extronics iUPS101 User manual

Installation & Operating Manual
iUPS101

Operating Manual
2
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Document Number 331435 (See Last Page for Revision Details)
©2013 Extronics Limited. This document is Copyright Extronics limited.
Extronics reserve the right to change this manual and its contents without notice, the latest
version applies.

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Contents
1 Introduction.......................................................................................................... 6
2 Safety Information and Notes.............................................................................. 7
2.1 Storage of this Manual................................................................................... 7
2.2 Special Conditions for Safe Use.................................................................... 7
2.3 List of Notes .................................................................................................. 7
3 Installation and Set-to-work................................................................................. 9
3.1 Installation..................................................................................................... 9
3.2 Fitting the Cables......................................................................................... 10
3.2.1 Grid-connected emergency systems..................................................... 10
3.2.2 Distributed Minigrid............................................................................... 10
3.2.3 Earthing system.................................................................................... 10
3.2.4 Mobile installation or installation connected to the grid via plug connector
11
3.2.5 Fixed Installation................................................................................... 11
3.2.6 Installation with automatic PE-neutral switching ................................... 12
3.2.7 Connecting the cables .......................................................................... 12
3.2.8 24V Cable Termination:........................................................................ 13
3.2.9 48V Cable Termination:........................................................................ 13
3.2.10 Parallel AC Output Termination:........................................................ 14
3.2.11 Auxiliary Output & CANBUS:............................................................. 14
3.2.12 Emergency Shutdown Signal............................................................. 15
3.2.13 CAN bus connections........................................................................ 15
3.2.14 Connecting the AC supply sources.................................................... 15
3.2.15 Connecting the AC output.................................................................. 16
3.2.16 Connecting the battery....................................................................... 16
3.2.17 Wiring auxiliary contacts.................................................................... 17
3.3 Setting to work............................................................................................. 17
3.4 Fusing.......................................................................................................... 18
3.4.1 Fuse Values.......................................................................................... 18
4 Description and Functioning.............................................................................. 19
4.1 Circuit Diagram............................................................................................ 19
4.2 Description of the main functions................................................................. 19
4.2.1 Overview............................................................................................... 19
4.2.2 Inverter.................................................................................................. 19
4.2.3 Battery protection circuit ....................................................................... 19
4.2.4 Automatic load detection....................................................................... 20
4.2.5 Transfer relay........................................................................................ 20
4.2.6 Fast voltage loss detection mode (fast transfer): .................................. 20
4.2.7 Battery charger ..................................................................................... 21
4.2.8 The inverter as source backup (“smart boost” function)........................ 21
4.2.9 Battery protection.................................................................................. 21
4.2.10 iUPS101 protection............................................................................ 22
4.2.11 Auxiliary contacts............................................................................... 22
4.2.12 Remote Emergency Disconnect........................................................ 23
5 Operation........................................................................................................... 25
5.1.1 Powering up the installation.................................................................. 25

