Aros Flexus FM Series User manual

THE SCIENCE OF CONTINUITY
MANUALE D’USO
USER MANUAL
BETRIEBSHANDBUCH
MANUEL D’UTILISATEUR
MANUAL DE USUARII

- 53 -
INTRODUCTION
Thank you for choosing this product.
Our company is specialized in the design, development and production of uninterruptible power supplies (UPS).
The UPS described in this manual is a high-quality, meticulously-designed product, built to guarantee the best
performance.
This manual contains detailed instructions on how to use and install the product.
For information on how to use your equipment to its full potential, this manual should be kept close at hand
beside the UPS and READ BEFORE STARTING TO WORK ON IT.
© Copying all or any part of this manual is strictly prohibited unless due authorization has been granted by the manufacturers.
In order to improve the product, the manufacturers reserve the right to make changes to it at any time and with no notice.

- 54 -
CONTENTS
OVERVIEW 56
FLEXUS FM 56
FRONT VIEWS OF THE UPS 57
VIEW OF THE UPS CONNECTIONS 58
REAR VIEW OF THE UPS 59
VIEW OF THE CONTROL PANEL 60
BATTERY BOX (OPTIONAL) 61
SEPARATE BYPASS INPUT (OPTIONAL) 62
ADDITIONAL INTERNAL BATTERY CHARGERS (OPTIONAL) 62
INSTALLATION 63
STORAGE OF THE UPS AND THE BATTERY BOX 63
PREPARATION FOR INSTALLATION 63
PRELIMINARY INFORMATION 63
ELECTROMAGNETIC COMPATIBILITY 64
INSTALLATION ENVIRONMENT 64
REMOVING THE UPS AND THE BATTERY BOX FROM THE PALLET 65
PRELIMINARY CHECK OF CONTENTS 66
INSTALLING THE UPS AND THE BATTERY BOX 66
STEPS TO BE TAKEN TO GAIN ACCESS TO THE TERMINALS OF THE UPS /BATTERY BOX 66
ELECTRICAL CONNECTIONS 67
DIAGRAMS OF CONNECTIONS TO THE ELECTRICAL SYSTEM 67
PROTECTIONS INSIDE THE UPS 70
EXTERNAL PROTECTION DEVICES 71
CABLE SIZES 72
CONNECTIONS 72
CONNECTIONS FOR THE MODEL WITH SEPARATE BYPASS 73
CONNECTION OF UPS SINGLE-PHASE INPUT 73
R.E.P.O. (REMOTE EMERGENCY POWER OFF) 74
EXTERNAL SYNC 74
CONNECTION OF THE REMOTE MAINTENANCE BYPASS 75
CONNECTING THE BATTERY BOX TO THE UPS 77
MULTIPLE EXPANSIONS 78
SETTING THE RATED BATTERY CAPACITY –SOFTWARE CONFIGURATION 78

- 55 -
EXTERNAL TEMPERATURE PROBE 78
USE 79
DESCRIPTION 79
PRELIMINARY OPERATIONS 80
POWERING ON FOR THE FIRST TIME 81
POWERING ON FROM THE MAINS 82
POWERING ON FROM THE BATTERY 82
POWERING OFF THE UPS 82
GRAPHIC DISPLAY 83
DISPLAY MENUS 84
OPERATING MODES 85
MAINTENANCE BYPASS (SWMB) 85
REDUNDANT AUXILIARY POWER SUPPLY FOR AUTOMATIC BYPASS 86
PROGRAMMABLE AUXILIARY SOCKET (POWER SHARE) 86
POWER WALK-IN 86
REDUCING THE LOAD (TO 200V AND 208V) 86
CONFIGURING THE UPS 87
COMMUNICATION PORTS 89
RS232 AND USB CONNECTORS 89
COMMUNICATION SLOTS 89
AS400 PORT 90
BUZZER 91
SOFTWARE 92
MONITORING AND CONTROL SOFTWARE 92
CONFIGURATION SOFTWARE 92
TROUBLESHOOTING GUIDE 93
STATUS /ALARM CODES 97
TECHNICAL SPECIFICATIONS 101

