Dale Power Solutions E200 Series User manual

Dale Power Solutions Ltd
Salter Road, Eastfield Industrial Estate, Scarborough, North Yorkshire, YO11 3DU, UK
[e-mail] | www.dalepowersolutions.com | [phone]
S5264FU02 Rev 3
Dale Power Solutions Ltd
User Manual
E200 Series UPS
E206(E)
E2010(E)

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Dale Power Solutions Ltd. own the copyright to this document, which may not be copied, reproduced or
disclosed to a third party without written permission.
Dale Power Solutions Ltd. reserves the right to make changes in specification without notice or liability. All
information is subject to Dale Power Solutions Ltd. own data and is considered accurate at time of
publishing.

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Contents
Safety..................................................................................................................................................... 5
EMC....................................................................................................................................................5
Warning symbols .................................................................................................................................5
Product description.............................................................................................................................. 6
Applications .........................................................................................................................................6
Product range......................................................................................................................................6
System block diagram..........................................................................................................................7
Features ..............................................................................................................................................7
Installation............................................................................................................................................. 8
Siting considerations............................................................................................................................8
Wiring considerations...........................................................................................................................8
Operation from a generator..................................................................................................................9
Circuit breaker and cable sizes.............................................................................................................9
Unpacking the UPS..............................................................................................................................9
Rear panel layout...............................................................................................................................10
Wiring the UPS..................................................................................................................................11
Wiring units in parallel........................................................................................................................12
Operation..............................................................................................................................................14
Working modes..................................................................................................................................14
On-Line mode ..............................................................................................................................................14
Bypass mode ...............................................................................................................................................14
Battery mode................................................................................................................................................14
ECO mode...................................................................................................................................................14
Before switch on ................................................................................................................................15
Switching on the UPS ........................................................................................................................15
Switching off the UPS ........................................................................................................................16
Swapping out a UPS on a live system................................................................................................16
Front panel controls and indicators.....................................................................................................17
Navigating the system menu.........................................................................................................................18
Figure menu items........................................................................................................................................18
Status menu items........................................................................................................................................18
Setting menu items.......................................................................................................................................19
Command menu items..................................................................................................................................20
LCD display messages.................................................................................................................................21
Maintenance.........................................................................................................................................22
Fan....................................................................................................................................................22
Battery...............................................................................................................................................22
External battery change .....................................................................................................................22
Visual check.......................................................................................................................................22
UPS status check...............................................................................................................................22
Function check...................................................................................................................................22

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Troubleshooting ..................................................................................................................................23
Appendix 1 Signals options ................................................................................................................24
RS232 serial port...............................................................................................................................24
Contact closure (basic monitoring and control)...................................................................................24
SNMP card (advanced monitoring and control)...................................................................................25
Relay card (advanced monitoring and control)....................................................................................25
Appendix 2 Parallel board signals ......................................................................................................27
LBS (Load Bus Synchronisation)........................................................................................................27
Dry contact relay signals....................................................................................................................27
Appendix 3 Specifications...................................................................................................................28
Electrical............................................................................................................................................28
Mechanical ........................................................................................................................................30
Appendix 4 Optional equipment..........................................................................................................30
Appendix 5 UPS alarm tables..............................................................................................................31

