EPC GC Series User manual

GC SERIES INDUSTRIAL
UNINTERRUPTIBLE POWER SUPPLY
USERS MANUAL

GC Series Industrial UPS
Users Manual
Ver1.0 Rev1 PAGE :
1
IMPORTANT
This users manual contains setup, operation and maintenance information for GC
Series Uninterruptible Power Supplies.
Before starting setup and operation of the equipment, complete users manual
should be read carefully.
Before operation, the Industrial UPS should be prepared by an authorized
technical personnel approved by EPC ENERGY&POWER CONVERTION
SYSTEMS CO. The warranty will be void, if this direction is not followed.
Please contact EPC ENERGY&POWER CONVERTION SYSTEMS CO
POWER SYSTEMS customer service, if you see any problem about any process
described in this users manual.
The manufacturer reserves the right to change the design of the equipment without
notice.
HIGH LEAKAGE CURRENT
Because of the high leakage current, this equipment should be operated only after
it is earthed.
ELECTROMAGNETIC COMPABILITY
This equipment if compatable to EMC directive 89/336/EEC and to conditions in
released technical specifications. The compability remains only if related
directions are followed and only if the equipment is used with accessories
approved by the manufacturer.
IMPORTANT
In custom designs, there can be minor differences between this manual and the
equipment.

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Users Manual
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CAUTION
1. There are no user servicable parts inside.
2. Even after the equipment is disconnected from batteries, input and output
connections, a intervention to the interior of the equipment contains risk of
electric shock.
3. Ventilation holes should be kept open and no objects should be inserted.
4. In the environment where the equipment will be operated, the temperature and
humidity should be relevant.
5. Batteries should be kept away from high temperature, otherwise they can
explode.
6. The equipment can not be operated in an environment having flammable and
explosive devices.
7. Setup, maintenance and repair of the equipment should be performed only by
trained, experienced and authorised technical personnel.
8. When working on live equipment a second person who is aware of all safety
precautions and emergency actions should be present at all times.
9. It is the responsibility of each individual to be aware of national legislation,
local legislation and site rules governing safety and working practices.
10. Use only good quality insulated tools and accessories, properly maintained
and calibrated instruments, and suitable and adequate supports and lifting
equipment.
11. Electrical energy can be supplied from the AC supply, internal / external
batteries or the external alarm or auxiliary control terminals.

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Users Manual
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CONTENT
1. GENERAL INTRODUCTION 4
1.1 SYSTEM DESCRIPTION 4
1.2 BYPASS SUPPLY 4
1.3 12 PULSE (RECTIFIER) DEVICES 4
1.4 TECHNICAL SPECIFICATIONS 5
2. SETUP 11
2.1 OPENING PACKAGE 11
2.2 CHOOSING PROPER PLACE 11
2.3 ELECTRICAL CONNECTION 11
3. OPERATION 12
3.1 SWITCHING THE UPS TO POWER THE LOAD FROM A POWER OFF 12
3.2 SWITCHING THE UPS ON FROM A MAINTENANCE BYPASS POWER DOWN 13
3.3 PROCEDURE FOR COMPLETELY POWRING DOWN THE UPS 13
3.4 PROCEDURE FOR SWITCING THE UPS INTO A MAINTENANCE BYPASS POWER DOWN 14
4. SERVICE AND MAINTENANCE 15
4.1 INTRODUCTION 15
4.2 SAFETY PRECAUTIONS 15
4.3 SCHEDULED MAINTENANCE 15
4.4 DAILY CHECKS 16
4.5 WEEKLY CHECKS 16
4.6 ANNUAL SERVICE 16
4.7 EXTENDED SERVICE 17
4.8 BATTERY MAINTENANCE 17
5. DISPLAY PANEL 18
5.1 STRUCTURE OF FRONT PANEL 18
5.2 MONITOR, INFORMATION AND WARNING MESSAGES 20
5.3 MEASUREMENT, CONTROL AND SETTINGS MENU STRUCTURE 23
5.4 ALARM & COMMUNICATION INTERFACE BOARD 27