- 56 -
OVERVIEW
FLEXUS FM
The UPS in the Flexus FM 10 – 12 – 15 – 20 kVA series (VFI-SS-111 type) was designed using state-of-the-art
technology so as to ensure the best performance for the user. The use of the new control boards based on
multiprocessor architecture (DSL + μP inside) together with high-frequency IGBT technology ensures extraordinary
performance from both the input stage (absorbed current harmonic distortion ≤3%) and the output stage (output voltage
distortion ≤1%).
Thanks to its new, modern design, the use of a large graphic display, and above all the extra power provided by the
battery charger (up to 6A recharge), the Flexus FM series represents a new reference standard for single-phase output
UPS systems.
10 kVA 12 kVA 15 kVA 20 kVA
Rated power 10000 VA
9000 W
12000 VA
10800 W
15000 VA
13500 W
20000 VA
18000 W
Output power factor 0.9 0.9 0.9 0.9
Weight (including batteries) 180 Kg 182 Kg 190 Kg 195 Kg
Width x Depth x Height 320 x 840 x 930 mm
Options Parallel kit – Separate bypass input –
Built-in isolation transformer – Built-in additional battery charger
Accessories Battery cabinets – Communication boards – Remote synoptic panel

- 57 -
FRONT VIEWS OF THE UPS
Control panel with graphic display
From left:
Battery fuse holder isolator /Manual bypass
switch /Battery start button (COLD START) /1/0
main power switch
Front door (to open the door, press and release
the area marked X)
From left:
Input switch /Separate bypass switch (optional) /
Output switch
Ventilation grid Terminal cover with ventilation grids
Wheels for moving the UPS
Brake rod

- 58 -
VIEW OF THE UPS CONNECTIONS
Power connections: BATTERY, INPUT, SEPARATE BYPASS (optional), OUTPUT
Connection for remote maintenance bypass command
Connection for external Battery Box temperature probe
Connection for external synchronization signal
Connection for R.E.P.O. (Remote Emergency Power Off) command
Area for the single-phase short-circuit bar
Slot for power relay board

- 59 -
REAR VIEW OF THE UPS
Slots for accessory communication cards RS232 communication port
Powershare sockets
(max. total 10A on two sockets) USB communication port
Powershare socket thermal protector
(manual reset) Ventilation fans
Contact holder for AS400 Area for the parallel board (optional)

- 60 -
VIEW OF THE CONTROL PANEL
Mains power LED Battery low LED
Battery power LED ECO mode LED
Load on bypass LED Graphic display
Stand-by / alarm LED
F1, F2, F3, F4= FUNCTION KEYS. The function of each key is indicated at the bottom of the display and
varies according to the menu used.

- 61 -
BATTERY BOX (OPTIONAL)
THE BATTERY BOX IS AN OPTIONAL ACCESSORY PROVIDED FOR THIS RANGE OF UPS (SAME SIZE AND
AESTHETIC DESIGN).
The Battery Box contains batteries that increase the operating time of the UPS during prolonged black-outs. The number
of batteries contained in it will vary according to the type of UPS to which the Battery Box is to be installed. The utmost
attention must be paid to ensure that the battery voltage of the Battery Box corresponds to that supported by the UPS.
Additional Battery Boxes may be connected in a chain to obtain the desired autonomy time during a power failure.
This series of Battery Box contains two separate strings of batteries, one with a positive voltage and the other with a
negative voltage with respect to the neutral terminal (N).
The basic diagram for the Battery Box is shown here below.
ET06-480A-- (1) ET06-480M-- (1)
Rated voltage 240 + 240 Vdc 240 + 240 Vdc
Weight 150Kg 270Kg
Width x Depth x Height 320 x 840 x 930 mm
(1) The “-” symbol stands for an alphanumeric code for in-house use

- 62 -
SEPARATE BYPASS INPUT (OPTIONAL)
THE “DI” (OPTIONAL) VERSION OF THE UPS SERIES HAS SEPARATE BYPASS AND INPUT LINES.
The UPS series with separate Bypass ensures a separate connection between the input and bypass lines.
The UPS output is synchronised with the bypass line so as to safeguard against incorrect voltage changeovers in the
alternate phases, in the event of automatic bypass or closing of the maintenance switch (SWMB).
ADDITIONAL INTERNAL BATTERY CHARGERS (OPTIONAL)
THE “AC” (OPTIONAL) VERSION OF THE UPS SERIES DIFFERS FROM THE STANDARD VERSION IN THAT
SOME ADDITIONAL BATTERY CHARGERS ARE USED INSTEAD OF THE BATTERIES.
This series of UPS must be used together with an external Battery Box and is suitable for applications requiring long
back-up times.
NOTE: A separate bypass line is supplied on this UPS version.
The additional internal battery charger cards are powered directly on mains power and have pseudo-sinusoidal wave
form absorption.
If the input switch is closed but the I/O switch is open (UPS switched off) the battery chargers operate
independently. Open the input switch (SWIN) to totally shutdown the UPS and the additional battery chargers.
AC Version 10 kVA 12 kVA 15 kVA 20 kVA
Nominal voltage 240 + 240 Vdc
Current in addition to that supplied
by the internal battery charger 6A@240Vdc
UPS weight 86kg 88Kg 96Kg 101Kg

