Ametek electronic systems Surgex ups-32020-80 User manual

Uninterruptible Power Supply

UPS-32020-80

User Manual

Table of

Contents

1. Introduction and Safety

Important Safety

Instructions 4

Note to

Users 6

2. Installation

UPS Unpacking

Instructions 8

UPS

Installation 10

Clearance

Guide 11

Wiring

Guide 12

UPS Connector Terminals and Lug

locations 13

3. Product Specifications

UPS-32020-80 Product

Specifications 17

4. Operation

UPS Operational

Overview 19

UPS Operation: Normal

Mode 19

UPS Operation: Battery

Mode 20

UPS Operation: Bypass

Mode 21

UPS Operation: Emergency

Bypass 22

UPS Operation: Manual Maintenance Bypass

Mode 23

Touch Screen Description, Calibration, Using the Touch

Screen 24

Touch Screen Descriptions

(Monitoring) 25

UPS Startup

Sequence 26

UPS Shutdown

Sequence 31

UPS Maintenance Bypass

Sequence 33

Monitor

Functions 41

Control Functions 43

Touch Screen Menu’s 57

5. Maintenance

UPS Maintenance 75

Battery Maintenance 76

Battery Replacement 77

6. Service and Troubleshooting

Alarm Severity Definitions 85

Alarms Messages 86

7. Drawings

UPS Outline Drawings 90

Block Diagram (UPS + External Battery Cabinet) 91

Block Diagram (UPS + Input Transformer Cabinet) 92

Block Diagram (UPS + Output Transformer Cabinet) 93

Block Diagram (UPS + Input/Output Transformer) 94

Block Diagram (UPS + 3 Breaker MBS) 95

Block Diagram (UPS + 3 Breaker MBS + Input Step-Down Transformer) 96

Block Diagram (UPS + 3 Breaker MBS + Output Isolation Transformer) 97

Block Diagram (UPS + 3 Breaker MBS + Input/Output Transformers) 98

Facility Data Planning Guide 100

1.

Introduction and

Safety

****IMPORTANTSAFETY

INSTRUCTIONS****

****SAVE THESE

INSTRUCTIONS****

This manual contains important instructions to be followed during installation and maintenance of the

UPS and batteries.

Please read all instructions before installing or operating the described equipment and

PLEASE SAVE THIS MANUAL FOR FUTURE REFERENCE!

SPECIAL SYMBOLS: The following are examples of symbols used on the UPS, or within this manual to

alert you to important information. Please familiarize yourself with these symbols.

Risk of Electric Shock- observe the warnings associated with the risk of electrical

shock.

CAUTION: HOT SURFACE –Do not touch! Risk of burn hazard.

CAUTION: REFER TO OPERATOR’S MANUAL—refer to operator’s

manual for additional information, such as specific

operating and/or maintenance instructions.

Do Not Discard--this equipment utilizes components that contain lead and must be

disposed of properly. For more information, contact your local recycling/refuse or hazardous waste

center.

Do Not Discard-- never discard Waste Electrical or Electronic Equipment

(WEEE) in the trash. For proper disposal contact your local recycling/refuse or hazardous waste center.

Information of Special Note--Specific handling or operational instructions may

apply.

Phase--This is the electrical symbol for the word “phase”.

Recycle—equipment or components are made of recyclable material, please

contact your local recycling center for proper disposal.

NOTE TO USERS

To ensure correct operation of the UPS, please read this instruction manual carefully. Please

keep this manual handy for future reference.

This UPS has dangerouslyhigh voltageson both its Input and output

connections. Contact with these voltages may

be life threatening. Please follow the operating instructions

carefully. Please give close attention to the warnings in this manual and those

posted on the UPS. There are no user serviceable parts inside the UPS.

Disassembly and/or

maintenance should only be done by authorizedpersonnel.

IMPORTANT INFORMATION FOR USERS OF THIS

UNINTERRUPTIBLE POWER SUPPLY

1. Before operating the UPS or connecting any load equipment, please ensure the UPS

is connected to a properly grounded electrical supply.

2. This UPS has dangerouslyhigh voltages on both its input and output connections.

Contact with these voltages may be life threatening.

3. Please do not disassemble the covers. There is a risk of electric shock.

4. In an emergency, immediately turn off the circuit breaker for the circuit supplying power to the UPS.

Also immediately turn off the battery circuit breaker.

5. This UPS has two power sources. One is the circuit supplying the UPS with input power. The other is the

UPS battery. Prior to any maintenance, both of these power sources must be disconnected to ensure that

the UPS is de-energized. If only the input power is disconnected, the UPS can still operate from the

battery, and hazardous voltages may still exist.