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Users Manual
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1. GENERAL INTRODUCTION
1.1 SYSTEM DESCRIPTION
The GC Series Industrial UPS System is designed to be connected between a critical load, such as a
computer, medical systems, industrial systems and its three phase mains power supply. It provides
increased ower quality and uninterruption for critical loads.
System is designed in modular structure. Every main block is controlled seperately. There are 3
main blocks:
Recifier :Converts 3 phase mains input ac voltage to regulated DC voltage and feeds the inverter
and charges the batteries.
Inverter : Converts DC voltage to single phase AC voltage.
Static Transfer Switch (STS) : Connects bypass line voltage or inverter voltage to the output of the
UPS.
1.2 BYPASS SUPPLY
System allows the user to have seperate bypass input line. Therefore, mains input and bypass input
can be disconnected and bypass line can be feed by seperate source.
1.3 12 PULSE (RECTIFIER) DEVICES
To have reduced input current harmonics, especially at higher power ranges, GC Series UPSs are
also manufactuted with 12 pulse rectifier option. There are 2 completely seperate rectifiers
operating in paralel in such devices. Additional rectifier contains a phase shift transformer, sized for
the half power of the UPS values.
MAINS INPUT
(AC)
BYPASS INPUT
(AC)
UPS OUTPUT
(AC)
BATTERY INPUT
(DC)
RECTIFIER
INVERTER
STS
~
=
=
~

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1.4 TECHNICAL SPECIFICATIONS
1.4.1 SPECIFICATIONS for 15 –20 –30 - 40 kVA
INPUT DATA (MAINS)
Units
Power (kVA)
15
20
30
40
Line voltage
V
380 - 400 –415 3P + N
Permissible input voltage variation
%
+15% / -15
Line frequency
Hz
50 –60
Permissible input freq. variation
%
±10
Input current @ 380V
(normal operation)
A
25
32
49
65
Power factor (nominal)
-
0.8
Current total harmonic distortion
%
< 30
Current rating of neutral cable
-
1.4 times rated current
INPUT DATA (BYPASS)
Units
Power (kVA)
15
20
30
40
Bypass voltage
V
220V –230V –240V
Permissible bypass voltage variation
%
± 5
Bypass frequency
Hz
50 - 60
Permissible bypass freq. variation
%
± 5
BATTERY & DC
Units
Power (kVA)
15
20
30
40
Limits for proper inverter operation
V
320 –475
Number of batteries in one arm
-
32
Float charge voltage
V
432
End of discharge voltage
V
320
Rectifier output current rating
A
40
50
75
100
Battery charging current (maximum)
A
10
10
15
20
Ripple
%
< 1%
INVERTER OUTPUT
Units
Power (kVA)
15
20
30
40
Voltage
V
220V –230V –240V
Current (pf = 0.8) nominal
A
22
30
45
60
Power factor
-
0.8 lagging
Power at 0.8 power factor
kVA
15
20
30
40
Power at 1.0 power factor
kVA
12
16
24
32
Maximum non-lineer load
-
3 : 1
Voltage stability –steady state
%
± 1 %
Voltage stability - transient
%
± 7 %
Voltage phase shift
Degress
120
Output voltage distorsion (lineer
load)
%
< 3 %
Output voltage distortion (non-lineer
load, 3:1 crest factor)
%
< 10 %

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ENVIROMENTAL
Units
Power (kVA)
15
20
30
40
Operating temperature
º C
0 / 40
Relative humidity
%
< 90% at 23 º C
Altitude
M
< 1000 m
Storage temperature
º C
-25 / 70
Acoustic noise
dBA
52
54
56
56
Standart –EMC
-
EN 50091 - 2
Standart - Safety
-
EN 50091 - 1

