Gamatronic B60US-IB User manual

GAMATRONIC
THREE PHASE MODULAR UPS
FOR THE 208V GRID
B60US-IB
INSTALLATION GUIDE
Revision 3.0, January 2020 (Doc. 2MUM-B60I)
This installation
guide is for product
#101SW463-1.

UPS for 208 Vac Grid, Installation Guide, doc. rel. 3.0
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Remember to register your product at:
http://www.gamatronic.com/product-warranty
in order to activate your warranty.

iii
UPS for 208 Vac Grid, B60US-IB Installation Guide, doc. rel. 3.0
STANDARDS AND CONVENTIONS
This user manual contains diagrams which include images of the display screen of the UPS. Unless
otherwise indicated, the readings shown in the screen images are only illustrative, and are not
intended to match the readings on a specific system in any particular environment.
Operation and control of the UPS is accomplished through a touch-sensitive LCD display screen. In
this manual, when explaining how to navigate the control software via the touch-sensitive screen,
the terms "tap", "press", "choose", and "select" may be used interchangeably to indicate selection
of a screen option.
Most of the electrical abbreviations in this document are according to IEEE 280 Standard Letter
Symbols for Quantities Used in Electrical Science and Electrical Engineering.

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TABLE OF CONTENTS
1. UNPACKING INSTRUCTIONS ............................................................................................................................. 5
2. SAFETY PRECAUTIONS...................................................................................................................................... 8
2.1. DO’S.................................................................................................................................................................8
2.2. DON’TS............................................................................................................................................................10
3. SYSTEM STRUCTURE AND INSTALLATION....................................................................................................... 11
3.1. IMPORTANT INSTALLATION INFORMATION ..............................................................................................................13
3.2. INSTALLATION CHECKLIST ....................................................................................................................................14
3.3. INSTALLATION PROCEDURE ..................................................................................................................................23
3.3.1. Visual Inspection ..................................................................................................................................23
3.3.2. Physical Site Preparation......................................................................................................................23
3.3.3. Electrical Site Preparation ....................................................................................................................26
3.3.4. Cable Site Preparation..........................................................................................................................27
3.3.4.1. The Ground Line ............................................................................................................................................... 27
3.3.4.2. The Neutral Line ............................................................................................................................................... 28
3.3.4.3. Ac Input and Output connections .................................................................................................................... 28
3.3.4.4. Connecting the UPS to the electrical panel ...................................................................................................... 31
3.3.4.5. Assembling and connecting internal batteries ................................................................................................. 33
3.3.4.6. Assembling and connecting external batteries ................................................................................................ 38
3.3.5. Powering up the system .......................................................................................................................41
3.3.5.1. Before starting up the UPS ............................................................................................................................... 41
3.3.6. Initial Configuration .............................................................................................................................41
3.3.6.1. System Startup Wizard..................................................................................................................................... 42
3.3.6.2. Continuing First Time UPS configuration.......................................................................................................... 46
3.3.6.3. Assigning IP Address to the UPS ....................................................................................................................... 54
3.4. TESTS ..............................................................................................................................................................56
3.4.1. Test: Self-loading/PQ mode..................................................................................................................56
3.4.2. Test: Under load ...................................................................................................................................60
3.4.3. Test: Battery mode or Blackout............................................................................................................60
3.4.4. Test: ATS...............................................................................................................................................61
3.4.5. Test: ECO mode ....................................................................................................................................62
3.4.6. Test - IP Communication with Controller..............................................................................................65
4. AUXILIARY CONNECTIONS.............................................................................................................................. 67
4.1. INPUT AND OUTPUT DRY CONTACTS .......................................................................................................................72
4.2. EMERGENCY POWER OFF –EPO (MANUAL) ...........................................................................................................72
4.2.1. Restarting the UPS after EPO ...............................................................................................................72
4.3. SURGE PROTECTOR MALFUNCTION ALARM ..............................................................................................................73
4.4. LVD BATTERY PROTECTOR ...................................................................................................................................73
5. CIRCUIT BREAKER SELECTIVITY....................................................................................................................... 74
6. PARALLEL OPERATION ................................................................................................................................... 76
6.1. THEORY ...........................................................................................................................................................76
6.1.1. Decentralized static switch method .....................................................................................................76
6.1.2. Parallel communication........................................................................................................................77
6.1.2.1. EPO and parallel operation .............................................................................................................................. 79