6. To prevent damage or a safety hazard, keep the UPS away from open flame and any other devices that

may cause sparks.

7. Do not open or damage individual battery cases as spillage of caustic electrolyte may occur resulting

in danger to life, safety, and the environment.

8. The charging characteristicsof UPS batteries vary by both brand and type. For this reason, replacement

batteries should be of the same brand and type as those specified by the manufacturer. Using batteries

other than the brand and type specified by the manufacturermay affect the performance of the UPS.

Before installing batteries of different brand or type, please consult with the manufacturer.

9. The UPS has an internal EMI filter for purposes of enhancing electromagnetic compatibility with the

input mains supply. This filter produces leakage current to earth on the input mains. When selecting a

circuit breaker for the branch circuit

supplying power to the UPS, ensure that the breaker selected is not an ELCB type circuit breaker that

detects earth leakage current.

10. Please contact the manufacturer or an authorized distributor for any assistance with troubleshooting.

11. The UPS should only be serviced or maintained by a factory authorized service technician.

12. This UPS meets FCC Class A electromagnetic compatibility requirements.

13. Depleted batteries must be disposed of in a proper manner. Contact your local recycling or

hazardous waste center or the UPS manufacturer for instructions concerning proper disposal.

LIFE CRITICAL APPLICATIONS

While SURGEX believes it designs and manufactures very reliable Products, many of the

vendors that SURGEX sources components from do not recommend or endorse the use of

their Products in life critical applications. By extension, SURGEX must adhere to the same

business policy and does not recommend the use of our Products in life critical applications.

Disclaimer

SURGEX Products are not designed, intended, authorized, tested, or UL Listed for use in

systems intended to support or sustain life, or for any other application in which the failure of a

SURGEX Product could create a situation where personal injury or death may occur. Should

Buyer purchase or use SURGEX Products for any such unintended or unauthorized application,

Buyer shall indemnify and hold SURGEX and its officers, employees, subsidiaries, affiliates

and distributors harmless against all claims, costs, damages and expenses, and reasonable

attorney fees arising out of, directly or indirectly, any claim or personal injury or death

associated with such unintended or unauthorized use, even if such claim alleges that SURGEX

was negligent regarding the design or manufacture of the part.

2. Installation

UPS Unpacking Instructions

The SURGEX UPS-32020-80 comes packed in heavy cardboard with foam

dividers on a heavy wooden pallet. The unit is bolted to the skid with two metal brackets. A

wooden ramp is stored vertically in front of the UPS. This ramp is used to move the UPS off of

its shipping pallet.

Note: SURGEX encourages the end user to retain all shipping materials

until the UPS has been inspected, installed and verified for proper operation.

The SURGEX UPS-32020-80 UPS utilizes internal batteries which are pre-assembled in

individual trays and shipped separately from the UPS. These trays come completely wired and

ready for connection to the internal battery harness of the UPS. A quick visual inspection is

requested to determine if any connections were unseated during the shipping process.

Unpacking the UPS requires a 19mm wrench or socket. To remove the UPS from the packing

materials:

1. Visually inspect the unit for any signs of transit damage (Fig. 2-1). Remove and retain all

associated paperwork (packing list, user’s manual etc.) that is affixed to the top of the

unit. Remove the cardboard lid from the top of the container.

2. Remove any fasteners from the lower edge of the cardboard container.

3. With the help of an assistant, carefully lift the heavy cardboard container straight up until

it is clear of the UPS. (Fig. 2-2)

4. Remove the foam dividers. (Fig. 2-3)

5. Lift the ramp clear of the alignment pin, and place it sloping downward at the front of the

UPS, using the pin to hold the back of the ramp in place.

6. Remove the protective plastic cover from the UPS.

7. The UPS is attached to the shipping pallet with two shipping brackets—one on each side

of the UPS. Using an adjustable wrench or 19mm socket, remove the three bolts that

attach the bracket to the UPS. If your location has a Seismic requirement, please contact

factory for Seismic installation instructions. (Fig. 2-4)

8. The UPS has two leveling feet. Be sure to check that the levelers are up against the

bottom of the UPS to ensure it rolls freely on the ramp.

9. With the help of an assistant, carefully roll the UPS off the pallet and down the ramp to

the floor of your facility. If the floor at your desired UPS location is uneven, the levelers

may be used to steady the UPS, once it is in place.

Please do not install batteries in the UPS. Batteries should be installed ONLY

by factory authorized personnel once the UPS is in its final location, and at the time of

initial startup.