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1.4.2 SPECIFICATIONS for 60 –80 - 100 kVA
INPUT DATA (MAINS)
Units
Power (kVA)
60
80
100
Line voltage
V
380 - 400 –415 3P + N
Permissible input voltage variation
%
+15% / -15
Line frequency
Hz
50 –60
Permissible input freq. variation
%
± 10
Input current @ 380V
(normal operation)
A
99
131
164
Power factor (nominal)
-
0.8
Current total harmonic distortion
%
< 30
Current rating of neutral cable
-
1.4 times rated current
INPUT DATA (BYPASS)
Units
Power (kVA)
60
80
100
Bypass voltage
V
220V –230V –240V
Permissible bypass voltage variation
%
± 5
Bypass frequency
Hz
50 - 60
Permissible bypass freq. variation
%
± 5
BATTERY & DC
Units
Power (kVA)
60
80
100
Limits for proper inverter operation
V
320 –475
Number of batteries in one arm
-
32
Float charge voltage
V
432
End of discharge voltage
V
320
Rectifier output current rating
A
150
200
250
Battery charging current (maximum)
A
30
40
50
Ripple
%
< 1%
INVERTER OUTPUT
Units
Power (kVA)
60
80
100
Voltage
V
220V –230V –240V
Current (@380V , pf = 0.8, nominal)
A
91
121
151
Power factor
-
0.8 lagging
Power at 0.8 power factor
kVA
60
80
100
Power at 1.0 power factor
kVA
48
64
80
Maximum non-lineer load
-
3 : 1
Voltage stability –steady state
%
± 1 %
Voltage stability - transient
%
± 7 %
Voltage phase shift
Degress
120
Output voltage distorsion (lineer
load)
%
< 3 %
Output voltage distortion (non-lineer
load, 3:1 crest factor)
%
< 10 %

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ENVIROMENTAL
Units
Power (kVA)
60
80
100
Operating temperature
º C
0 / 40
Relative humidity
%
< 90% at 23 º C
Altitude
M
< 1000 m
Storage temperature
º C
-25 / 70
Acoustic noise
dBA
57
57
58
Standart –EMC
-
EN 50091 - 2
Standart - Safety
-
EN 50091 - 1

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1.4.3 SPECIFICATIONS for 120 –160 - 200 kVA
INPUT DATA (MAINS)
Units
Power (kVA)
120
160
200
Line voltage
V
380 - 400 –415 3P + N
Permissible input voltage variation
%
+15% / -15
Line frequency
Hz
50 –60
Permissible input freq. variation
%
± 10
Input current @ 380V
(normal operation)
A
196
263
328
Power factor (nominal)
-
0.8
Current total harmonic distortion
%
< 30
Current rating of neutral cable
-
1.4 times rated current
INPUT DATA (BYPASS)
Units
Power (kVA)
120
160
200
Bypass voltage
V
220V –230V –240V
Permissible bypass voltage variation
%
± 5
Bypass frequency
Hz
50 –60
Permissible bypass freq. variation
%
± 5
BATTERY & DC
Units
Power (kVA)
120
160
200
Limits for proper inverter operation
V
320 –475
Number of batteries in one arm
-
32
Float charge voltage
V
432
End of discharge voltage
V
320
Rectifier output current rating
A
300
400
500
Battery charging current (maximum)
A
60
80
100
Ripple
%
< 1%
INVERTER OUTPUT
Units
Power (kVA)
120
160
200
Voltage
V
220V –230V –240V
Current (@380V , pf = 0.8, nominal)
A
182
242
303
Power factor
-
0.8 lagging
Power at 0.8 power factor
kVA
120
160
200
Power at 1.0 power factor
kVA
96
128
160
Maximum non-lineer load
-
3 : 1
Voltage stability –steady state
%
± 1 %
Voltage stability - transient
%
± 7 %
Voltage phase shift
Degress
120
Output voltage distorsion (lineer
load)
%
< 3 %
Output voltage distortion (non-lineer
load, 3:1 crest factor)
%
< 10 %

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Users Manual
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ENVIROMENTAL
Units
Power (kVA)
120
160
200
Operating temperature
º C
0 / 40
Relative humidity
%
< 90% at 23 º C
Altitude
M
< 1000 m
Storage temperature
º C
-25 / 70
Acoustic noise
dBA
58
59
59
Standart –EMC
-
EN 50091 - 2
Standart - Safety
-
EN 50091 - 1