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6.1.2.2. Common vs. Decentralized battery .................................................................................................................. 79
6.2. INSTRUCTIONS FOR PARALLEL CONFIGURATION.........................................................................................................79
6.2.1. Maintenance bypass for parallel systems ............................................................................................87
7. MAINTENANCE BYPASS MODE PROCEDURE .................................................................................................. 88
7.1. CIRCUIT BREAKER LAYOUT ....................................................................................................................................89
7.2. TRANSFERRING THE UPS TO MAINTENANCE BYPASS MODE FROM NORMAL MODE...........................................................89
7.3. TRANSFERRING THE UPS BACK TO NORMAL MODE FROM MAINTENANCE BYPASS MODE...................................................92
8. USING THE UPS WITH A GENERATOR ............................................................................................................. 94
8.1. THE AUTOMATIC TRANSFER SWITCH (ATS) ............................................................................................................94
9. SERVICE AND REPAIRS ................................................................................................................................... 96

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LIST OF FIGURES
Figure 1: Inspect the shipping crate for signs of damage ....................................................................5
Figure 2: ShockWatch and TiltWatch devices......................................................................................6
Figure 3: Remove the roof and support beams (use electric screwdriver) ...........................................7
Figure 4: Remove the walls of the crate...............................................................................................7
Figure 5: Major components of the UPS system................................................................................12
Figure 6: Main terminals viewed from the UPS rear ..........................................................................12
Figure 7: Dimensions of the Gamatronic UPS ...................................................................................25
Figure 8: Recommended clearance around the UPS .........................................................................26
Figure 9: Recommended system connections....................................................................................29
Figure 10: Recommended connections with input isolation transformer ...........................................30
Figure 11: Terminal connections.........................................................................................................31
Figure 12: Internal battery bank layout................................................................................................34
Figure 13: Battery wire terminals.........................................................................................................34
Figure 14: Single battery tray ..............................................................................................................34
Figure 15: Connect the eighth battery on each tray...........................................................................35
Figure 16: Link the four batteries on each side of the tray.................................................................35
Figure 17: For safe disconnection of the batteries.............................................................................36
Figure 18: Cable plugs on one end, Anderson-type plugs on the other.............................................36
Figure 19: One of the internal battery banks......................................................................................37
Figure 20: Connecting a Single Battery Set........................................................................................39
Figure 21: Connecting multiple battery sets, using CBs ....................................................................40
Figure 22: Initial configuration wizard: Start screen ...........................................................................42
Figure 23: Initial configuration wizard: password entry.....................................................................43
Figure 24: Initial configuration wizard: battery capacity in Ah ...........................................................43
Figure 25: Initial configuration wizard: set time zone .........................................................................44
Figure 26: Finish configuration wizard................................................................................................45
Figure 27: Flat cables..........................................................................................................................46
Figure 28: Static Switch.......................................................................................................................46
Figure 29: Modules Off Screen ...........................................................................................................47
Figure 30: Modules..............................................................................................................................48
Figure 31: Confirm Disconnecting the Load........................................................................................49
Figure 32: Confirm Switch on All Modules ..........................................................................................49
Figure 33: The "alarms" icon indicates alarm conditions ...................................................................50
Figure 34: Next scheduled test screen................................................................................................50
Figure 35: Battery Test in Progress screen.........................................................................................51
Figure 36: Confirm Transfer Load to Bypass ......................................................................................51
Figure 37: Confirm Transfer Load to Inverter......................................................................................52
Figure 38: Set Last Maintenance Date screen....................................................................................53
Figure 39: Confirm Save User Settings...............................................................................................53
Figure 40: IP Address Configuration ...................................................................................................54
Figure 41: IP address configuration ...................................................................................................55
Figure 42: Enable PQ Mode................................................................................................................57
Figure 43: PQ Mode setup ..................................................................................................................57
Figure 44: PQ Mode............................................................................................................................58
Figure 45: Reactive load testing..........................................................................................................59
Figure 46: Disable PQ mode...............................................................................................................59
Figure 47: Generator mode.................................................................................................................61