Fig. 2-1 Fig. 2-2 Fig. 2-3

UPS

Leveler

Shipping

bracket

bolts (3

per side)

Fig. 2-4

UPS Installation

The installation of this UPS should be performed only by

qualified personnel who are familiar with UPS and battery systems and

the required precautions necessary for safe and proper installation.

Unauthorized and /or unqualified personnel should not attempt to install

or service this

equipment.

Any damage resulting from installation or

service performed by unauthorized/unqualifiedpersonnel, or non-

compliance with any pertinent local codes will void the warranty

of

this

equipment.

Maximum operating ambient temperature is 40°C

Storage (non-operating) ambient temperature range is -20°C to 60°C

Please consult the Facility Data Planning Guide for floor loading and unit cooling characteristics.

The levelers are not designed to support the weight of the entire unit, they are to be used when

the floor is not entirely level.

CAUTION: Please confirm that the AC Input switch and the Battery Disconnect

switch are in the “Off”position, and the Manual Maintenance Bypass is in the “Normal”

position, before making any connections to this UPS.

The SURGEX UPS-32020-80 requires a 208V three phase, four wire (+ ground) input for

proper operation. Input over current protection and the output disconnect are to be

provided by the user. The Facility Data Planning Guide is available as a guideline to assist with

the installation of the UPS. This document however, is not intended as a substitute or to

supersede any regional or local electrical codes. In the event of questions or controversy

regarding the installation of this equipment, the local Authority Having Jurisdiction (AHJ)

should always be consulted and will have the ultimate final approval over the installation.

SURGEX UPS-32020-80 Clearance Guide

Location Minimum Clearance (Inches)

Top (Above) of Cabinet 36

Front of Cabinet 36

Rear of Cabinet 12

Sides of Cabinet 6*

*Matching peripheral cabinets are considered to be part of the UPS system, so the 6”

spacing should be taken from the outside edge of the peripheral cabinet.

12 Inches

6 Inches SURGEX

UPS-32020-80

UPS

6 Inches

Front of UPS

36 Inches

Minimum Clearance Guidelines

The following steps refer to bottom feed installations only.

Once the UPS has been properly unpacked (see page 9) and placed in its installation location,

the leveling feet must be lowered. These levelers are located in the front of the unit below the

door.

SURGEX recommends the following overcurrent device (provided by customer) to be used as

the electrical supply (input) to the UPS-32020-80 UPS:

UPS Model

(kVA)

External

Overcurrent

Protection*

Recommended

Wire Size

Terminal Wire

Range

(Min. –Max.)

Tightening

Torque

(Min. –Max.)

20 70A #4 AWG #16 to # 0 2.8 Nm (min) /

AWG** 3.0 Nm (max)

* To be provided by customer ** 75°C min. rated CU conductors only

The terminals for input and output connections to the UPS are accessed by opening the hinged

front door of the UPS (Fig.2.6) Firmly grab the left hand side of the door and pull outward. The

magnetic keepers will release and the door will open exposing the flat front of the UPS (Fig.2.7).

Fig. 2-6 Fig. 2-7

UPS-front view UPS –front view with door open

Once opened, the connection terminals can be accessed by removing the screws holding the

terminal safety cover in place (Fig 2.8). This cover is located just below the three rotating

handles used for the operation of the UPS. (Their operation is described elsewhere in this

manual)

Fig. 2-8

UPS-front view with door opened and terminal safety cover removed

L1 L2 L3 N

T1 T2 T3 N

Pos. Batt. Neg.

Neut.

The terminals to accommodate the input and output conductors are laid out as follows (Fig. 2.9):

AC Input

ON Maintenance Bypass

NORMAL BYPASS

Battery Disconnect

ON

OFF OFF

AC MAIN INPUT

TB1 UPS OUTPUT

TB2 TB3

Fig. 2-9

As shown above, the input (LINE or “L”designated terminals) conductors are connected to the

(L-R) first four terminals. This UPS will not operate without an incoming neutral conductor. The

required input phase rotation is ABC. The output (LOAD or “T” designated terminals)

conductors are connected to the (L-R) next four terminals. In all cases the conductors should

enter the enclosure from the bottom and enter the lugs or terminals from the bottom. All

conductors entering this terminal area must be kept to the left of the barrier separating terminal

TB2 from TB3.

The grounding locations are marked with the following symbols:

Protected Earth (Input) Earth (Output)

Top side of terminal-

To Internal UPS wiring

Bottom side of Terminal -

To customer wiring

20kVA Terminal

Care should be taken when installing these conductors so as to not confuse the

input (LINE) and output (LOAD) phase conductors. Keeping in mind this UPS requires an input

neutral for proper operation. Once all conductors are properly landed and sufficiently tightened

to their respective torque specs, the terminal safety cover may be reinstalled.