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5.1.2 Activating and deactivating the iUPS101.............................................. 25
5.1.3 Status Information................................................................................. 26
5.1.4 Basic displays....................................................................................... 27
6 Advanced Programming.................................................................................... 29
6.1 Adaptation to the source.............................................................................. 29
6.2 Adaptation to the battery ............................................................................. 29
6.3 Activation of the function Smart-Boost......................................................... 29
6.4 Adjusting the AC Output Frequency {1112}................................................. 29
6.5 Setting of the RCC remote control............................................................... 30
6.6 Setting of the language {5000}.................................................................... 30
6.7 Setting of time {5001} and date {5002}........................................................ 30
6.8 User level {5012}......................................................................................... 31
6.9 Drive the remote control to the user level basic {5019} ............................... 31
6.10 Information on the operating mode of the installation............................... 32
6.11 Display of the parallel and three-phase systems...................................... 34
7 Messages and account of events...................................................................... 35
7.1 (000) Alarm: Low battery voltage................................................................. 35
7.2 (003) Message: AC IN synchronization in progress..................................... 36
7.3 (004) Message: Wrong AC-In input frequency ............................................ 36
7.4 (006) Message: Too high AC-In input voltage............................................. 36
7.5 (007) Message: Too low AC-In input voltage............................................... 36
7.6 (008) Stop: Overload inverter SC ................................................................ 36
7.7 (014) Stop: Overtemperature EL ................................................................. 37
7.8 (015) Stop: Overload inverter BL................................................................. 37
7.9 (016) Alarm: Ventilation fault detected......................................................... 37
7.10 (018) Alarm: Excessive battery ondulation............................................... 37
7.11 (019) Stop: Too low battery voltage ......................................................... 37
7.12 (020) Stop: high battery voltage ............................................................... 37
7.13 (021) Message: Maximum Current of the source (Input limit) exceeded;
transfer prohibited................................................................................................. 38
7.14 (022) Error: Voltage at AC Out................................................................. 38
7.15 (023) Error: Phase not defined................................................................. 38
7.16 (024) Message: Control the battery of the clock...................................... 38
7.17 (041) Alarm: Overtemperature TR............................................................ 38
7.18 (042) Stop: Source at the output.............................................................. 38
7.19 (058) Error: Lost of synchro master.......................................................... 39
7.20 (059) Stop: Overload inverter HW............................................................ 39
7.21 (060) (061) Alarm: Maximum duration security for auxiliary contact......... 39
7.22 (062) Alarm: Genset problem, no AC-In after a start by means of the
auxiliary contact.................................................................................................... 39
7.23 Stored events........................................................................................... 39
7.24 Utilisation and access levels .................................................................... 40
7.25 Pre-defined functions of the auxiliary relays............................................. 40
7.26 Access to the parameters......................................................................... 40
7.26.1 Access to a parameter by its number................................................ 41
7.26.2 Access to a parameter via the menu ................................................. 41
8 Configuration for auxiliary contacts 1 and 2 {1201} {1310}................................ 42
8.1.1 Simple functions.................................................................................... 43
8.1.2 AUXILIARY CONTACTS 1 AND 2 EXTENDED FUNCT. {1489}.......... 49
9 Configuration of AC Transfer............................................................................. 51

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9.1 Activate immediate detection of grid outage (UPS) {1435}.......................... 51
9.2 Tolerance on the immediate detection of a grid loss {1510}........................ 51
9.3 Transfer AC-In for delayed transfer opening {1199}.................................... 51
9.4 Delay before passing to inverter {1198}....................................................... 51
9.5 Immediate transfer AC-In voltage {1200}..................................................... 51
9.6 Frequency delta accepted above End {1505}.............................................. 51
9.7 Frequency delta accepted below End {1506}.............................................. 52
9.8 Duration of erroneous frequency before disconnecting the transfer relay
{1507}.................................................................................................................... 52
9.9 AC-In current active filtering {1575}............................................................. 52
10 Intended Purpose Usage................................................................................ 53
10.1 Transportation and Storage...................................................................... 53
10.2 Authorized Persons.................................................................................. 53
10.3 Cleaning and Maintenance....................................................................... 53
10.4 Safety Precautions................................................................................... 54
10.5 Cleaning and Maintenance Intervals........................................................ 54
10.6 Aggressive substances and environments............................................... 54
10.7 Exposure to external stresses.................................................................. 54
11 Technical Data................................................................................................ 56
11.1 Specification............................................................................................. 56
Table 7.0............................................................................................................... 56
11.2 Product De-rating..................................................................................... 57
11.3 Replacement Parts................................................................................... 57
11.4 System Run Times................................................................................... 58
11.5 System Assembly Details......................................................................... 59
12 Warranty Information...................................................................................... 60
13 Type Codes .................................................................................................... 61
14 Certification..................................................................................................... 62
14.1 Atex Label................................................................................................ 62
14.2 Atex Certificate......................................................................................... 63
14.3 iUPS101 EC Declaration of Conformity.................................................... 68
14.4 UPS System EC Declaration of Conformity.............................................. 69
15 Manual Revision............................................................................................. 70

