Georator Triathlon III User manual

Triathlon IIITM UPS
T3UPS-33-700K
3Phase Input - 3 Phase Output
700 KVA
Instruction Manual
GEORATOR Corporation
9617 Center Street
Manassas, Virginia 20110
USA
800-523-9938, 703-368-2101, fax [phone]
WWW.Georator.com

Contents Page
1. SYSTEM OVERVIEW ..............................................................................1-1
1.1. Construction of the UPS ......................................................................1-1
1.2. Features and Advantages......................................................................1-5
1.3. Rectifier ...............................................................................................1-8
1.4. Inverter...............................................................................................1-10
1.5. Static Switch ......................................................................................1-11
1.6. Maintenance Bypass Switch ..............................................................1-12
1.7. Dimension & Drawings .....................................................................1-13
1.8. Front Panel.........................................................................................1-20
2. TECHNICAL SPECIFICATIONS.................................................................2-1
750KVA UPS
Uninterruptible Power Source
3–Phase Input / 3-Phase Output
Frequency Converter with Battery Backup
Optionally Available
3. INSTALLATION ...........................................................................................3-1
3.1. Site & Environment Considerations ....................................................3-1
3.2. Unpacking............................................................................................3-5
3.3. Cable Selection ....................................................................................3-6
3.4. Terminal Connection..........................................................................3-10
4. OPERATIONS ...............................................................................................4-1
4.1. Switch on Procedure ............................................................................4-1
4.2. Shutdown Procedure ............................................................................4-2
4.3. From Inverter to Bypass Procedure .....................................................4-3
4.4. From Bypass to Inverter Procedure .....................................................4-4

5. LCD DISPLAY..............................................................................................5-1
5.1. Menu 0 – Main Menu...........................................................................5-1
5.2. Menu 1 – Select Menu .........................................................................5-2
5.3. Menu 2 – Status / Warning Menu.........................................................5-3
5.4. Menu 3 – Real Time Data Menu..........................................................5-4
5.5. Menu 4 – Historical Event Menu.........................................................5-5
5.6. Menu 5 – Parameter Setting Menu ......................................................5-6
5.7. Menu 6 – Rectifier Data Menu ............................................................5-7
5.8. Menu 7 – Output Data Menu ...............................................................5-8
5.9. Menu 8 – Other Data Menu .................................................................5-8
5.10. Menu 9 – Reserve Data Menu..............................................................5-9
5.11. Menu 10 – Boost Charge Setting Menu...............................................5-9
5.12. Menu 11 – Date Time Setting Menu..................................................5-11
5.13. Menu 12 – Other Settings Menu........................................................5-13
6. INTERFACE CONNECTIONS.....................................................................6-1
6.1. Dry Contacts ........................................................................................6-1
6.2. External Shutdown...............................................................................6-3
6.3. DB9 Connection...................................................................................6-3
7. OPTIONS.......................................................................................................7-1
7.1. Battery Cabinet ....................................................................................7-1
7.2. Emergency Stop Switch.......................................................................7-2
7.3. Remote Control Panel – UPSCAN™...................................................7-2
7.4. Software for PC Monitoring – UPSCOM™.........................................7-2
7.5. Auto Dialing Module – UPSCALL™..................................................7-3
7.6. Battery Monitoring Module - DCMAN™............................................7-3
8. REDUNDANCY............................................................................................8-1
8.1. Serial Redundancy ...............................................................................8-1
9. HELP..............................................................................................................9-1

Appendicies - Additional Data on Options
UPSCOM
TM
UPSCALL
TM
DCMAN
TM
Appendices – Additional Data on Other Available Software ***
Rups 2000
UPSilon 2000
Net Agent II
*** These items are available from Mega System Technologies, Inc.

CAUTION !
☆Hazardous voltage exits inside the UPS (includes the connection
terminals). Cable connection and maintenance should be done by
professional or qualified personnel.
☆ The UPS has its own internal power source (batteries). The output
terminals may be live even when the UPS is not connected to the AC
supply.
☆ DC capacitors are employed in this unit. Hazardous voltage still
exists even when the unit is not energized. Do not touch any part of
the inside of the UPS.
WARNING !
☆ Be sure to operate the UPS within the rated power level.
☆Prevent direct exposure to direct sunlight, rain or contaminating
environment.
☆ Only qualified technicians should replace the batteries. Since
batteries have high short-circuit current capacity, mistakes in
connection or disconnection can cause severe burns or death to
servicing personnel.