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Safety
WARNING! THIS UPS IS CLASSED AS PLUGGABLE TYPE B OR PERMANENTLY
CONNECTED EQUIPMENT AND MUST BE INSTALLED, COMMISSIONED AND
MAINTAINED BY A QUALIFIED ELECTRICIAN. AN APPROPIATE AND READILY
ACCESIBLE DISCONNECT DEVICE MUST BE INCORPORATED INTO THE FIXED SUPPLY
WIRING TO THE UPS.
There are dangerous voltages and high temperatures inside the UPS. During installation, operation and
maintenance please abide by local safety instructions, regulations and laws. Failure to do so may result in
injury to personnel or damage to equipment. Safety instructions in this manual are supplementary to local
safety instructions. Dale Power Solutions does not accept any liability caused as a result of failure to
follow safety instructions. Please note the following:
Do not operate the UPS in an environment or application outside of that detailed in the user manual.
Do not exceed rated load of UPS and ensure it operates in a dry, well ventilated location away from
any area or situation in which there is a risk of fire, such as direct sunlight or other sources of heat.
Under no circumstances open the UPS as there are no user serviceable parts. There are high
capacity batteries inside and other electronics that can cause electric shock. If the UPS requires
internal maintenance or battery replacement, contact Dale Power Solutions.
In pluggable type B applications the UPS must be switched off and isolated prior to removal of the
AC mains input plug from the mains supply socket, as detailed on the warning label fitted on the UPS.
The UPS mains input cable must be connected to an earthed mains supply for operator safety and
EMC compliance.
If the UPS emits smoke, turn off immediately the input circuit breaker at the back of the unit and, if
fitted, the battery circuit breaker, and contact Dale Power Solutions.
EMC
WARNING! This is a product for commercial and industrial applications in the second
environment.
This is a category C2 UPS product. In a residential environment, this product may cause
radio interference, in which case the user may be required to take additional measures. (As
stated in: EN62040-2:2006).
Warning symbols
The safety symbols used in this manual are shown in table below. They alert you to important safety
information that you need to be aware of when installing, operating and maintaining the UPS.
Safety Symbol
Indication
Attention
Static discharge sensitive
Electric shock
Caution: A caution describes a situation in which there is a risk of damage to equipment.

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Product description
Applications
This UPS series provides reliable AC backup power to various types of equipment, for example computer
centres, network management centres, auto control systems, and telecommunication systems.
Product range
The following table lists the models available in the E200 series. Models with an E suffix are designed for
operation with an external battery.
Capacity
6 kVA
10 kVA
Model
E206
E206E
E2010
E2010E
Battery location
Internal
External
Internal
External

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System block diagram
The UPS can be installed and operated as a single unit or it can be operated with other units of the same
type in parallel N+1 redundant mode for additional reliability, or in a parallel capacity mode for increased
output rating. To operate in parallel, units must be specified and purchased with a factory fitted parallel
kit. Figure 1 is a functional block diagram representing a single UPS. In cases where it is not possible to
meet the hold-up time with an internal battery, an E suffix unit with an external battery in place of the
internal battery can be used.
Figure 1 Single unit block diagram
Features
■E200 series units have an intelligent online sine-wave output with power factor correction. High
frequency double-conversion and a wide input voltage range ensure continuous output for areas with
poor power supply regulation.
■DSP technology for digital control ensures high reliability, circuit protection and self-diagnostics in the
unlikely event of a fault. Intelligent digital battery management extends battery life and ensures
optimum performance.
■An LCD panel and LED indicators clearly display the system status and system parameters such as
input/output voltage, frequency, load, and unit temperature.
■Network power management can be achieved by using UPS monitoring software.
■A hot-plug input/output and maintenance bypass switch assembly ensures power to the load is
maintained if you need to service or repair a single unit. Where units are used in parallel an external
maintenance bypass switch must be used as the built in bypass switch is only rated for the current of
a single UPS.

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Installation
Siting considerations
Before unpacking and installing the unit, consider the following:
■DO NOT expose the UPS to high temperatures, water ingress, flammable or corrosive gas, dust,
direct sunlight or explosives.
■Locate the UPS indoors on a level surface as close as possible to the equipment it will be powering to
minimise cable voltage drops. Allow enough spare cable to move the UPS and access the rear and
side panels during servicing.
■Maintain a gap of at least 20 cm from walls or other equipment and ensure the ventilation holes/slots
at the front and rear of the units are not obstructed.
■For maximum battery life and improved product reliability ensure cool air is available at the front of the
unit. As an approximation, battery life is halved for every 10K (10°C) rise in temperature.
Wiring considerations
To ensure a safe installation please follow these instructions and the local electrical code of the area or
country in which you are installing the equipment:
■If the UPS is to be supplied from a local transformer, ensure the transformer kVA rating is at least
50% greater than the UPS output kVA rating.
■Use circuit breakers and cables with the correct rating (see the next section).
■Always fit an MCB between the mains supply live line only and the UPS input (see Figure 2).
Caution: Do not fit an MCB in the neutral line.
■Because of the high leakage current, permanently hard wire all the a.c. cables or use industrial
connectors (not domestic connectors).
■Use ring terminal crimps on the end of all cable conductors to ensure the connections are secure.
■If using external batteries, always fit a 3 pole MCCB, with a suitable d.c. voltage rating and breaking
capacity, between the battery and the UPS (see Figure 2).
Caution: The UPS is designed to work with a centre-tap battery only.
■Although it may not be absolutely necessary, we recommend you fit an MCB between the UPS and
the load to protect the output load and cables in the event of a fault (see Figure 2). You may also wish
to connect the UPS output to your load via a distribution unit (PDU).
Figure 2 Power cable wiring configuration for a single UPS