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1 Introduction
The iUPS101 Uninterruptible Power Supply system is certified for use in Zone 1
hazardous areas and provides back up of 120VAC or 230VAC up to 3KVA load
as a stand alone system, or up to 9kVA load as part of a modular parallel
system. Critical equipment, such as SIL rated control systems, navigation or
landing lighting, or blow out prevention systems, are protected in the event of a
blackout or brownout.
System run times are outlined in this manual, and are achievable when using the
iUPS101 in conjunction with the iBATT100 Zone 1 ATEX / IECEx certified 24V
Battery Enclosure. System run times can also be increased by specifying a 48V
system which uses two iBATT100 enclosures to more than double the backup
time of a standard 24V system.
Designed to be wall mounted the iUPS101 UPS system comprises an aluminium
alloy Ex’d’ charger/inverter enclosure close coupled to a stainless steel Ex’e’
terminal enclosure. This allows easy access to incoming/ outgoing cables thus
alleviating the need to open the Ex’d’ enclosure
The Ex’d’ enclosure has a glass window housing the UPS display which shows
live system information and allows configurable parameters to be set by the
user. Various alarm and status information can be configured using the Ex’d’
buttons on the front panel on the UPS. Also included are two user programmable
volt free contacts, which allow the user to utilize various UPS alarms and status
information.
The system includes advanced battery charge controls including built in
temperature compensation to ensure the correct charging of the lead acid
battery.

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2 Safety Information and Notes
2.1 Storage of this Manual
Keep this user manual safe and in the vicinity of the device. All persons who have to work on
or with the device should be advised on where the manual is stored.
2.2 Special Conditions for Safe Use
None
2.3 List of Notes
The notes supplied in this chapter provide information on the following.
•Danger / Warning.
oPossible hazard to life or health.
•Caution
oPossible damage to property.
•Important
oPossible damage to enclosure, device or associated equipment.
•Information
oNotes on the optimum use of the device
Warning Installation to be by skilled electricians and instructed personnel in
accordance with national legislation, including the relevant standards
and, where applicable, in accordance with IEC 79.17 on electrical
apparatus for explosive atmospheres.
Warning! The iUPS101 may only be operated in Zone 1 and Zone 2 hazardous
areas. Refer to the ATEX certificate for further information.
Warning! All parts of the enclosure must never be opened while energised, or
when an explosive gas atmosphere is present.
Warning! The iUPS101 has two different supplies. Both the AC mains input and DC
battery input must be isolated before accessing the enclosure
Important The technical data indicated on the iUPS101 ATEX rating plate, in this
manual and the ATEX certificate must be observed at all times.
Important The ATEX rating plate must be fitted at all times, if damaged it must be
replaced immediately or the iUPS101 must be removed from service and
the hazardous area.

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Important Changes in the design and modifications to the equipment are not
permitted.
Important The iUPS101 shall be operated as intended and only in an undamaged
condition.
Important Only suitably rated loads may be connected to the iUPS101.
Important For systems with periods of inactivity, such as a long shutdown or
moving/storing a mobile system where the UPS is not in use and there is
no AC mains supply. Users should remove DC supplies to the system
when not in use.
Caution The iUPS101 may weigh up to 90Kg, therefore ensure that the assembly
is mounted using suitable fixtures.
Caution Never operate the iUPS101 unit outside of its rated voltage, current &
power as indicated in the specification or the safety of the unit may be
impaired.
Caution Never exceed the maximum output loading of the iUPS101 as stated in
the specifications. Adequate protection such as a fuse / breaker must be
fitted to connecting equipment to prevent exceeding maximum load.
Important For the installation, maintenance and cleaning of the units, it is
absolutely necessary to observe the applicable regulations and
provisions concerned with explosion protection (EN60079-0:2009, EN
60079-14:2008) as well as the Accident Prevention Regulations.
Important The iUPS101 must not be stored or operated outside of its rated
temperature range as stated on the ATEX certificate.
Important Any unused cable entries must be fitted with a suitably certified blanking
plug to maintain the IP of the equipment
Important Under no circumstances must the close coupled Ex ‘e’ Terminal
enclosure be used to lift the iUPS101. This will cause stress on the cable
glands and invalidate the ATEX certification. The iUPS101 must only be
handled by way of the Ex ‘d’ enclosure