1. SYSTEM OVERVIEW
1.1. Construction of the UPS
General Topology：
The UPS system is composed of input breakers, input filter & protection network,
rectifier, battery bank, inverter, static switch, bypass breaker, isolation transformer
and output filter. The basic topology is shown in the diagram above. Under normal AC
mode, energy from the AC source is converted to DC power and supplied to the
inverter to charge the batteries to its full capacity all the time, ready to support the
output load in case of AC source failure.
Although the principle and operation of a UPS seems simple and straightforward, the
requirement for a reliable and intelligent UPS makes the design and manufacturing of
a high power UPS one requiring advanced technology, intelligence, experience and
most important, consideration of the user interface. Many years have been spent in
designing the most rugged, intelligent and reliable UPS for the market, and a safe and
convenient UPS for the user.
Choosing the best and most suitable UPS for a given application can be easy or
difficult, depending on the client’s knowledge of key parameters. The most obvious
specification, output power, depends on the size of the load. Often, an allowance of
50% more power is added to the present load requirement, both for tolerance and for
future expansion.
1-1

Another important issue is reliability. The prime aim of a UPS is to protect your
load. Therefore, the UPS should be much more reliable than the AC source. An
unreliable UPS may suffer the problem of frequent break down, even more frequent
than AC failure, and the cost of repair may become more than the cost of the unit
itself.
Generally, there are four different modes of operation, the NORMAL OPERATION
MODE, the BACK-UP (BATTERY) MODE, the RESERVE MODE and the
MAINTENANCE BYPASS MODE. These are explained below.
Normal Operation Mode:
The rectifier converts the AC input to DC power to supply the inverter and charge the
batteries simultaneously. All the fluctuations, surges and spikes of the AC input are
removed during AC to DC conversion. Therefore the AC supplied by the inverter is
clean and stable.
1-2

Back-up Mode:
Since the batteries are connected directly to the DC bus, when the AC fails, the
batteries change immediately from receiver to donor, supplying energy to the inverter
instead of receiving energy from the rectifier. The output AC is not interrupted.
Therefore, the load connected to the output is protected.
Reserve Mode:
When the inverter is in an abnormal condition, such as over temperature, short circuit,
abnormal output voltage or overloaded for a period exceeding the inverter’s limit, the
inverter will automatically shut down in order to protect itself from damage. If the
utility power is normal, the static switch shall transfer the load to the reserve source
without interruption of AC output.
1-3

Maintenance Bypass Mode:
In case of UPS maintenance or battery replacement, and where the load cannot be
interrupted, the user can turn off the inverter, close the bypass breaker and then open
the rectifier and reserve breakers. The AC output will not be interrupted during
manual bypass transfer procedure. Therefore, the maintenance bypass switch keeps
continuously supplying power to the load. Electricity will not exist in UPS except the
output transformer, thus ensuring the safety of service personnel.
Generally, the UPS is expected to run 24 Hours a day in normal operation mode once
it is installed, except when the utility power fails, under overload conditions, or
during maintenance.
Normal operation with batteries connected provides clean, stable, regulated and
uninterrupted power to the load, free from any spikes and surges. Therefore, the UPS
can be regarded as a perfect AC power source, limited in back-up time, under mains
failure, only by the capacity of the batteries.
1-4

1.2. Features and Advantages
(a) Reliable input protection: Circuit breakers are placed in each individual input
loop to ensure power can continue through another loop in case of breaker trip
caused by an abnormal condition in either rectifier or load.
(b) Input surge protection: An MOV (surge protector) is added at the input,
providing protection to both UPS and the load from any lightning surges, or surges
caused by neighboring large loads.
(c) EMI suppression: An EMI filter is added to meet the international EMC limits.
Therefore, very low noise is emitted, and no interference is supplied to other
equipment connected to the same AC source.
(d) Ruggedness: The rectifier employs phase control technology to regulate the DC
bus voltage. This is the most efficient method to charge the batteries. The SCR
used are inherently rugged. Additionally, a large inductor is added at the input to
avoid deforming the AC source waveform.
(e) High frequency design: The inverter uses high frequency, high efficiency IGBT,
PWM methodology to convert the DC power to AC power. Therefore, the number
of components is fewer, reliability is improved, and the size and weight of UPS is
reduced, performance is improved, and acoustic noise is minimized.
(f) True Galvanic isolation: An isolation transformer is placed at the output.
This can solve the problem of poor input grounding, can allow a different ground
between input and output, can avoid the annoying problem of ground leakage
current, and can be tied to any potential provided on site. The AC output is
isolated under every mode of operation. Additionally, the user gets the bonus of
attenuation of common mode noise from the output isolation transformer.
1-5

