Gamatronic MEGA V2 SA25 User manual

GAMATRONIC ELECTRONIC INDUSTRIES LTD.
17 Hartom St., PO Box 45029, Jerusalem 91450, Israel
Tel: [phone] Fax: [phone]
Email: [email protected] Website: www.gamatronic.com
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User Guide
Release 1.5, February 2014

User Guide: MEGA V2 SA25, Release 1.5
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Gamatronic Electronic Industries Ltd.
Har Hotzvim Industrial Park
17 Hartom St., PO Box 45029, Jerusalem 91450 Israel
Tel: [phone] Fax: [phone]
Email: [email protected] Website: www.gamatronic.com
The equipment described in this document is not intended to be used in connection with any
application requiring fail-safe performance, unless the application design includes appropriate
redundancy. This exclusion includes, but is not limited to, the direct operation of any life support
system or any other system whose failure could lead to serious injury, death, environmental damage or
mass destruction.
Copyright 2014 by Gamatronic Electronic Industries Ltd. All rights reserved worldwide.
Any representations in this document concerning the performance of Gamatronic's product(s) are for informational purposes only and are
not warranties of future performance, either express or implied. Gamatronic's standard limited Warranty, which accompanies its sales
contract or order confirmation form, is the only warranty offered by Gamatronic Electronic Industries Ltd. in relation thereto.
Gamatronic Electronic Industries Ltd. ("Gamatronic") warrants the products it manufactures to be free from defect for a period of one
calendar year from the date of invoice, including the date of invoice. Gamatronic's liability is limited to repairing or replacing any defective
parts in the equipment under warranty. Gamatronic reserves the right to determine whether the repair work shall be performed at
Gamatronic's factory, at the customer's premises, or at an alternate site. The customer must obtain authorization from Gamatronic before
returning any parts or equipment to Gamatronic for repair or replacement. Any items returned to Gamatronic must be sent freight prepaid.
Gamatronic’s liability and warranty to the product are according and subject to the fulfillment and implementation by the customer of all the
terms and instructions in connection with “preventive maintenance” and “service and repair” as further detailed in the user guide which is
attached to the product and forms an integral part of it.”
Gamatronic is not responsible for any damage to the product due to unauthorized repair work, misuse or abuse of the product, or force
majeure. If the product is delivered without batteries, Gamatronic is not responsible for any damage or malfunction due to incorrect wiring
of the batteries.
Gamatronic is not liable for and the Purchaser waives any right of action it has or may have against Gamatronic for any consequential or
special damages arising out of any breach of warranty, and for any damages that the Purchaser may claim for damage to any property or
injury or death to any person arising out of its purchase or the use, operation or maintenance of the subject product.
This warranty includes parts and labor; however, Gamatronic shall not be responsible for any labor subcontracted or performed by the
Purchaser to prepare the warranted item for return to Gamatronic or Gamatronic's agent.
The information contained in this document is proprietary and is subject to all relevant copyright, patent and other laws protecting
intellectual property, as well as any specific agreement protecting Gamatronic's rights in the aforesaid information. Neither this document
nor the information contained herein may be published, reproduced or disclosed to third parties, in whole or in part, without the express,
prior, written permission of Gamatronic. In addition, any use of this document or the information contained herein for any purposes other
than those for which it was disclosed is strictly forbidden.
Gamatronic reserves the right, without prior notice or liability, to make changes in equipment design or specifications.
Information supplied by Gamatronic is believed to be accurate and reliable. However, no responsibility is assumed by Gamatronic for the
use thereof nor for the rights of third parties which may be affected in any way by the use thereof.
This document may contain flaws, omissions or typesetting errors; no warranty is granted nor liability assumed in relation thereto unless
specifically undertaken in Gamatronic Electronic Industries Ltd. standard limited Warranty. Information contained herein is periodically
updated and changes will be incorporated into subsequent editions. If you have encountered an error, please notify Gamatronic Electronic
Industries Ltd. All specifications are subject to change without prior notice.

