Dale Power Solutions E420 User manual

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Dale Power Solutions Ltd
Salter Road, Eastfield Industrial Estate, Scarborough, North Yorkshire YO11 3DU, United Kingdom
Telephone: [phone] Email: [e-mail] www.dalepowersolutions.com
Registration No 941798 England
S5264FU09 Rev 2
Dale Power Solutions Ltd
User Manual
E400 Series UPS
E420
E430
E440
E460
E480

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

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Contents
Safety ............................................................................................................................................................5 
Warning symbols.......................................................................................................................................5 
Conformity and standards..........................................................................................................................6 
Energy conservation and environmental protection ...............................................................................6 
Product description.....................................................................................................................................7 
Applications ...............................................................................................................................................7 
Product range............................................................................................................................................7 
System block diagram ...............................................................................................................................8 
Split bypass input ................................................................................................................................................. 8 
Static transfer switch ............................................................................................................................................ 8 
Battery temperature compensation ...........................................................................................................9 
Redundant control power supply board ....................................................................................................9 
Single phase outlet....................................................................................................................................9 
Multi-unit operation....................................................................................................................................9 
Installation................................................................................................................................................. 10 
Siting considerations ...............................................................................................................................10 
Wiring considerations ..............................................................................................................................10 
Units in parallel................................................................................................................................................... 11 
Earth leakage current ..............................................................................................................................11 
Operation from a generator .....................................................................................................................12 
Cable sizes..............................................................................................................................................12 
Unpacking the UPS .................................................................................................................................12 
Internal layout (door open) ......................................................................................................................13 
Wiring the UPS........................................................................................................................................14 
Wiring units in parallel .............................................................................................................................17 
Operation................................................................................................................................................... 19 
Working modes........................................................................................................................................19 
On-Line mode..................................................................................................................................................... 19 
Battery mode ...................................................................................................................................................... 19 
Auto-restart mode............................................................................................................................................... 19 
Bypass mode...................................................................................................................................................... 19 
ECO mode.......................................................................................................................................................... 20 
Frequency converter mode................................................................................................................................. 20 
Before switch on......................................................................................................................................20 
Switching on the UPS..............................................................................................................................20 
Commissioning test procedure................................................................................................................22 
Switching off the UPS..............................................................................................................................22 
Transferring the load to an EMBS...........................................................................................................22 
Front panel controls and indicators .........................................................................................................23 
Navigating the system menu .............................................................................................................................. 24 
Input information................................................................................................................................................. 24 
Output information.............................................................................................................................................. 25 

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Inverter information .............................................................................................................................................25 
Battery information..............................................................................................................................................25 
State information.................................................................................................................................................25 
Parallel information .............................................................................................................................................26 
Command information.........................................................................................................................................26 
Setting information ..............................................................................................................................................26 
Recorded events list............................................................................................................................................26 
Version information .............................................................................................................................................27 
Change settings...................................................................................................................................... 27 
LCD display messages........................................................................................................................... 29 
Maintenance .............................................................................................................................................. 30 
Fan.......................................................................................................................................................... 30 
Battery .................................................................................................................................................... 30 
Battery change ....................................................................................................................................... 30 
Visual check............................................................................................................................................ 30 
UPS status check ................................................................................................................................... 30 
Function check ....................................................................................................................................... 31 
Troubleshooting ....................................................................................................................................... 31 
Black Start procedure ............................................................................................................................. 31 
Events..................................................................................................................................................... 31 
Alarm information ................................................................................................................................... 32 
Frequently asked questions.................................................................................................................... 34 
Appendix 1 Signals options .................................................................................................................... 35 
RS232 serial port.................................................................................................................................... 35 
Contact closure for external breakers .................................................................................................... 35 
SNMP card with environmental monitor................................................................................................. 36 
Relay card (monitoring and control) ....................................................................................................... 37 
Dry contact relay signals ........................................................................................................................ 38 
Battery temperature sensor.................................................................................................................... 39 
Appendix 2 Parallel operation ................................................................................................................. 40 
LBS (Load Bus Synchronisation)............................................................................................................ 40 
Remote emergency power off (EPO) ..................................................................................................... 40 
Appendix 3 Specifications ....................................................................................................................... 41 
Electrical ................................................................................................................................................. 41 
Mechanical.............................................................................................................................................. 43 
Appendix 4 Optional equipment ............................................................................................................. 43 

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Safety
WARNING!
THIS EQUIPMENT MUST BE INSTALLED, COMMISSIONED AND MAINTAINED BY A
QUALIFIED ELECTRICIAN.
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 plc does not accept any liability caused as a result of failure to
follow safety instructions. Please note the following:
Do not use the UPS for any other purpose than the one for which it was designed.
Do not exceed the rated load of the UPS.
Under no circumstances open the UPS. There are high voltages inside that can cause electric shock.
If the UPS requires internal maintenance or battery replacement, contact Dale Power Solutions plc.
Keep the UPS 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.
If the UPS emits smoke, turn off immediately the input circuit breaker and battery circuit breaker, and
contact Dale Power Solutions plc.
WARNING!
THIS IS A PRODUCT FOR COMMERCIAL AND INDUSTRIAL APPLICATION IN THE
SECOND ENVIRONMENT. INSTALLATION RESTRICTIONS OR ADDITIONAL MEASURES
MAY BE NEEDED TO PREVENT DISTURBANCES (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.
WARNING!
A WARNING DESCRIBES A SITUATION IN WHICH THERE IS A RISK OF INJURY OR
DEATH TO PERSONNEL.