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Operation from a generator
As a guide we recommend that the load capacity should be less than 30% of the generator capacity, and
the generator rating should be 1.5 to 2 times the rating of the UPS, depending on the type of generator
used.
Caution: Ensure that the neutral line from the generator is permanently connected to the
mains neutral line. Do not use an MCB or any other type of switch in this line.
Circuit breaker and cable sizes
Use the following sizes of circuit breakers and cables to connect the UPS between mains power and the
load.
Model
Battery breaker
(A)
Battery
breaker
type
Input and output
breakers (A)
Breaker
type
Input, output and
battery cable sizes
(mm2)
E206
-
-
C40/C63
MCB
6 (10 AWG)
E206E
32
MCCB
E2010
-
-
C63/C80
MCB
10 (8 AWG)
E2010E
50
MCCB
Caution: When installing suffix E units, do not use an MCB breaker in the battery line as this
type of breaker is not rated for the d.c. battery voltage. Instead use an MCCB breaker that is
rated for the d.c. battery voltage and the battery short-circuit current breaking capacity.
Unpacking the UPS
To unpack the UPS:
1. Cut the two straps securing the packing box to the pallet and remove the packing box by lifting it up
and over the UPS.
2. Remove and retain the documentation, CD and leads from the top of the UPS.
3. Dispose of packets of desiccant correctly.
4. Move the UPS off the pallet.
WARNING!
UNITS CANWEIGH UP TO 80 KG. TO PREVENT THE UPS FROM FALLING DO NOT
LEAN IT WHEN MOVING IT OFF THE PALLET.
5. Check the appearance of the UPS to see if it is damaged. If any damage is found, do not switch on
the UPS and contact the dealer.
6. Check the packing list. Contact your distributor if any of the accessories are missing.

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Rear panel layout
Figure 3 Rear panel layout

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Wiring the UPS
Before connecting the UPS, read the siting considerations above and check you have selected breakers
and cables with the correct ratings.
WARNING!
BEFORE ATTEMPTING TO WIRE THE UPS ENSURE ALL BREAKERS ARE IN THE OFF
POSITION.
Caution: If your system uses external batteries, DO NOT mix batteries from different
manufacturers or mix different types of batteries. DO NOT use old and new batteries together.
Note: In addition to the normal tools required for electrical installation you will need a PH2 Phillips
screwdriver to remove the UPS gland box and panels. Do not use a pozidrive (PZ) screwdriver.
To connect the UPS to your system:
1. If your system uses external batteries:
a. Check that the number of 12 V blocks in each string (positive and negative) is equal and matches
the number specified in your order.
b. Measure the battery voltage. The voltage should be approximately 192 Vd.c. for 16 batteries, 216
Vd.c. for 18 batteries and 240 Vd.c. for 20 batteries.
2. On the rear of the unit, remove the bypass box (4 screws).
3. Remove the gland box cover.
4. Remove the terminal cover. On suffix E units there are four screws, two of which are located inside
the gland box.
5. Feed all the cables through the gland box cover.
Caution: Ring crimps are required on all wires to ensure the connections are secure.
Note: Complete steps 6 and 7 in the order shown or you won’t be able to access the earth
terminals.
6. Wire the input and output earth cables to the UPS bypass box terminals. Ensure that both
connections are made.
7. Wire the input, output and battery cables to the UPS bypass box terminals.
WARNING!
CHECK THAT ALL CABLES ARE WIRED TO THE CORRECT TERMINALS. DO NOT
REVERSE THE INPUT LIVE AND NEUTRAL CONNECTIONS OR THE POLARITY OF
ANY OF THE BATTERY WIRES.
8. Refit all the covers and ensure all cable glands are fully tightened.
9. Refit the bypass box to the UPS.