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TABLE OF CONTENTS
CONVENTIONS USED IN THIS BOOK.................................................................................................VI
SAFETY CONSIDERATIONS............................................................................................................VII
DO’SVII
DON’TS.............................................................................................................................VII
1. INTRODUCTION ....................................................................................................................1
1.1 MAJOR PARTS OF THE MEGA V2 SA25........................................................................3
Control Panel................................................................................................................3
Rectifier ........................................................................................................................3
Inverter.........................................................................................................................3
Static Switch (ST/SW)..................................................................................................3
Battery..........................................................................................................................3
2. OPERATING MODES .............................................................................................................4
2.1 NORMAL MODE...........................................................................................................4
2.2 BATTERY MODE..........................................................................................................5
2.3 BYPASS MODE............................................................................................................6
3. USER INTERFACE.................................................................................................................7
3.1 CONTROL PANEL ........................................................................................................7
3.1.1 On/Off button....................................................................................................8
3.1.2 Navigation keys................................................................................................8
3.1.3 Indicators..........................................................................................................8
3.2 THE POWER+ DISPLAY SCREEN ................................................................................9
3.2.1 The main screen...............................................................................................9
3.2.2 Status screens................................................................................................17
4. DAILY OPERATION .............................................................................................................23
4.1 POWER +SA25 START-UP........................................................................................23
4.2 POWER +SA25 SHUTDOWN .....................................................................................24
5. THE EVENT LOG.................................................................................................................25
5.1 ALARMS...................................................................................................................25
5.2 NAVIGATING TO THE EVENT LOG................................................................................25
5.2.1 Active alarm display .......................................................................................25
5.2.2 Event log entries.............................................................................................25
5.2.3 Resetting the event log ..................................................................................26
6. BATTERY TESTS ................................................................................................................30
6.1 AUTOMATIC BATTERY TEST.......................................................................................30
6.2 MANUAL BATTERY TEST ............................................................................................30
7. FIRST-TIME SETUP .............................................................................................................31
7.1 CABLE CONNECTIONS...............................................................................................31
7.2 START-UP SEQUENCE...............................................................................................38
7.2.1 To start the UPS:............................................................................................38
7.2.2 Verify proper number of input and output phases..........................................38
7.2.3 Verify proper output voltage...........................................................................39
7.2.4 Set the system clock ......................................................................................39
7.2.5 Modify the screen contrast (optional step).....................................................39
7.2.6 Set automatic restart mode (optional step)....................................................39
7.2.7 Operation........................................................................................................40
8. SETTING SYSTEM PARAMETERS..........................................................................................41
8.1 SETTING THE SYSTEM CLOCK....................................................................................41
8.2 SETTING SCREEN CONTRAST.....................................................................................42
8.3 CHANGING THE NOMINAL OUTPUT VOLTAGE ...............................................................42
8.4 FINE-TUNE THE OUTPUT VOLTAGE .............................................................................43
9. AUTOMATIC RESTART........................................................................................................45
9.1 DETERMINING THE CURRENT AUTOMATIC RESTART SETTING .......................................45
9.2 CHANGING THE AUTOMATIC RESTART STATUS............................................................45
10. MISCELLANEOUS FUNCTIONS.............................................................................................47
10.1 MANUALLY ENTERING OR LEAVING BYPASS MODE.......................................................47
10.1.1 Entering bypass mode manually..................................................................47