Terminal safety cover must be installed prior to operation of the UPS.

SURGEX recommends a disconnecting means with the following overcurrent ratings

(provided by customer) to be used as the electrical supply (output) from the UPS-32020-80 UPS

to the critical load:

UPS Model

(kVA)

External

Overcurrent

Protection*

Recommended

Wire Size

Terminal Wire

Range

(Min. –Max.)

Tightening

Torque

(Min. –Max.)

20 70A #4 AWG #16 to # 0

AWG**

Gnd. (All

models) #6 AWG #6 -2/0 AWG** 120 In-lbs.

* To be provided by customer ** 75°C min. rated CU conductors only

3. Product Specifications

SURGEXUPS-32020-80 Specifications

Applicable Standards:

UL1778 and CSA 22.2

IEC, 62040 UPS Standard

ISO 9001 Quality Assurance Program

EMI compatibility: FCC Title 47 Part 15,

Subpart B

IEEE C62, 41-1991

OSHPD Special Seismic Certification # -

OSP-0336-10

Model Power Rating (kVA): Capacity(kW): Frequency:

UPS-32020-80 20 18 50/60Hz

System Input (Converter):

Operating Input Voltage 208VAC (operating window = 177to 239VAC)

(Nominal +15% / -15%) 3 Phase 5 wire

Frequency Range +/- 5Hz

Input Current THD < 1 % @ 100% load, < 2 % @ 50 % load

Input Power Factor .99 @ 100% load, .98 minimum @ 50% load

Battery Voltage 432VDC Nominal (36 batteries x 12V)

Converter Walk-in Time 20 Seconds

System Input (Bypass):

Nominal Input Voltage 208VAC, 3Phase 4 Wire

Input Synchronization Voltage Range +/- 10% of Nominal

Input Frequency Tracking Range +/- 3 HZ

Output Fault Clearing 400% for 10s, 1000% for ½ cycle

System Output:

Nominal Output Voltage 208VAC 3 Phase 4 Wire

Static Voltage Regulation +/- 2%

Output Frequency 60Hz (tracks frequency of static bypass source)

(Inverter Synchronous) +/- .2, .5, 1 and 2Hz (user settable)

Output Frequency Slew Rate +/- 1 Hz per second

Frequency Regulation 60Hz +/- .01% (free running)

Output Voltage Harmonic Distortion Less than 1% (linear load0

Less than 2% with a crest factor of 2.5 to 1

Output Overload Capacity 125% for 10min., OR 150% for 60 seconds

Voltage Transient Response +/- 2% for a 100% step load

Environmental:

Efficiency (100% load)

Operating Ambient Temperature DC to AC = 94% AC to AC = 92%

Storage Temp. (non-operating) 0° to 40° C (no derating required)

Relative Humidity (non-condensing) -20° to +60° C (without batteries)

Recommended: 30% to 90%

Acoustical Noise level Maximum: 5% to 95%

Heat Dissipation ( @ 208v input) < 54dba @ 1 meter

20kVA = 7.60 kBTU / Hr.

4. Operation

UPS Operational Overview:

The SURGEX UPS-32020-80 UPS is a continuous-duty, solid state, transformerless, 208V three

phase 4 wire true online double conversion system, which provides uninterruptible power to

critical loads. The SURGEX UPS-32020-80 UPS maintains power to the critical load during

commercial electrical power brownout, blackout, overvoltage, undervoltage, and out-of-tolerance

frequency conditions.

The basic system consists of a rectifier, battery, and inverter, which are complemented by static

bypass and manual maintenance bypass switches.

UPS Operation: Normal Mode

With the AC supply present, the rectifier transforms the AC input into DC, raising the DC to a

suitable level to supply the inverter and to charge the batteries.

The inverter transforms the DC bus voltage into AC, providing a sine wave AC output, stabilized

in voltage and frequency, to the critical load.

Manual Maint.

Bypass

Static Bypass

Switch

CUSTOMER

SUPPLY AC

Disconnect

Battery

Breaker

Rectifier Inverter

Static

Switch

CRITICAL

LOAD

Battery

UPS Cabinet

UPS Operation: Battery Mode

In the event of an AC input failure, the batteries provide the power necessary to supply the

inverter. The inverter continues functioning as in normal mode, supplying AC power to the

critical load.

Manual

Maint.

Bypass

Static

Bypass

Switch

CUSTOMER

SUPPLY

AC

Disconnect

Battery

Breaker

Rectifier Inverter

Static

Switch

CRITICAL

LOAD

Battery

UPS Cabinet

AMETEK Electronic Systems SURGEX UPS-32020-80 User manual

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