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Users Manual
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2. SETUP
2.1 OPENING PACKAGE
When the equipment is delivered to you, first to be examined is a possible damage during transport.
Therefore, examine the equipment carefully. For a possible future use, save the packet and wooden
pad of the rectifier after unpacking.
2.2 CHOOSING PROPER PLACE
1. For a proper ventilation, minimum distance between the rear of the rectifier and any nearby
object should me minimum 20 cm.
2. Choose a place with proper temperature and humidity.
3. Do not choose any place which can cause dust and corrosion.
4. The place chosen should not have direct sunshine and shouldnt be near any heating source.
5. Operating the equipment in proper conditions will increase it lifetime.
2.3 ELECTRICAL CONNECTION
All electrical connections of the UPS exist on the back of the front door of the enclosure. All
required connections to connection panel of UPS should be made by EPC ENERGY&POWER
CONVERTION SYSTEMS CO. service personnel or by the approval of EPC ENERGY&POWER
CONVERTION SYSTEMS CO. service personnel.
Before making the connections all power switches, isolators and circuit breakers must be in OFF
position.
Ground must be connected to the distribution panel.
CAUTION
Connect and control ground (PE) connection. Definitly, the equipment should’nt be operated
without ground connection.
NOTE
For 6 pulse rectifier, 3 phase input devices, input supply phase sequence and direction is ignorable.

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For 12 pulse rectifier, 3 phase input devices, input supply phase sequence is important. The input
phase sequence may be seen inside the About->Rectifier submenu, Input Voltage item. After
connecting supply, be sure that the phase rotation direction sign is ‘-‘ (minus)
3. OPERATION
Figure 3-1 GC Series Industrial UPS Breaker Configuration
3.1 SWITCHING THE UPS TO POWER THE LOAD FROM A POWER OFF
This procedure should be followed when turning on the UPS from a fully powered down condition -
i.e. where the load is not being initially supplied at all.
1. Switch K1 mains input circuit breaker and K4 bypass input circuit breaker into ON position.
Display panel will be energized and a welcome message will be displayed on LCD display.
2. Rectifier will start operation in 10 seconds and generate DC. DC Low alarm will disappear.
3. If the bypass input is within tolerances, the UPS will switch the load to bypass line. Cooling
fans will start operation.
~
=
=
~
K1
K4
K3
PK1
K2*1
BYPASS
MAINS
OUTPUT
BATTERIES
*1 K2 is internal or external depending on
model and/or power.
RECTIFIER
INVERTER
STS
PK1

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4. After the DC bus voltage is stabilized, inverter will start its operation. 10 seconds later, the STS
will switch its output the inverter. Inverter Fail and Outpyu Fail alarms will disappear.
5. Now, it is safe to turn the K2 battery circuit breaker (internal or external) on.
6. Now, you can switch the K3 output circuit breaker into ON position. UPS is now feding your
loads.
3.2 SWITCHING THE UPS ON FROM A MAINTENANCE BYPASS POWER DOWN
This procedure will describe how to start the UPS and the how to transfer the load from the
maintenance bypass to the UPS inverter.
1. Switch K1 mains input circuit breaker and K4 bypass input circuit breaker into ON position.
Display panel will be energized and the welcome message will be displayed on LCD display.
2. After a short period, rectifier and inverter will start operation. STS will feed output through the
bypass line. Cooling fans will start operation.
3. Switch K3 output circuit breaker into ON position.
4. Although the inverter is operational and generates AC voltage, STS will never switch the output
to inverter source, as long as the PK1 maintenance bypass circuit breaker is in BYPASS
position. Switch PK1 maintenance bypass circuit breaker into OFF position. The UPS will
detect this action and after a short period, STS will transfer the output to the inverter side.
7. Switch K2 battery circuit breaker (internal or external) to ON position. The UPS will enter to
the normal operation condition.
3.3 PROCEDURE FOR COMPLETELY POWRING DOWN THE UPS
This procedure should be followed to completely power down the UPS and LOAD. All power
switches, isolators and circuit breakers will be opened and there will be no load power.
1. Switch the K3 output circuit breaker to OFF position. This will power down your output loads.
2. Switch the K2 battery circuit breaker to OFF position.
3. Switch the K1 mains input circuit breaker and K4 bypass input circuit breaker to OFF position.
4. After a short period, display panel will be deenergized.
NOTE
After the UPS is completly powered down, UPS output loads can be powered any time by switching
the PK1 maintenance bypass circuit breaker into BYPASS position.