- 63 -
INSTALLATION
ALL THE OPERATIONS DESCRIBED IN THIS SECTION MUST BE CARRIED OUT EXCLUSIVELY BY
QUALIFIED STAFF.
The Company may no be held liable for any damage caused by incorrect connections or by
operations that are not described in this manual.
STORAGE OF THE UPS AND THE BATTERY BOX
The storage area must have the following characteristics:
Temperature: 0°-40°C (32°-104°F)
Relative humidity: 95% max
PREPARATION FOR INSTALLATION
PRELIMINARY INFORMATION
UPS Models 10 kVA 12 kVA 15 kVA 20 kVA
Nominal power 10000 VA 12000 VA 15000 VA 20000 VA
Operating temperature 0 - 40 °C
Max. relative humidity during operation 90% (non-condensing)
Max. installation height 1000 m at nominal power rating
(-1% Power for every 100 m over 1000 m)
max 4000 m
Dimension W x D x H 320 x 840 x 930 mm
Weight (with batteries) 180 Kg 182 Kg 190 Kg 195 Kg
Dissipated power with nominal resistive
load (pf=0.8) and with back up battery *
0.56 kW
480 kcal/h
1910 B.T.U./h
0.670 kW
580 kcal/h
2290 B.T.U./h
0.765 kW
660 kcal/h
2610 B.T.U./h
1.02 kW
880 kcal/h
3480 B.T.U./h
Dissipated power with nominal
distorting load (pf=0.7) and with charged
battery *
0.49 kW
420 kcal/h
1660 B.T.U./h
0.58 kW
500 kcal/h
1990 B.T.U./h
0.670 kW
580 kcal/h
2290 B.T.U./h
0.90 kW
775 kcal/h
3070 B.T.U./h
Fan capacity at installation premises for
heat dissipation ** 300 mc/h 355 mc/h 410 mc/h 545 mc/h
Current dispersed to earth *** < 7 mA
Protection level IP20
Cable input From base / on rear
*3.97 B.T.U./h = 1 kcal/h
** The following formula can be used to calculate the fan capacity: Q [mc/h] = 3.1 x Pdiss [kcal/h] / (ta - te) [°C]
Pdiss is the dissipated power of all the installed apparatus at the installation premises expressed in kcal/h.
ta= environmental temperature, te= external temperature. To account for leaks, increase the value obtained by 10%.
The table shows an example of the fan capacity with (ta - te)=5°C and with nominal resistive load (pf=0.8).
(N.B.: The formula applies if ta>te; otherwise an air conditioner should be installed).
*** The dispersion current of the load is added to the dispersion current of the UPS on the earth protection conductor.

- 64 -
ELECTROMAGNETIC COMPATIBILITY
This Uninterruptible Power Supply (UPS) conforms to the class C2 specifications (in accordance with the provisions laid
down by the EN62040-2 standard: UPS - EMC requirement). In the home environment, it may cause radio interference.
The user may have to take supplementary measures.
This product is designed for professional use in industrial and commercial environments. Connections to the USB and
RS232 connectors should be made with the cables provided or, in any case, with shielded cables less than 3 metres
long.
INSTALLATION ENVIRONMENT
When choosing the site in which to install the UPS and the Battery Box, the following points should be taken into
consideration:
Avoid dusty environments
Check that the floor is level and capable of withstanding the weight of the UPS and the Battery Box
Avoid cramped environments that could impede the normal maintenance activities
The relative humidity should not exceed 90%, non-condensing
Check that the ambient temperature, with the UPS running, remains between 0 and 40°C
The UPS may be operated with an ambient temperature of between 0 and 40°C. The recommended
working temperature for the UPS and the batteries is between 20 and 25°C. In fact, if the battery has
an average life of 5 years with a working temperature of 20°C, the life is halved if the working
temperature is increased to 30°C.
Avoid installing the equipment in places exposed to the direct sunlight or hot air
To keep the temperature of the installation room within the range indicated above, there must be a system for eliminating
the dissipated heat (the Kw / Kcal/h / B.T.U./h values dissipated by the UPS are indicated in the table above). The
methods that may be used are:
Natural ventilation
Forced ventilation, recommended if the outside temperature is less (e.g. 20°C) than the temperature at which
the UPS or Battery Box is to be operated (e.g. 25°C)
Air-conditioning system, recommended if the outside temperature is higher (e.g. 30°C) than the temperature at
which the UPS or Battery Box is to be operated (e.g. 25°C)