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Figure 48: Changing the auxiliary contact to normally closed.............................................................62
Figure 49: ECO Mode..........................................................................................................................63
Figure 50: Enable ECO mode .............................................................................................................64
Figure 51: Turning on ECO mode.......................................................................................................64
Figure 52: ECO Mode Status ..............................................................................................................65
Figure 53: Web View...........................................................................................................................66
Figure 54: Location of Connector Groups 1 and 2 on the front of the UPS. ......................................67
Figure 55: Close-up of Connector Group 1........................................................................................68
Figure 56: Connector group 2 ............................................................................................................69
Figure 57: Four pin connectors ..........................................................................................................72
Figure 58: LVD wiring diagram............................................................................................................73
Figure 76: A UPS's bypass circuit......................................................................................................74
Figure 77: The static switch in context (stand-alone system) ............................................................77
Figure 78: Parallel comm. connections (see Table 7)........................................................................78
Figure 79: Location of the parallel comm. connections at inside rear of the system .........................78
Figure 80: Common DC Parallel communication cable ....................................................................81
Figure 81: Decentralized DC Parallel communication cable..............................................................81
Figure 82: System Menu main screen................................................................................................82
Figure 83: The crown icon indicates the Master UPS.........................................................................83
Figure 84: Modules screen..................................................................................................................83
Figure 85: Ac output voltage display for a single module...................................................................84
Figure 86: Connection diagram for 2 parallel units ............................................................................85
Figure 87: Connection diagram for 4 Units in Parallel.........................................................................86
Figure 88: Electrical setup...................................................................................................................89
Figure 89: UPS On - Normal Mode.....................................................................................................90
Figure 90: Transfer load to bypass confirm dialog..............................................................................91
Figure 91: UPS ON - Bypass mode ....................................................................................................91
Figure 92: Timing variables when using a generator and an ATS.....................................................94
Figure 93: Example of an ATS control panel ......................................................................................95
LIST OF TABLES
Table 1: Recommended clearances...................................................................................................25
Table 2: Recommended circuit breakers for the current rating for 20-60kva UPS 208 .....................32
Table 3: Battery current ratings for semiconductor fuses and circuit breakers...................................39
Table 4: Battery lifetime vs environmental temp. (illustrative, as per Eurobat)..................................40
Table 5: Key to 1Figure 55: Close-up of Connector Group 1............................................................68
Table 6: Description of Connector Group 2 (Key to Figure 56)...........................................................69
Table 7: Cable sets for parallel communication between UPSs ........................................................80
Table 8: Rating of CB12 (for maintenance bypass option) ................................................................87
Table 9: Normal mode operating position of the circuit breakers........................................................90
Table 10: Position of the CBs in maintenance bypass mode..............................................................92
Table 11: Maintenance bypass operating position of the circuit breakers ..........................................92
Table 12: Position of the CBs in normal mode....................................................................................93

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1. Unpacking Instructions
1. Inspect the shipping crate for any signs of damage that may have occurred while in
transit.
Figure 1: Inspect the shipping crate for signs of damage
2. Inspect the ShockWatch and TiltWatch devices, which are adhered to the outside of the
wooden packing crate. Verify that their indicators are not red.
A red indicator is a sign of rough handling (ShockWatch) or tip-over (TiltWatch).
Notify the carrier and Gamatronic Support immediately if rough handling of the
UPS is suspected or if any damage is found or suspected.
3. Retain the shipping crate and packaging materials for future use.

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- OR -
Figure 2: ShockWatch and TiltWatch devices
These devices indicate if the package was subject to shock or tip-over.
4. Using a forklift, move the shipping crate close to the place in which the UPS will be
installed.
5. Cut and remove any straps on the shipping crate.
6. Stand on a secure ladder and use an electric screwdriver to remove the screws that are
holding the roof of the shipping crate in place. Then remove the roof.

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Figure 3: Remove the roof and support beams (use electric screwdriver)
7. Remove the screws that are holding the walls and support beams of the crate in place.
Then carefully remove the walls themselves leaving the UPS standing on its wooden
shipping pallet.
Figure 4: Remove the walls of the crate
8. Cut and remove any straps that are securing the UPS to the shipping pallet.
9. Remove the plastic wrapping and all other packaging material from the UPS.
Be careful to avoid scratching the finish of the Modular UPS.
10.Lift the UPS from the shipping pallet and move it to the location where it will be
installed.