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11. IN THE EVENT OF AN AC POWER OUTAGE.............................................................................49
12. TROUBLESHOOTING...........................................................................................................52
12.1 ALARM SOUNDS AND/OR ALARM LED LIGHTS UP........................................................52
12.2 ELECTRICITY RETURNED BUT UPS REMAINS IN BATTERY MODE..................................52
12.3 BATTERY TEST FAILED..............................................................................................52
12.4 THE UPS REMAINS IN BYPASS MODE .........................................................................52
12.5 SYNC FAULT ............................................................................................................52
13. ALARM DRY CONTACTS.....................................................................................................53
14. RS232 INTERFACE............................................................................................................55
15. SNMP AGENT (OPTIONAL) .................................................................................................56
16. WIRELESS CONTROL (OPTIONAL).......................................................................................57
17. PREVENTIVE MAINTENANCE...............................................................................................58
18. SERVICE AND REPAIRS ......................................................................................................59
19. MEGA V2 SA25 SPECIFICATIONS ......................................................................................60
LIST OF FIGURES
FIGURE 1: THE MEGA V2 SA25.....................................................................................................2
FIGURE 2: BLOCK DIAGRAM OF THE MEGA V2 SA25.......................................................................2
FIGURE 3: NORMAL MODE DISPLAY ................................................................................................4
FIGURE 4: BATTERY MODE DISPLAY................................................................................................5
FIGURE 5: BYPASS MODE DISPLAY (MANUAL)..................................................................................6
FIGURE 6: THE MEGA V2 SA25 CONTROL PANEL............................................................................7
FIGURE 7: THE MAIN SCREEN.........................................................................................................9
FIGURE 8: MAIN SCREEN,NORMAL MODE......................................................................................10
FIGURE 9: MAIN SCREEN WITH ALARM INDICATION.........................................................................10
FIGURE 10: MAIN SCREEN,NORMAL MODE WITH OVERLOAD INDICATION.........................................11
FIGURE 11: MAIN SCREEN,BYPASS MODE WITH OVERLOAD INDICATION..........................................11
FIGURE 12: THE MAIN SCREEN,IN BATTERY MODE ........................................................................12
FIGURE 13: MAIN SCREEN,BATTERY LOW.....................................................................................13
FIGURE 14: MAIN SCREEN,UPS OFF AT END OF BACKUP.............................................................13
FIGURE 15: MAIN SCREEN,UPS ON AT END OF BACKUP...............................................................14
FIGURE 16: BYPASS MODE (MANUAL)...........................................................................................15
FIGURE 17: UPS OFF, NO OUTPUT..............................................................................................16
FIGURE 18: UPS ON, END OF BACKUP.........................................................................................16
FIGURE 19: MEGA V2 SA25 MAIN MENU ......................................................................................22
FIGURE 20: UPS OFF, NO OUTPUT..............................................................................................23
FIGURE 21: UPS ON, NORMAL MODE...........................................................................................23
FIGURE 22: UPS ON, NORMAL MODE...........................................................................................24
FIGURE 23: UPS OFF, NO OUTPUT..............................................................................................24
FIGURE 24: ACTIVE ALARMS ........................................................................................................25
FIGURE 25: NO ACTIVE ALARMS...................................................................................................25
FIGURE 26: TYPICAL LOG ENTRY..................................................................................................26
FIGURE 27: NEXT AUTOMATIC BATTERY TEST ...............................................................................30
FIGURE 28: BATTERY TEST IN PROGRESS.....................................................................................30
FIGURE 29: CONNECTION DIAGRAM,NO INPUT ISOLATION TRANSFORMER ......................................32
FIGURE 30: CONNECTION DIAGRAM,WITH INPUT ISOLATION TRANSFORMER ...................................33
FIGURE 31: RECOMMENDED SWITCH OR CB RATINGS FOR THE MEGA SA 25 KVA..........................34
FIGURE 32: REMOVE THE UPS'S "FEET".......................................................................................34
FIGURE 33: REMOVE THE 4SCREWS ON RIGHT SIDE,2SCREWS ON LEFT SIDE ...............................35
FIGURE 34: REAR VIEW OF THE UPS SHOWING CABLE ENTRY HOLES AT UPS REAR .......................36