- 65 -
REMOVING THE UPS AND THE BATTERY BOX FROM THE PALLET
Cut the straps and remove the
cardboard box by sliding it
upwards
Remove the accessory box and
side blocks.
NOTE 1: You will find the
accessory box either inside the
door of the UPS or on top of the
UPS.
FRONT VIEW REAR VIEW
Open the door and remove the
slides.
NOTE 2: The slides are fixed to
the pallet by a screw (marked C
in the figure).
Remove the 4 brackets securing
the UPS to the pallet (the
screws are marked A and B in
the figures).
A
AA
A
B
B
C
B
B
AA
A
A
Using 4 of the previously
removed screws (type A) secure
the slides to the pallet (as
shown). Push the UPS from the
rear off the pallet with great
care. Make sure that the door
is closed before doing this
NOTE: All parts of the packaging should be kept for future use.

- 66 -
PRELIMINARY CHECK OF CONTENTS
Having opened the package, start by checking the contents.
UPS BATTERY BOX (optional)
Metal slides, Guarantee document, User manual,
Cd-rom containing the UPS management software,
Serial connecting cable, 4 battery fuses (to be
inserted in the "SWBATT" fuse holders), Short circuit
bar (with 3 fastening screws)
Metal slides, Guarantee document, Cable for connecting
the Battery Box to the UPS, 4 battery fuses (to be
inserted in the "SWBATT" fuse holders)
INSTALLING THE UPS AND THE BATTERY BOX
When installing the equipment, the following points should be considered:
The wheels are to be used exclusively for fine positioning, and thus for small distances only.
The plastic parts and the door are not to be used for gripping or pushing the UPS.
Sufficient space should be left in front of the equipment for it to be turned on/off and maintenance operations to
be performed on it ( ≥1.5 mt )
The rear part of the UPS should be set at least 30 cm from the wall, to enable the air blown by the ventilation
fans to flow away correctly
No objects should be left on its top surface
Having set the equipment in position, secure it by engaging the brake rod (see "Front Views of the UPS" point 8) situated
below the connecting terminals.
STEPS TO BE TAKEN TO GAIN ACCESS TO THE TERMINALS OF THE UPS /BATTERY BOX
The operations indicated below are to be performed with the UPS disconnected from the mains
powers, turned off and with all the switches and fuse holders of the equipment open.
Follow the instructions provided below to open the UPS:
Open the door by pressing on the top right-hand area of the door
Remove the terminal and switches cover (see "Front Views of the UPS" ref. 7)
Having completed the installation operations inside the equipment, replace the terminal cover and close the door.

- 67 -
ELECTRICAL CONNECTIONS
WARNING: a 4-wire three-phase distribution system is required for the three-phase input connection.
The standard version of the UPS must be connected to a TT, TN or IT type 3-phase power line + neutral +
protective earth (PE), in compliance with the IEC 60364-3 specification; therefore phase rotation must be
respected.
Optional TRANSFORMER BOXES are available to convert the distribution system from 3 to 4-wires.
DIAGRAMS OF CONNECTIONS TO THE ELECTRICAL SYSTEM
NOTE: for the following diagrams, in cases of single-phase connections on the input line, instead of 3P=N, please read
P+N.
UPS with no variation of the neutral arrangements
UPS with galvanic isolation on input
Note: For three-phase connections, the transformer must be suitably sized to operate off the bypass
UPS with galvanic isolation on output

- 68 -
UPS without any variation in neutral condition and with separate bypass input
UPS with galvanic isolation and with separate bypass input
UPS with galvanic isolation at output and separate bypass input

- 69 -
Separate bypass:
if the separate bypass option is present, protective devices must be present on both the main power supply line and the
bypass line.
Note: the neutral of the input line and that of the bypass are commoned inside the equipment, so they must refer to the
same potential. If the two power supplies were different, an isolation transformer would have to be used on one of the
inputs.
UPS without any variation in neutral condition and with separate bypass input
connected to independent power supply line
UPS with separate bypass input on independent power supply line
and with galvanic isolation at input
UPS with separate bypass input connected to independent power supply line
and with galvanic isolation at output