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Conformity and standards
This equipment complies with CE directives 73/23 & 93/68 (LV Safety) and 89/336 (EMC), and the
following product standards for Uninterruptible Power System (UPS):
IEC 62040-1-1 General and safety requirements for use in operator access area
IEC 62040-2 EMC requirements; Class C3 compliant
IEC 62040-3 Performance requirements and test methods
Caution:
Continued compliance requires installation in accordance with the instructions this
manual and the use of manufacturer approved accessories only.
According to IEC62040, this is a low emission class C3 Uninterruptible Power System (UPS) product. In a
residential environment, this product may nevertheless cause radio interference, in which case, you may
be required to take additional measures.
Energy conservation and environmental protection
With an efficiency of greater than 97% in ECO mode the UPS meets the technical specifications for
energy conservation. An input power factor of 0.99 results in minimum current contamination of the power
grid. All the material and components comply with the ROSH standards, ensuring that no hazardous
waste is produced.

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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.
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 parallel capacity mode for increased
output rating.
Product range
The following table lists the models available in the E400 series. All models are designed to operate with
an external battery.
Capacity 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA
Model E420 E430 E440 E460 E480
Battery location External
E420, E430, E440 E460, E480

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System block diagram
The UPS is connected between the mains a.c. input source and the critical load to provide uninterruptible
power free from disturbances on the mains supply such as voltage and frequency variations. This is
achieved using high-frequency double-conversion pulse width modulation (PWM) and full digital signal
processing (DSP) control.
As shown in Figure 1, input mains is converted to d.c., which in turn feeds a d.c./d.c. battery charger and
an inverter. The inverter then converts the battery voltage to a clean a.c. source, output-independent of
the input. The battery powers the load through the inverter in case of an input mains power failure.
If the inverter is unable to supply power for any reason the load is supplied via the bypass circuit, which
includes the bypass input breaker and the static transfer switch (STS).
If maintenance or repair is necessary the UPS can supply the load via the internal and manually
controlled maintenance bypass breaker. With the exception of the maintenance bypass breakers (internal
and external) all the breakers shown are closed during normal UPS operation.
Mains
supply
Output
breaker
Manual
maintenance
breaker Output
REC/PFC Inverter STS
Input
breakers
UPS
Bypass
supply
External bypass (recommended)
Battery
breaker
Battery
Figure 1 Single unit block diagram
An external bypass breaker enables a UPS to be replaced without interrupting the load and is
recommended in most installations.
Split bypass input
Figure 1 shows the UPS in what is known as the ‘split bypass’ configuration, in which a separate input
supply (the bypass supply) feeds the internal bypass circuits instead of the mains supply. In this
configuration the link (dotted line) between mains and bypass supply is removed.
Static transfer switch
The static transfer switch (STS) is a power-electronic circuit. During normal operation the load is supplied
via the inverter, however in the event of a UPS overload or inverter failure, the STS transfers the load
automatically to the bypass circuit. To provide a clean (no-break) load transfer between the inverter
output and bypass line, the inverter output is synchronized to the bypass supply during normal operating
conditions.

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Battery temperature compensation
Using optional external battery temperature sensors the UPS is capable of optimising the battery charger
output to enhance battery life and performance. This is a non-standard feature that must be purchased
separately. Contact your distributor for details.
Redundant control power supply board
The UPS is equipped with two identical and fully redundant control power supply boards. Each board is
powered by the input a.c. and battery d.c. Therefore, if one of these sources or even if a board fails the
UPS continues to operate normally. This feature further enhances the reliability of the system.
Single phase outlet
A 250 Va.c. 5 A single-phase fused outlet is provided on the front panel. This supply is generated from
the battery, independent of other UPS power circuits, and can be used for ease of testing, commissioning,
and servicing. This output is accessible when the cabinet door is open.
250VAC 5AFUSE
Multi-unit operation
Up to four units can be operated in N+X parallel mode to provide additional power or higher reliability. In
this configuration the load is shared equally between the units.
It is also possible to operate with load bus synchronisation (LBS), which allows the load to be transferred
seamlessly between two UPS systems. Each system can be a single UPS or a parallel group of units.
Multi-unit operation is enabled by:
Hardware and firmware built into each UPS, controlled by software settings.
Parallel control cables, connected in a ring to enhance reliability. Dual-bus control cables are
connected between any two UPS modules of each bus. The intelligent paralleling logic provides the
user with maximum flexibility. For example, shutting down or starting up UPS units in a parallel
system can be done in any sequence. Transfers between Normal and Bypass modes of operation
are synchronised and self-recovering.
The total load of a multi-unit system can be queried from each unit’s LCD display.

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Installation
Siting considerations
Before unpacking and installing the unit, consider the following:
DONOT 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. If required, allow enough spare cable to move the UPS after
installation.
Maintain a gap of at least 50 cm from walls or other equipment, and ensure the ventilation holes/slots
at the front and rear of the units are not obstructed.
For improved product reliability ensure cool air is available at the front of the unit.
Battery location. We recommend you site batteries in a separate room to maintain the optimum
working temperature of between 15°C and 25°C. 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 and the output is 4-wire star configuration.
Use circuit breakers and cables with the correct rating (see the next section).
Always fit an MCB between the mains supply live lines only and the UPS input (see Figure 2).
Caution:
Do not fit an MCB in the neutral line.
Because of the high leakage current (see Earth leakage current below), permanently hard wire all the
a.c. cables.
Fit ring terminal crimps on the ends of all cables that fasten to studs (see Cable sizes on page 12).
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 power distribution unit (PDU).
Ensure correct phase rotation in the 3-phase wiring.