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FIGURE 35: THE UPS TERMINAL CONNECTIONS............................................................................37
FIGURE 36: THE UPS TERMINAL CONNECTIONS (CLOSE-UP).........................................................37
FIGURE 37: VERIFY PROPER LINE CONFIGURATION........................................................................38
FIGURE 38: VERIFY PROPER OUTPUT VOLTAGE.............................................................................39
FIGURE 39: RS232 CONNECTOR.................................................................................................55
FIGURE 40: FLOWCHART OF THE MEGA V2 SA25 OPERATION SCREENS.......................................61
LIST OF TABLES
TABLE 1: BATTERY LIFETIME VS ENVIRONMENTAL TEMPERATURE.....................................................3
TABLE 2: MAIN MENU OPTIONS.....................................................................................................22
TABLE 3: OUTSTANDING ALARM MESSAGES ..................................................................................27
TABLE 4: LOG MESSAGES ............................................................................................................29
TABLE 5: RECOMMENDED CABLE DIAMETERS................................................................................31

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CONVENTIONS USED IN THIS BOOK
•This manual contains diagrams which include images of the UPS and of its LCD display
screen. Unless otherwise indicated, these images are representational only, and are not
intended to match the exact appearance of a particular unit nor the readings on the screen of
a specific unit in a particular environment.
•Abbreviations and notational conventions are in most instances as per the IEEE Standards
Style Manual.

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SAFETY CONSIDERATIONS
The MEGA V2 SA25 UPS system is designed for industrial applications and harsh
environments. Nevertheless the Mega V2 SA25 UPS system is a sophisticated power system
and should be handled with appropriate care, following these guidelines.
Do’s
•Read this manual carefully before starting installation and operation of the UPS.
•Review the safety precautions described below to avoid injury to users or damaging
equipment.
•All power connections must be completed by a licensed electrician who is experienced in
wiring this type of equipment, and who is knowledgeable about all federal, state, and local
electrical codes and regulations. Improper wiring may cause damage to the equipment or
injury to personnel.
•Pay attention to the warning signs, labels and marks on the unit. A warning sign signals the
presence of a possibly serious, life-threatening condition.
•Keep the surroundings clean, uncluttered and free from excess moisture.
•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 battery drawer contains a series of 12-Volt batteries that provide high voltage
and energy in the UPS body even when the UPS is not connected to the ac input.
Appropriate precautions should be taken during installation, inspection and
servicing.
WARNING - RISK OF LETHAL ELECTRIC SHOCK:
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 during transportation.
•Do not connect or disconnect the cable to the battery cabinet before the battery circuit breaker
is turned OFF.
•Do not turn ON the battery circuit breaker when the battery cabinet is disconnected from the
UPS.
•Do not install next to any gas or electrical heaters. A restricted location is recommended in
order to prevent access by unauthorized personnel.

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WARNING: RISK OF
SEVERE DAMAGE TO THE UPS!!!
FAILURE TO USE A NEUTRAL CONDUCTOR MAY
CAUSE PERMANENT DAMAGE TO THE SYSTEM
.
THIS SYSTEM USES THE NEUTRAL LINE FOR
OPERATION.THEREFORE,IT IS STRICTLY
FORBIDDEN TO CONNECT THIS SYSTEM TO
THE AC POWER SOURCE WITHOUT A NEUTRAL
(NULL)CONDUCTOR!!