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10. If your unit has an SNMP or relay contact card fitted or you plan to use the RS232 port or other
standard signals, see Appendix 1 Signals options on page 24.
Wiring units in parallel
You can operate 2, 3 or 4 units in parallel. Each unit must be ordered with a factory fitted parallel board
option.
Caution: If you are using units with external batteries, each unit requires its own battery bank.
You cannot use a common battery bank for more than one unit working in parallel mode.
When operating units in parallel you must not use the built-in bypass as it is rated for one unit
only. If you need a bypass for the parallel system it must be wired as an external item.
WARNING!
BEFORE ATTEMPTING TO WIRE THE UNITS, ENSURE ALL BREAKERS ARE IN THE OFF
POSITION.
To connect two or more units in parallel:
1. Wire the power cables and optional signals as described above.
2. If a system bypass is required, wire in a separate MCB capable of carrying the total system load
current as shown below. This is not required if you have only two units working in N+1 mode where
the load never exceed the rating of a single unit.
3. On the parallel board of each UPS, connect the CAN bus labelled Parallel 1 and Parallel 2, in a ring
arrangement using the supplied RS232 cables as shown below. Make sure you wire all CAN bus
connectors and secure them in place using their captive screw locks.

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4. Locate a locking plate over each pair of connectors and secure in place. This provides extra
protection against accidental removal of a CAN bus cable.
5. Optional connection. You can control and monitor all units using the RS232 port on one UPS. To do
this, connect the pink RS485 socket of one unit to the green RS485 socket of the next unit and so on
until all units are connected in a daisy-chain. Do not connect the units in a loop.
Note: Do not confuse the RS485 sockets with the LBS sockets on the parallel cards.

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Operation
Working modes
The UPS has four distinct modes of operation:
■On-line mode
■Bypass mode
■Battery mode
■ECO mode
Each operating mode is described below.
On-Line mode
This is the default mode of operation in which the load is supplied via the inverter when the a.c. input and
load are within their normal ranges. The battery is trickle charged in this mode.
During fault conditions the UPS automatically switches to either bypass mode or battery mode without
interruption to the load.
Bypass mode
In bypass mode the load is supplied directly from the a.c. mains input and the battery is charged. The
UPS switches to bypass mode when any of the following conditions occur:
■An output overload –the unit beeps twice every second, indicating that the load must be reduced to
within its normal range as soon as possible. Once the overload is removed the inverter re-starts after
a 5 minute delay. If the UPS is overloaded too many times in any one hour it will eventually remain in
bypass mode.
■The UPS is too hot –the UPS reverts to on-line mode as soon as the unit temperature returns to
normal.
■The UPS fails –a serious fault has occurred within the UPS that must be repaired.
■The UPS is turned off.
In bypass mode the Inverter LED is off and the Bypass LED is on.
Battery mode
In battery mode the load is supplied from the battery via the inverter, the UPS beeps every 3 s, and the
rectifier and charger are turned off. The UPS switches to battery mode when there is no a.c. input or the
a.c. input is outside its normal range. On the front panel the Mains LED if off and the Battery LED is on.
When the battery reaches a preset low limit, the system gives a low battery voltage alarm signal, the LCD
provides a low battery alarm, and the UPS beeps every second. Eventually the UPS shuts down to
prevent damage to the batteries.
When the a.c. mains is restored the inverter starts automatically and the UPS reverts to on-line mode. If
you turn off the UPS in battery mode it restarts in bypass mode and you must press the ON button to start
the inverter.
ECO mode
If specified, your UPS may be set to operate in ECO mode instead of on-line mode. In ECO mode the
load is supplied via the bypass circuit and not the inverter, allowing the UPS to work at higher efficiency.
The battery is trickle charged in this mode. If the a.c. input is lost or goes beyond its normal range the
UPS automatically switches to battery mode, however, the transfer speed is slower than on-line mode
and may not be suitable for all applications.