- 70 -
PROTECTIONS INSIDE THE UPS
The following table shows the sizes of the disconnecting switches on the UPS system as well as the sizes of the battery
fuses (SWBATT); these devices can be accessed from the front of the UPS.
The table also provides details on the internal fuses (not accessible) used to protect the input and output lines, and the
maximum input and nominal output currents. Please refer to the block diagrams in the “USAGE” section of the
“Description paragraph for the position of the fuses.
Fuses must be replaced with fuses of the same rating and with the same characteristics as indicated in the table.
Disconnecting switches and Internal protections
UPS
Model Non automatic switches Battery fuse Current
[kVA] UPS Input
UPS Output/
Maintenance/Separate
Bypass
Input current
[A] Max *
Output
current
[A]
3P+N **
SWIN SWOUT / SWMB /
SWBYP (optional) SWBATT
L1*** L2/L3
P+N Nominal
10 63A(4P) 63A(2P) 32A gG 400V (10x38) 49A 18A 55A 45A
12 63A(4P) 63A(2P) 32A gG 400V (10x38) 59A 21A 64A 55A
15 100A(4P) 100A(2P) 50A gG 400V (14x51) 72A 25A 76A 68A
20 100A(4P) 100A(2P) 50A gG 400V (14x51) 95A 33A 98A 91A
*The maximum input current refers to a nominal load (PF = 0,8) and to an input voltage of 346V (200V for single-
phase connections), and with the battery charger under charge at 4A.
** On versions with additional internal battery chargers (optional), the maximum input current on lines L2 and L3 should
be increased to 7A.
*** When operating off the bypass with a three-phase connection, all the output current is applied to L1 and Neutral.
SHORT-CIRCUIT
In the event of a fault on the load, in order to protect itself the UPS limits the value and the duration of the power supplied
(short circuit current). These values also depend on the operating status of the unit at the time of the fault, which is
either:
UPS in NORMAL MODE: the load is instantly switched over to the bypass line (I2t=25000A2s): the input line is
connected to the output without any internal protection and shuts down after t>0.5s
UPS in BATTERY MODE: the UPS protects itself by supplying output current of around 1.5 times the nominal
current for 0.5s and then shuts down.
BACKFEED
The UPS is also protected internally against backfeed through metal separation devices.
An optional relay output card is available to ensure the control of a release device to be installed upstream of the UPS.
The UPS has an internal device (redundant bypass power supply) which in the event of a fault automatically
activates the bypass while ensuring power to the load without any internal protection and without any limit on
the power supplied to the load.
In these emergency conditions, any disturbance on the input line will have repercussions on the charge.
Please also refer to the “Usage” section of the paragraph entitled “Redundant auxiliary power supply for
automatic bypass”.

- 71 -
EXTERNAL PROTECTION DEVICES
MAGNETOTHERMAL SWITCH
As outlined above, the UPS has devices to protect against faults on the output and internal faults.
To set up the power line install a magneto-thermal switch upstream of the UPS with intervention curve C in
compliance with the EN 60947 specification, following the indications given in the following table:
Automatic external protections
Mains input
UPS Model
Single-phase input (P+N) Three-phase input (3P+N)
Separate bypass input (P+N)
Standard Ups
10 – 12 – 15 – 20 kVA 100A 100A N.D.
Ups with separate bypass
15 – 20 kVA 100A 63A 100A
Ups with separate bypass
10 – 12 kVA 63A 40A 100A
If the protection device upstream of the UPS interrupts the neutral conductor, at the same time it must also
interrupt all the phase conductors (quadri-polar switch).
Output protection (recommended selectivity values)
Normal fuses (GI) In (Nominal current)/7
Normal switches (C Curve) In (Nominal current)/7
Ultra rapid fuses (GF) In (Nominal current)/2
DIFFERENTIAL
In the standard version, the neutral from the mains power is connected to the UPS output neutral and the neutral settings
of the installation remain unchanged.
THE INPUT NEUTRAL IS CONNECTED TO THE OUTPUT NEUTRAL
THE DISTRIBUTION SYSTEM THAT POWERS THE UPS IS NOT CHANGED BY THE UPS
The neutral settings are changed only if an isolation transformer is installed or when the UPS operates with a
differential switch located upstream.
Make sure that the input neutral is connected correctly, because errors could damage the UPS
When operating from mains power, a differential switch located at the input intervenes so that the output circuit is not
isolated from the input circuit.
Extra differential switches can always be inserted at the output, and where possible, co-ordinated with the differential
switches at the input.
The differential switch upstream of the UPS must have the following features:
Differential current adjusted to the UPS load value; an adequate margin should be kept to avoid delayed
interventions (recommended value: 100mA min. - 300mA)
type B or type A
delay greater than or equal to 0.1s