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1. INTRODUCTION
In general, an Uninterruptible Power Supply (UPS) provides backup power for use when the
utility ac electric power mains fail or drop to an unacceptable voltage level. Mega V2 SA25
answers this critical need, and more.
Mega V2 SA25 is designed to protect your data and equipment and minimize downtime and
other adverse effects normally incurred by power irregularities and failures.
Mega V2 SA25 continually eliminates surges, spikes and sags that are inherent in commercial
utility power. Over time, these irregularities shorten the life of equipment and components. The
efficiency of Mega V2 SA25 thus helps to extend the life of your equipment, even during normal
use when the input power is constant and continuous.
Mega V2 SA25
•is a true on-line battery design according to IEC 62040-31
•is a "green" (environmentally friendly) power solution thanks to THD of 5% at the input, and
provides “clean” power to your loads.
.
•has an overall efficiency of up to 96% and backup efficiency of 98%.
•provides high power density.
Mega V2 SA25 requires little attention or intervention during normal operation; however, you
should read and understand the procedures described in this manual to ensure trouble-free
operation.
1IEC 62040-3 is a technical standard for UPSs, authored by the International Electrotechnical Commission (IEC). The
IEC is the leading global organization that prepares and publishes international standards for all electrical, electronic
and related technologies. These serve as a basis for national standardization and as references when drafting
international tenders and contracts.

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Figure 1: The Mega V2 SA25
Figure 2: Block diagram of the Mega V2 SA25

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1.1 Major parts of the Mega V2 SA25
The Mega V2 SA25 includes the following sub-assemblies:
CONTROL PANEL
The Mega V2 SA25 control panel allows the user to:
•manage and control the Mega V2 SA25
•monitor the parameters of all sections of the Mega V2 SA25
RECTIFIER
The UPS includes a 3-phase rectifier with Power Factor Correction (PFC)2
INVERTER
. The rectifier converts
the ac input voltage to dc voltage, which feeds the inverter and also charges the UPS's battery.
The inverter receives dc current from the rectifier or from the batteries, and converts it to ac
current, which feeds the load devices. The 3-phase PWM inverter is connected to batteries by a
classic dc link.
STATIC SWITCH (ST/SW)
The static switch enables an automatic transfer of the load from the output of the inverters to an
alternate source whenever the inverter can no longer supply power to the load. The static switch
transfers current at high speed.
BATTERY
The Mega V2 SA25 battery bank is used as a backup in the event that the utility ac input fails.
The batteries are housed in an external cabinet next to the Mega V2 SA25 cabinet. Batteries are
charged by the rectifier, which supplies both the inverter and the battery charger.
The battery cabinet should be installed as close to the UPS as is practically possible.
Protect the batteries from moisture, dampness, and foreign substances.
The temperature of the battery's surroundings influences the batteries' useful lifetime.
Table 1: Battery lifetime vs environmental temperature
ENVIRONMENTAL
TEMPERATURE ACHIEVABLE PERCENTAGE OF BATTERY'S RATED LIFETIME
20 °C 100 %
30 °C 50 %
40 °C 20 %
2In power factor correction, the power factor (represented as "k") is the ratio of true power (kwatts) divided
by reactive power (kvar). The power factor value is between 0.0 and 1.00. The greater the power factor, the
more efficient the device. A standard power supply has a power factor of 0.70-0.75, and a power supply
with PFC has a power factor of 0.95-0.99.

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2. OPERATING MODES
The Mega V2 SA25 is installed between the power mains and your load devices, and supplies
ac electrical power to your equipment. The Mega V2 SA25 has three automatic modes of
operation:
•Normal mode
•Battery mode
•Bypass mode
2.1 Normal mode
Mega V2 SA25 almost always operates in normal mode. In normal mode the load receives its
power from the inverters that supply stabilized voltage, protected from spikes and irregularities in
the ac input. The ac input system feeds the charger which supplies dc power to the inverter,
while concurrently charging the batteries.
Figure 3: Normal mode display

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2.2 Battery mode
If the input ac power fails or the voltage drops below an acceptable level, the UPS operates in
backup mode. In backup mode the load continues to receive power from the inverters, but the dc
input to the inverter is taken from the batteries, instead of from the rectifier.
The batteries are galvanically connected by dc link to the inverter and the charger. The dc
inherently remains constant when the ac input supply drops out, without any switching devices.
The duration of the battery operation is determined by the load demand and battery capacity.
Figure 4: Battery mode display