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2. Safety Precautions
The UPS system is designed for a wide range of environments. Nevertheless, the modular UPS
should be handled with care, according to the following guidelines.
2.1. Do’s
Read this manual and the User Guide carefully before starting installation and operation of the
UPS.
Review the safety precautions described below to avoid injury to users and damage to the
equipment.
This UPS is intended for installation in a temperature-controlled, indoor area that is free from
conductive contaminants.
All power connections must be completed by a licensed electrician who is experienced in
wiring this type of equipment, and who is familiar with the local electrical codes and
regulations. Improper wiring may cause damage to the equipment, injury to personnel, or
even death.
Ensure all power is disconnected before performing installation or maintenance.
See Table 1 and Figure 7 for recommended clearances.
The UPS must be well grounded to the building’s grounding system with a conductor that has
a current carrying capacity that matches the rating of the UPS according to local codes.
Battery installation, battery maintenance, and battery replacement shall be performed only by
authorized service personnel.
Pay attention to all DANGER, CAUTION, and WARNING notices affixed to the inside and
outside of the UPS.
Keep surroundings clean, uncluttered and free from excess moisture.
Keep the operating environment within the parameters stated in this document.
Allow only qualified technicians to service the UPS. There are no user-serviceable components.
Do not try to repair it yourself!
Use the UPS only for its intended purpose.
The batteries should preferably be installed next to the UPS, or as close to it as is practically
possible.

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If you remove a power module from the UPS while the module is operating, wait five minutes
before reinserting the module. This allows the module’s capacitors time to discharge.
FAST FUSES (SEMICONDUCTOR FUSES) must be used between the battery and the UPS –for
example, the Ferraz Shawmut A70QS fuse.
WARNING - RISK OF LETHAL ELECTRIC SHOCK:
WARNING! HIGH TOUCH CURRENT!
EARTH CONNECTION ESSENTIAL BEFORE CONNECTING POWER
SUPPLY.
WARNING - RISK OF LETHAL ELECTRIC SHOCK:
The battery cabinet contains a series of batteries that provides high
voltage and energy in the UPS body even when the UPS is not
connected to the ac input.
Take appropriate precautions during installation, inspection and
servicing.

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2.2. Don’ts
Do not open the cover of the UPS or the battery cabinets under any circumstances. All UPS
panels and doors should be closed.
Do not insert any objects through the ventilation holes.
Do not put objects on the UPS.
Do not move the UPS while it is operating.
Do not use the UPS outdoors.
Do not turn the UPS upside down or lying down during transportation.
Do not connect or disconnect any AC or DC cables to the battery cabinet or UPS unless ALL
the battery circuit and AC circuit breakers are turned OFF.
Do not turn ON the battery circuit breaker when the battery cabinet is disconnected from the
UPS.
Do not install the UPS next to gas or electrical heaters. A restricted location is recommended
in order to prevent access by unauthorized personnel.
If you remove a power module from the UPS while the module is operating, do not reinsert
the module immediately. Wait five minutes.
WARNING - RISK OF LETHAL ELECTRIC SHOCK:
This UPS receives power from more than one source!
Disconnection of all ac sources and dc sources is
required to de-energize this unit before servicing.
WARNING - RISK OF LETHAL ELECTRIC SHOCK:
Do not touch uninsulated battery terminals.

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3. System Structure and Installation
The UPS is composed of:
Up to 3 power modules, each provides 20 kVA / 18 KW
Static switch module
System controller
Up to 3 internal battery banks
Maximum output capacity of the UPS is 60 kVA/54 kW.

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Figure 5: Major components of the UPS system
Figure 6: Main terminals viewed from the UPS rear

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ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED
ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT,
AND WHO IS FAMILIAR WITH THE LOCAL ELECTRICAL CODES AND
REGULATIONS.
IMPROPER WIRING MAY CAUSE INJURY TO PERSONNEL AND/OR DAMAGE
TO THE EQUIPMENT.
IN THE EVENT THAT THE UPS HAS BEEN DISCONNECTED FROM THE AC
MAINS FOR FOUR MONTHS OR LONGER FOLLOWING ITS DELIVERY TO THE
CUSTOMER SITE,THE UPS MUST BE CONNECTED TO THE AC MAINS AND
OPERATED WITH NO LOAD FOR A PERIOD OF FOUR HOURS,BEFORE
APPLYING A LOAD.
3.1. Important Installation Information
The Gamatronic UPS must be connected in a “4-wire + Ground” configuration (i.e., 3 phases +
Neutral + Ground). The voltage displayed on the status screen is the Phase-to-Neutral voltage.
The Neutral line MUST be connected to the UPS on the input and output stages of the UPS. The
UPS will support phase-to-phase loads and phase-to-Neutral loads. The Neutral line must always
remain connected when the UPS is operating. All input, output and dc cables must be armored
and the armored layer must be connected to the UPS ground connection terminals only.