(g) Plug & Play Modular design: The power circuit is separated into several
modules plugged into slots in the UPS, which are easy to pull out, permitting
quick maintenance and easier trouble shooting.
(h) Cold start function: the UPS can be started without an AC source, that is, can
be started with battery power only. This is possible because current limit
circuitry is added, preventing the problem of large inrush current blowing the
battery fuse and damaging the DC capacitors when batteries are connected to an
empty DC bus (before the DC bus is energized).
(i) Multi-CPU design: Several CPUs are employed in the control circuit, and
critical functions are designed with parallel redundancy to improve reliability.
Therefore, in case of one CPU failure, the other CPUs keep the UPS operational,
and the output AC is not affected.
(j) Protection against misuse: The UPS is designed with breaker on/off sensor,
power supply sensor, etc. Therefore, any operational mistake made by the user
causes no harm to the UPS.
(k) Accepts wide input range: The UPS is designed to accept a wide input range,
so that it can work effectively under an unstable AC source. All of the input
components used are specifically selected to handle extreme high voltage and high
current.
(l) Operating environment: Each component of the UPS is chosen with large
safety margin to accommodate extreme environments, such as temperature,
humidity, altitude, shock or contamination.
(m) Intelligent charger: The UPS will automatically recharge (boost charge) the
batteries every time the batteries are depleted to a voltage level equal to 2V/Cell.
Thus, the batteries can be restored to full capacity as soon as possible, and made
ready for the next back-up requirement. In order to keep the batteries in the best
condition, the UPS will boost charge the batteries for several hours (selectable)
automatically every month. To avoid over charging the batteries, boost charge will
stop when the ambient temperature is over 35oC (95oF)
1-6

(n) Intelligent battery test: The batteries are tested after every boost (initiated by
battery discharge or by the monthly boost charge cycle). This is done without
interrupting the operation of the rectifier, preventing the risk of output AC failure
in case of a bad battery. The user is informed of the battery condition, so that
action can be taken before the full capacity of the batteries is needed.
(o) Huge charging power: The charging power is selectable (Lo/Me/Hi) according
to Ah rating of the batteries, and can charge up battery banks providing more than
8Hrs back-up time without adding an extra charger.
(p) MTBF of fans are extended: Fans used to cool the UPS, are designed to slow
down under light load, so that the life expectancy of the fans is extended beyond
the normal.
(q) Redundant power supply: Asupplemental power supply is added to provide
redundancy for supplying power to the static switch, so that there will be AC
output no matter what happens to the UPS.
(r) Intelligent interface: One remote control panel (or one PC) can be used to
monitor up to 99 UPS. The remote control can be used to switch, on or off, any
or all of the UPS systems. When any UPS encounters an emergency condition, the
system will warn the user immediately. All the UPS status, data or commands are
transmitted to external modules through 4 RS-485 ports (for long distance
communication under harsh environment).
(s) Emergency stop is available: In case of hazard, for example electric shock, fire
or earthquake, the UPS can be shutdown (will have no AC at the output) either
through a switch (can be added upon request) or through smoke detector signal
(can be added upon request) to prevent further injuries or destruction.
1-7

1.3. Rectifier
The main function of a rectifier is to convert the AC input to DC power, and supply it
to the inverter. The inverter then converts the DC power to AC power for the load.
The UPS use the DC power to charge the batteries as well, which is the most efficient
method of charging.
RECTIFIER
AC
SCR
DC
BREAKER INDUCTOR
INPUT OUTPUT
CAPACITOR
6-PULSE FULL CONTROL RECTIFIER
UPSs in the sizes 10KVA to 80KVA use 6-pulse fully controlled rectification. An
inductor is added before the rectifier to improve the power factor, smooth the current
waveform and eliminate the harmonic current. The control circuit regulates the DC bus
within 1%. Soft walk-in circuitry (approximately 20sec.) and current limit circuitry is
used to prevent over current or instantaneous surge current.
Extra under-voltage and over-voltage protections are added to improve reliability and
to shutdown the rectifier in case of abnormal conditions. The DC bus is adjustable to fit
different types of batteries. The power component used in the rectifier is specially
selected to handle extreme high voltage and high current. The rectifier is designed to
operate under a wide range of AC input, from 177 to 300VAC, to operate under the
poor power conditions found in some areas.
1-8