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2.3 Bypass mode
In bypass mode the load receives power directly from the ac input via the static switch.
Whenever the inverters cannot provide power to the load, for example, due to an overload or a
short-circuit in the load, the UPS supplies the load directly from the ac input, bypassing the
inverter. As soon as the problem is corrected, the load is transferred back to the inverter
automatically.
Figure 5: Bypass mode display (manual)

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3. USER INTERFACE
This section describes the buttons and indicators used to operate the Mega V2 SA25.
3.1 Control panel
The Mega V2 SA25 Control Panel includes an LCD display, control buttons, and LED indicators.
The control panel has three principle functions:
•Shows the current operating mode
•Lets you display other current readings
•Lets you modify UPS settings and operating mode
The control panel is for use by the end-user and the service technician.
Figure 6: The Mega V2 SA25 control panel

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3.1.1 On/Off button
To turn the UPS on, press the button twice.
To turn the UPS off, press the button twice.
3.1.2 50BNavigation keys
The control panel has four navigation keys, for navigating through the control software's menus
and options.
•The UP and DOWN buttons are used to navigate through screens and
browse the Event Log.
•The Ent (Enter) key is used to select an item or apply a change.
•The Esc (Escape) key returns you to the main screen.
During an active alarm condition, pressing the Esc button from the
main screen silences the audible alarm.
3.1.3 51BIndicators
The top of the control panel contains four LCD indicators. The status indicators show what is
running and how the UPS is providing power to the load.
The table shows the color and meaning of the LCD status indicators when lit.
AC INPUT Green – ac input is present and within normal range.
NORMAL Green – The UPS is in normal mode.
BATTERY Yellow – The UPS is in Battery mode
BYPASS Yellow – The UPS is in bypass mode
ALARM Red – Indicates an alarm condition.
To determine the nature of the alarm:
From the main screen press Ent to display the main menu,
press Ent again to see the Alarm Status,
press Ent once more to see the Event Log.

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3.2 The POWER+ display screen
The display screen on the Mega V2 SA25 control panel shows the current operating mode and
related critical data. There are several distinct data screens that can be shown on the Mega V2
SA25 display screen.
3.2.1 The main screen
The Mega V2 SA25 main screen is the default display on the Mega V2 SA25 screen. From any
other screen, if the keyboard is not used for 45 seconds, the Mega V2 SA25 returns to the main
screen.
The main screen shows the UPS’s current operating mode and other critical data.
Other screens describing current operating conditions can be seen by navigating “upwards” or
“downward” with the UP/DOWN key.
The first line of the main screen shows whether the UPS is currently on or off. The second line
tells you the most important information about the UPS’s current status. Most of the time it will
read “NORMAL MODE”. The UPS can also automatically transfer to:
•BATTERY MODE
•BYPASS MODE
•UPS OFF
The L1, L2, and L3 numbers in the main screen show the current load rate as a percent of
maximal ac load at each phase.
Figure 7: The main screen

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3.2.1.1 Normal mode
In Normal mode, the main screen displays the message:
UPS ON, NORMAL MODE. The AC INPUT and NORMAL LEDs are lit.
The following picture shows the main screen as you will see it most of the time, in Normal Mode.
Figure 8: Main screen, normal mode
In the event of a battery test failure, an icon indicating this appears in the lower right quadrant of
the screen, the alarm LED lights, and the audible alarm sounds.
Figure 9: Main screen with alarm indication

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In the event of an overload condition, an icon indicating this appears in the lower right quadrant
of the main screen, the alarm LED ligits, and the audible alarm sounds.
Figure 10: Main screen, normal mode with overload indication
If the overload is severe or continues for more than a few seconds, the UPS will transfer the load
to the bypass power source.
Figure 11: Main screen, bypass mode with overload indication

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3.2.1.2 Battery mode
When the UPS is operating in battery mode, the main screen first displays the message: UPS
ON, BATTERY MODE.
Figure 12: The main screen, in battery mode
As the battery discharges, the number of “stripes” on the battery icon decreases.