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Before switch on
Before turning on the unit for the first time or after any wiring or battery changes:
1. Read the section above on working modes.
2. Check all the wiring.
3. Check that the rated load does not exceed the rated output of the UPS.
Note: If your installation uses a 16 or 18 block external battery string the UPS power output (kW
rating) is limited to 70% of the kVA rating instead of the normal 80% (see Appendix 3 Specifications
on page 28).
4. If the UPS is supplied by a generator, check that the generator is correctly rated and wired (see
Operation from a generator on page 9).
5. Apply the wheel locks to prevent the UPS from moving.
Switching on the UPS
Note: It is important to switch on your UPS as described below as damage may occur when supplying
certain load types.
Caution: When using the UPS for the first time, charge the batteries for at least 8 hours as
they may have lost charge during the time between production and installation.
To switch on your UPS:
1. If your installation has an external bypass breaker, ensure it is open.
2. If your installation has an external battery, switch on the battery breaker.
3. Switch on the input breaker.
4. On the rear panel, switch on the unit main breaker.
Note: If switching on into a transformer load, ensure the UPS is initially working in bypass mode
before switching to on-line mode.
5. Switch on the output breaker. Ideally it is best to apply the load gradually if this is possible.
Caution: If the UPS input power is provided by a generator it is important to apply the load
gradually.
You should immediately hear the fan start up. The model number and rating is initially displayed on the
front panel LCD. After a few seconds this changes to system information.
At the same time that the fan starts the Bypass and Output LEDs are illuminated. After a few seconds the
Mains and Inverter LEDs are illuminated and the Bypass LED goes out (see Figure 4 on page 17).
In this state your unit is working correctly and delivering power to the load. There is no need to alter any
settings.
Mode:On-Line
Battery 7AH
Vin 230V 50Hz
Vout 230V 50Hz
E206
6KVA

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Switching off the UPS
Caution: All power to the load will be removed when you follow this procedure.
To switch off the UPS:
1. On the front panel (see Figure 4 on page 17), press OFF to place the unit in bypass mode.
2. When prompted by the LCD, press Ent to confirm your action. The Bypass LED turns on and the
Inverter LED turns off.
3. On the rear panel, turn off the unit main breaker. After a few seconds the unit shuts down (the fan
stops and LCD and LEDs turn off).
Swapping out a UPS on a live system
E200 series units are fitted with a bypass box that allows you to swap a UPS without the need to do any
wiring.
Note: Always use a PH2 Phillips screwdriver and not a pozidrive (PZ) screwdriver.
To exchange a UPS while maintaining the load:
1. On the front panel, press OFF to switch the unit to bypass mode.
2. When prompted by the LCD, press Ent to confirm your action. The Bypass LED turns on and the
Inverter LED turns off.
3. Access the rear panel and remove the screw that holds the maintenance breaker cover in place. It is
located just above the input breaker.
4. Turn on the maintenance breaker.
5. Turn off the UPS main breaker. At this point power flows into and out of the bypass box only.
6. Remove the four screws that hold the bypass box in place and extract the box from the UPS.
7. Replace the UPS.
8. Slide the bypass box into the new UPS.
9. Turn on the new UPS’s main breaker.
10. Ensure that the Mains and Bypass LEDs are illuminated. This indicates that the UPS is working
correctly.
11. Turn off the maintenance breaker and fasten its protective cover in place. After a few seconds the
UPS automatically switches to on-line mode.

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Front panel controls and indicators
The front panel controls and indicators are shown in Figure 4. Using the buttons, LEDs and the menu
structure displayed on the LCD panel you can:
■Check the status of the UPS
■Check and make changes to the settings
Note: Your UPS is setup to your requirements by the distributor prior to delivery. There is normally
no reason to change any of the settings.
Figure 4 Front panel
The following table describes the operation of the LED indicators:
LED
Description
Output
On when the load is being supplied.
Inverter
On when the UPS is supplying power. The LED flashes when the inverter is overloaded.
Battery
On when the power is supplied from the battery. The LED flashes if the battery is low or disconnected.
Mains
On when mains in present and within limits. The LED flashes if the mains is outside its normal range.
Fault
On when there is any type of fault.
The following table describes the button functions:
Button
Definition
ON
Press and hold for 1 s to turn on the inverter when in battery mode or bypass mode.
OFF
Press and hold for 1 s to turn off the inverter and put the unit into bypass mode.
Ent
Press to confirm an operation or enter a lower menu level.
Esc
Press to cancel an operation or return to the previous menu level.
◄
Press to select another menu item or change a parameter.
►
Press to select another menu item or change a parameter.