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3.4 PROCEDURE FOR SWITCING THE UPS INTO A MAINTENANCE BYPASS
POWER DOWN
This procedure should be followed to transfer the load from the UPS inverter output to the
maintenance bypass system. This may be required during UPS maintenance procedures.
1. From the display panel, access to the control submenu and switch inverter OFF. After doing
this, inverter will stop operation and STS will switch to the bypass line.
2. Switch PK1 maintenance bypass circuit breaker to BYPASS position.
3. Switch K3 output circuit breaker to OFF position.
4. Switch K2 battery circuit breaker, K1 mains input circuit breaker, K4 bypass input circuit
breaker to OFF position. After a short period, display panel will be deenergized.
5. Your load is feeded through the maintenance bypass circuit breaker. An interuption on bypass
line will affect your load.

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4. SERVICE AND MAINTENANCE
CAUTION
There are no by the user servicable parts inside the equipment, therefore DO NOT OPEN THE
COVER OF THE EQUIPMENT. Because of possible external battery connection and dry contact
relay outputs, THERE MAY BE HIGH VOLTAGE INSIDE THE EQUIPMENT, EVEN WHEN
THE RECTIFIER IS TURNED OFF. Do not permit unauthorized persons to intervent any failure,
otherwise, the warranty will be void and moreover, significant injury may occour.
4.1 INTRODUCTION
This chapter contains the procedures necessary to effect general maintenance of the UPS module
and battery. Certain procedures entail gaining internal access to the UPS, and should only be
undertaken by a competent engineer who is familiar with the operation and layout of the equipment
and understands the areas of potential hazard. If you have any doubts concerning safety or the
method of carrying out any procedure then contact an approved service agent for assistance or
advice. If the locally approved agent is not known to you, then you should contact the Customer
Services & Support department of the dealer or manufacturer.
The manufacturer offers customer training, at a nominal fee, if required. Such training can range
from a one-day operator course to in-depth training on maintenance and troubleshooting lasting
several days, and can be carried out at the manufacturer's plant or at the customer premises.
4.2 SAFETY PRECAUTIONS
When working on the UPS remember that the equipment contains live voltages at ALL TIMES
unless it is externally isolated from the mains supply, bypass supply and batteries. It is essential that
the safety and precautionary notes contained throughout this manual are read and FULLY
UNDERSTOOD before touching any UPS internal component part.
4.3 SCHEDULED MAINTENANCE
The UPS utilizes solid-state components which are not subject to wear, with the only moving parts
being the cooling fans. Scheduled maintenance requirements, beyond ensuring that the
environmental conditions remain suitably cool and clean, are therefore minimal. However, a well

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documented periodic program of inspection and preventive maintenance, as suggested below, will
help to ensure optimum equipment performance and may serve to detect certain minor malfunctions
prior to them developing into a major fault.
4.4 DAILY CHECKS
Carry out a daily walk-by inspection of the UPS, checking the following points:
1. Carry out a spot check of the operator control panel; ensuring that all mimic LED indications
are normal, all metered parameters are normal and no warning or alarm messages are present on
the display panel.
2. Check for obvious signs of overheating.
3. Listen for any noticeable change in audible noise.
4. Ensure that the ventilation grills around the UPS are unobstructed.
5. If possible, log the results of the inspection, noting any discrepancies from the norm.
4.5 WEEKLY CHECKS
Carry out the following checks from the mimic panel and log the results:
Measure and record the battery charge voltage.
Measure and record the battery charge current.
Measure and record the UPS output voltage on all three phases.
Measure and record the UPS output line currents. If these are significantly different from the values
previously logged then, if possible, record the size, type and location of any additional load
connected to the UPS supply since the previous inspection. This type of information could prove
useful to the troubleshooting engineer should a problem occur.
If any of the above indications differ greatly from the previously logged values for no apparent
reason then you should contact the Customer Service & Support Department of the dealer /
manufacturer.
4.6 ANNUAL SERVICE
The equipment should be thoroughly cleaned and the following checks carried out annually. This
entails working inside the equipment in regions containing hazardous voltages.
A manufacturer-trained engineer is fully aware of the hazards concerned and will carry out this
procedure with the load connected to the maintenance bypass supply; however if the customer
decides to carry out this service procedure himself it is imperative that the UPS be totally shut
down and isolated from the input mains and bypass supplies and batteries using the procedure

