to
be performed without interruption of power to the load.
The communications port, in conjunction with multi-platform monitoring and control
software, enables the unit to be connected to a local or networked computer system.
Detailed operating information including voltages, currents, and alarm status is available
to the monitoring system.
Other communications options include:
•An SNMP adapter to remotely control and monitor the unit via a network or the
Internet.
•An AS-400 interface to allow for relay communications in PLC or dry contact
environments.