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Navigating the system menu
To access a menu item:
1. Press ◄ or ► until the following list is displayed:
2. Press Ent. An arrow ( ) appears next to Figure. The arrow must be next to the menu item you wish
to enter.
3. Press ◄or ► to move the arrow up or down the list to the menu item you wish to enter.
4. Press Ent.
You can then use the ◄, ► and Ent buttons in a similar way to navigate to the various sub-menus and
make changes if necessary. To return to the previous menu level, press ESC.
The following sections show the full menu structure for each of the four main menu items listed above.
Note: The values shown below are examples only. The values in your system are likely to be different.
Figure menu items
These menu items provide UPS operating information only.
Status menu items
These menu items provide UPS system information only. There are five sub-menu items as shown below:
State information
Alarm and Fault info. Rate Power information
Status
Rate POWER
MachInfo: 0101
Rate: 6KVA
Status
Rate POWER
Code
Version
Status
Alarm & Fault
Status
State
Alarm & Fault
Rated POWER
Status
State
Battery Charging
Battery Boost
Status
State
Inverter ON
Battery Charging
Status
State
CurState: Mains
SWMB OFF
Figure
Temperature °C
Inner: 20
REC: 20 INV: 20
Figure
Bus
-390V +390V
Figure
NBatt Charge
111.1V 0.4A
Figure
PBatt Charge
111.1V 0.4A
Figure
Invert
230.0V
50.0Hz
Figure
Output
0KW PAK: 0
0KVA
Figure
Output
230.0V 0.0A
50.0Hz Load:0%
Figure
Mains
230.0V 0.0A
50.0Hz
Figure
Status
Setting
Command

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Version information
Setting menu items
These menu items allow you to change the UPS settings.
Note: We strongly recommend that you don’t alter any of these settings. However, you may wish to
alter the display backlight timeout and brightness using the User set sub-menu. If you suspect
someone has accidently made some changes, compare the values in each of the sub-menus with the
Equipment Setup Sheet provided with your UPS.
There are five sub-menu items as shown below:
User set menu items
System set menu items
Parallel set menu items
Setting
Parallel set
►P-Redund 0
LBS No LBS
Setting
Parallel set
►ID 1
P-Amount 1
Setting
System set
►Output Enable
Buzzer Enable
Setting
System set
►Mode On-Line
Power Enable
Setting
System set
►V-Fine 0%
SWTimes 9
Setting
System set
►V-Upper 15%
V-Lower -45%
Setting
System set
►Auto Enable
F-Range 5%
Setting
System set
►V-Level 220V
F-Level 50Hz
Setting
User set
►BL. ON
Backlight 5
Setting
Battery set
Revise set
Setting
User set
System set
Parallel set
Status
Version
LCD Ver:D000B001
DSP Ver:D000B001
Status
Code/CAlarm
05 0x0000
0x0000
Status
Code/BAlarm
04 0x0000
0x0000
Status
Code/AAlarm
03 0x0000
0x0000
Status
Code/Status
01 0x00
02 0x000000

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Battery set menu items
Revise set menu items
Caution: Do not adjust these menu items as they change the calibration of the UPS.
Command menu items
These menu items allow you to perform a battery test for a user defined period and to set the Turn on /
Turn off delay time. In the Command menu there are two sub-menu items as shown below:
The second command toggles between ‘Turn On Delay’ and ‘Turn Off Delay’ and so you may see either
command. displayed.
Battery test menu items
Turn on / turn off delay menu item
Command
After: ►1 sec
Ent: sure
Esc: cancel
Command
STOP Testing
Ent: sure
Esc: cancel
Command
For: ►1 sec
Ent: sure
Esc: cancel
Command
►Battery Test
Turn On Delay
Setting
Revise set
►NBatRevise 4096
Setting
Revise set
►-BusRevise 4096
PBatRevise 4096
Setting
Revise set
►VoutRevise 4096
+BusRevise 4096
Setting
Revise set
►VRevise 4096
InvRevise 4096
Setting
Battery set
►Boost Enable
Setting
Battery set
►Boost 2.30
Float 2.20
Setting
Battery set
►Batt-G 1
Batt-C 7
Setting
Battery set
►EOD 1.60
Batt Num 16