PHASE SHIFT
AC
DC
INPUT
RECTIFIER
BREAKER INDUCTOR
CAPACITOR
SCR OUTPUT
SCR
TRANSFORMER
12-PULS E FULL CONTROL RECTIFIER
In order to further improve the power factor and reduce harmonic current drawn by the
rectifier, UPS at 100KVA and above, use the 12-pulse full controlled rectifier. The total
current harmonic current can be reduced to around 15%, and power factor improved to
over 0.8. A phase shift transformer is added to achieve this performance. The input
inductor is retained also to obtain the best result. Although this results in higher cost,
the unit is much more reliable and rugged. Users do not need to increase the input
breaker and cable sizes, since input KVA and harmonic current drawn is minimized,
fulfilling the worldwide energy saving requirements.
The harmonic current can be further lowered by adding harmonic filters (factory
installation available). The total harmonic current can be reduced to approximately 9%.
Another alternative method to reduce the harmonic current (especially for very large
KVA UPS) is to employ 18-pulse full controlled rectifier (available as an option). The
total harmonic current can be reduced to approximately 7%.
1-9

1.4. Inverter
DC-
AC
AC
DC+
IGBT INVERTER
The inverter is composed of IGBT, inductor, capacitor, snubber, control circuitry and
protection circuitry. The inverter converts the DC power from the DC bus to AC power
to supply the output load. The UPS uses IGBT technology which switches at
frequencies beyond the audible range, therefore producing no audible noise.
The UPS uses voltage regulation circuitry to limit the voltage variation within 1%.
Special compensation circuitry is added to eliminate the output distortion. Every
component is oversized to accept the wide DC input range (from 285 to 420VDC), so
that the output waveform remains sinusoidal throughout the range. With the aid of
dynamic feedback loop the inverter will keep a sine waveform even under non-linear
load.
An independent inverter is used for each phase. Although it is more expensive, each
inverter has its independent feedback, so that the voltage is unaffected when load is
added to the adjacent phase, producing excellent voltage regulation under 100%
unbalanced load.
The IGBT is operated in its optimal condition to obtain best efficiency, so as to
minimize the power cost of the user.
1-10

Usually, the most frequent failures of the UPS occur at the inverter. Therefore, we
have added redundant protection circuitry to protect the inverter. A strong snubber is
added to suppress the spikes and noise, oversized, high quality components are used
throughout, semi-conductor fuses are provided, and ventilation is maximized. The
result of this design is a more rugged, reliable and high efficient inverter. At the same
time, the inverter can sustain overload and high peak current drawn by the load.
Additionally, a longer MTBF is achieved.
1.5. Static Switch
TO
TO
FILTER
LOAD
RESERVE
FILTER
LOAD
INVERTER
RESERVE
INVERTER
RESERVE MODE INVERTER MODE
The static switch is composed of two pairs of SCRs, connected back-to-back. The
switch can transfer the load from reserve to inverter or from inverter to reserve without
losing power at the output. Therefore, it is a very important portion of a UPS.
Detection circuitry is added to the control circuit to achieve zero dead time transfer.
Extra detection logic is employed to control when the static switch should transfer. For
example, when output is short circuited, under normal mode operation, the UPS detects
the short circuit and stops the inverter. The static switch will not transfer power to the
reserve circuit, which might damage the reserve breaker. In case of an overload, the
UPS will stop the inverter after a period the inverter can endure, and then transfer the
load to the reserve circuit, since the overload capability of the static switch is higher
than the inverter.
1-11

The transfer action is determined according to the reserve-input voltage and frequency
to protect supplying incorrect power to the load. Finally, there is a double check by the
CPU as to whether the transfer is successful or not.
1.6. Maintenance Bypass Switch
Unlike other UPS, the maintenance bypass switch is already installed inside the UPS
for convenience. It should be open under normal operation, and only closed during
maintenance. For the sake of safety of maintenance personnel, all power supplies
inside the UPS should be disconnected before touching any parts inside the UPS.
Thus, the maintenance bypass switch is a necessity to maintain AC power at the output
and yet keep maintenance personnel safe at the same time. If the bypass breaker is
closed under normal operation, the inverter will stop and the load will be automatically
transferred to reserve to prevent the inverter connecting directly to the AC source. Of
course, you cannot switch on the inverter as long as the maintenance bypass breaker is
closed.
To properly use the maintenance bypass breaker, switch off the inverter first. The
static switch will automatically transfer the load to reserve without dead time. Then
one can close the maintenance bypass breaker, then open the reserve breaker, so that
the load gets power from the output without interruption.
1-12

1.7. Dimension & Drawings
10KVA - 60KVA
OUTLINE DRAWING
1-13

10KVA - 60KVA
INTERIOR DRAWING
1-14

75KVA - 160KVA
OUTLINE DRAWING
1-15