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3.2. Installation Checklist
Complete the following checklist as you perform the following installation, initialization,
configuration, and testing procedures. Refer to the appropriate sections (specified in the
Reference column) for detailed information about each checklist item. The detailed explanation of
each section can be found in section 3.3 and Section 0.
When the checklist is complete, e-mail it to your vendor and to Gamatronic at
[e-mail].
INSTALLATION CHECKLIST FOR THE GAMATRONIC MODULAR UPS .
Customer
Address
Site
Phone
E-mail
Serial numbers: System _________________Static Switch ____________________
Modules 1___________ 2___________ 3___________
Technician Name
Date
Signature
√
Activity
Requirement
Reference
Visual Inspection
1. Verify the physical integrity of the
system
No physical damage
In case of physical damage, photograph the damage and describe it here:
_____________________________________________________________________________________

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Mechanical Test
2. One by one, place each power module in a shelf and push it all the way in. Verify that each
module makes a mechanincal connection with the power backplane on the inside rear of
the shelf.
3. Slide out each Power module by about 3 inches, enough to unplug them from the power
backplane, and attach the right and left ribbon cables between the modules and the base.
Fully slide the bottom module securly into the base.
√
Activity
Requirement
Reference
Site Preparation –Physical
4. Check ambient temperature.
Between:
+59 °F / +77 °F
(+15°C / +25 °C )
Min/max:
+14 °F / +104 °F
(–10 °C / +40 °C)
3.3.2
5. Check humidity and condensation.
No condensation/dampness.
3.3.2
6. Check ventilation.
Proper airflow to batteries.
3.3.2
7. Check foundation and access.
Adequate structure for weight
and access.
3.3.2
8. Check for adequate clearances (easy
access).
See Figure 8.
3.3.2
Comments on site preparation –physical: __________________________________________
_______________________________________________________________________________
Site Preparation –Electrical
9. Before wiring the system, verify that all possible voltage sources are disconnected, and the
following circuit breakers are in the “OFF” position: Rectifier ac input, bypass ac input, ac output
and all battery cabinets.

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10. Verify that wire sizes for ac input, bypass ac
input, ac output and battery cabinet(s) meet
local code for maximum current values.
Verify that all ac phase,
neutral, dc pole and
midpoint wire sizes and
circuit breakers meet local
code for maximum
current.
Note any discrepancies
here.
Figure 9 and
Figure 10,
andTable 2.
11. Verify that input and output circuit breakers
on the electrical panel meet local code for
maximum current values.
12. Verify that the ground/PE cables, are of
appropriate size.
Meet local code.
13. Measure dc voltage at battery cabinet switch,
in reference to midpoint, and verify polarity.
+200 V and –200 V (±8 %)
14. Connect ground, neutral, rectfier ac input,
bypass ac input, and ac output cables to the
UPS according to figure 9 or 10.
All cables are connected and
tightened to the correct torque
values.
3.3.3
15. Remove all battery trays from the system, only
then begin assembly. Assemble all battery
trays and only connect the batteries to the
battery cabinet once you have populated ALL
battery trays, verified proper voltage and
polarity on EVERY tray!
Assemble all battery trays on a
flat secure surface out of the
system.
Keep any unpopulated battery
trays out of the system.
3.3.4.5
16. Verify that the connection of the battery to
the UPS is according to the diagram and
instructions.
Batteries are connected
according to recommendations
and with proper fuse values.
17. FAST FUSES (SEMICONDUCTOR FUSES) must
be used between the battery and the UPS. For
example, the Ferraz Shawmut A70QS fuse.
18. Verify that there is a switch or other means to
easily and safely disconnect the battery
cabinet from the UPS in the event of an
emergency. An Emergency Power-Off switch
(EPO) can be configured to include a 48V trip
for the battery disconnection.
Connector P19 is used to
trigger the battery trip coil in
concert with an EPO switch.