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3 Installation and Set-to-work
3.1 Installation
The iUPS101 is supplied ‘close-coupled’ to an Ex ‘e’ terminal box using potted cable
transits. All equipment is suitably certified, and assembled under the relevant codes
of practice (see section 7). This allows simple connection to suitably rated Ex ‘e’
cable terminals by the user.
For reference, the drilled cable entries on the bottom face of the Ex ‘d’ enclosure can
be up to 1-1/2”NPT type or up to M40. The information on the exact type of entry can
be found on the enclosure rating plate. The Ex ‘d’ box should never be opened apart
from scheduled maintenance / inspection by a qualified person. Please see Safety /
Information notes in section 2.
The iUPS101 is only permitted to be mounted in a vertical orientation.
The system weighs approximately 90Kg, so suitable lifting equipment and safety
provisions must be taken to ensure safe installation.
Correct Vertical Installation:
Fig 3.
Important! The information shown on the ATEX rating plate is in relation to the
safety of the equipment. The functional operating parameters of the
system may vary slightly. Please see section 7 for details

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3.2 Fitting the Cables
Warning! Installation to be by skilled electricians and instructed personnel in
accordance with national legislation, including the relevant standards
and, where applicable, in accordance with IEC 79.17 on electrical
apparatus for explosive atmospheres.
3.2.1 Grid-connected emergency systems
The UPS can be used as an emergency system, also known as an uninterruptible
power supply (UPS) – enabling a reliable supply to a site connected to an unreliable
network. In the event of an interruption to the energy supply from the public grid, the
UPS, connected to a battery, substitutes the faulty source and enables a support
supply to the users connected downstream.
These will be supplied as long as the energy stored in the battery allows. The battery
will quickly be recharged at the next reconnection to the public grid.
The AC input to the iUPS101 unit must be powered via an external site circuit
breaker/switch to allow disconnection of the power. This should be located close to
the unit and be suitably marked to identify it as the isolating device for the iUPS101
unit.
The use of the UPS must be carried out by qualified personnel who have been
checked by the responsible local authorities. The applicable local standards and
regulations must be adhered to.
3.2.2 Distributed Minigrid
The implementation of the UPS on top of a distributed minigrid requires special care
in choosing the distribution system. A TT distribution is recommended for the DC grid
as well as for the AC grid.
Warning! The IT system (Power distribution system which is isolated from earth) is
not recommended for the distribution. This distribution is generally
forbidden by local laws
3.2.3 Earthing system
The UPS is a protection class I unit, which is intended for cabling in a grid type TT,
TN-S or TNCS. The earthing of the neutral conductor *(E) is carried out at a sole
installation point, upstream of the RCD circuit breaker *(D).
*(E) Earth-neutral connection bridge:
The neutral is earthed at a single point of the installation, downstream of the source
and upstream of the protection device(s) at the default current (DDR). When several
sources are available, each source must have an earthed neutral. If the source has to
be retained with an isolated earthling system (IT) the applicable local provisions and
regulations must be applied.
*(D) Differential circuit breaker:
A protection device must be installed downstream of the source according to the local
requirements and in compliance with the applicable regulations and standards.