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given below. We therefore strongly recommend that the annual service is carried out by trained
personnel.
Carry out the weekly checks detailed above.
Shut down the UPS following the recommended operating procedure.
Isolate the UPS input mains supply externally (also the bypass supply if a split bypass system is
in use) and isolate the battery.
Ensure that the UPS is totally powered down by checking for voltage at the rectifier input
connections (U1, V1 & W1), the battery connection terminals, the output connections (U2, V2
& W2) and the bypass input connections (U3, V3 & W3).
Gain full access to the UPS interior by opening its internal hinged safety panel.
Carry out a thorough examination of the UPS power components and sub-assemblies, paying
particular attention to the following:
Electrolytic capacitors - Check for signs of leakage, buckling etc.
Magnetic components - Check for signs of overheating, security of fixture and signs of
delamination.
Cables and connections - Check cables for chaffing, fraying or signs of overheating. Check that
all printed circuit board connectors are secure.
Printed circuit boards - check the cleanliness and integrity of the circuit boards and replace if
any signs of deterioration are found.
Thoroughly clean inside the equipment enclosure using a vacuum cleaner and low pressure air
to remove any foreign debris.
Reconnect the UPS input mains power. Start the UPS and transfer the load to the inverter
following the appropriate operating procedure. If possible, check the battery autonomy time by
opening the rectifier input power switch (K1) with the UPS on-load.
4.7 EXTENDED SERVICE
We recommend that ALL the input/output power cables and their connections are checked
periodically. As this requires the UPS to be completely shut down such a check should be carried
out on an `opportunity' basis but at an interval not exceeding 2 years.
4.8 BATTERY MAINTENANCE
The batteries used with the UPS are generally sealed, valve-regulated type, and the only
maintenance requirement is to ensure that the cells are kept clean and dry. Maintenance procedures

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appropriate to both valve-regulated and non-sealed batteries vary, and should be obtained from the
battery manufacturer.
5. DISPLAY PANEL
5.1 STRUCTURE OF FRONT PANEL
The front panel of the Rectifier contains a 2x16 character LCD (Liquid Crystal Display), control
buttons and leds. Via LCD, measurements and status / alarm messages are displayed in a format,
which can be easyly understood. Parts in front panel and their functions are given below.
Figure 5.1 UPS Front Panel
1
LCD Display
Measured values, status and alarm messages of the equipment are displayed in this
2x16 character LCD display.
2
Esc Button
This buton is used to get back from a submenu or to escape from adjustment without
validating.
3
Up Button
In menus, this button is used to see the previous item (up). In adjustments, this button
is used to increase the adjusted quantity.
4
Down Button
In menus, this button is used to see the next item (down). In adjustments, this button
is used to decrease the adjusted quantity.
5
6
2
1
3
4
7
UPS 20kVA
3P/1P 230 Vac
A
8

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5
Enter Button
This buton is used to enter a submenu or to validate a setting performed.
6
Led Displays
These leds provide instantenaous information about the status of the equipment.
7
Led Indicaters
This led panel has individual leds for individual alarms.
An energized (lighting) led indicates an actual alarm condition.
A blinking led indicated an old, latched alarm condition, that do not exists anymore.
8
Type Indicater
The area has the information about the device model, nominal voltage and nominal
current.
Led
Color
Status
Description
Input OK
Green
Light

Interlink DC is OK.
No Light

Interlink DC is low or failed.
Operation
Green
Light

The equipment is generating AC.
Blinking

The equipment has stopped generating
AC, because of an alarm condition.
Because it is in Automatic Startup
mode, it will restart generating AC,
after the alarm condition is disappeard.
No Light

The equipment is not generationg AC.
Common
Alarm
Red
Light

There is an alarm condition.
No Light

There is no alarm condition.
In LCD display, measured values and status / alarm messages are displayed in seperate lines. Via
buttons, it is possible to stroll in measurements and submenus.
Figure 5.2 LCD Display, Measurements Menu
Figure 5.3 LCD Display, Main Menu
F
U
P
>
U
N
C
T
I
O
N
A
L
<
G
R
O
O
U
T
P
O
T
A
G
L
2
3
0
V
U
T
V
E