KStar HPM3340 200k User manual

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All rights reserved.
The information in this document is subject to change without notice.
Publish statement
Thank you for purchasing this series UPS.
This series UPS is an intelligent, three phase in Three phase out, high frequency online
UPS designed by our R&D team who is with years of designing experiences on UPS.
With excellent electrical performance, perfect intelligent monitoring and network
functions, smart appearance, complying with EMC and safety standards, The UPS
meets the world’s advanced level.
Read this manual carefully before installation
This manual provides technical support to the operator of the quipment.

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Contents
1
．
Safety.......................................................................................................................................2
1.1 Safety notes ....................................................................................................................................... 2
1.2 Symbols used in this guide............................................................................................................ 2
2
．
Main Features........................................................................................................................3
2.1 Summarization................................................................................................................................... 3
2.2 Functions and Features.................................................................................................................. 3
3
．
Installation..............................................................................................................................4
3.1 Unpack checking .............................................................................................................................. 4
3.2 The appearance of the product..................................................................................................... 4
3.3 UPS module appearance ................................................................................................................ 9
3.4 UPS Module LCD control panel................................................................................................... 10
3.5 Installation notes ............................................................................................................................ 10
3.6 External Protective Devices...........................................................................................................11
3.7 Power Cables................................................................................................................................... 12
3.8 Power cable connect...................................................................................................................... 12
3.9 Battery connection......................................................................................................................... 14
3.10 Online UPS Modules Replacement.......................................................................................... 16
3.11 UPS Multi
－
Module Installation................................................................................................. 16
3.11.1 Cabinet installation........................................................................................................... 17
3.11.2 Parallel cable installation ................................................................................................ 17
4
．
Operation..............................................................................................................................18
4.1 Operation Modes............................................................................................................................. 18
4.2 Turn on/off UPS............................................................................................................................... 18
4.2.1 Restart procedure................................................................................................................ 18
4.2.2 Test procedure ..................................................................................................................... 19
4.2.3 Black(Cold) start procedure.............................................................................................. 19
4.2.4 MAINTENANCE BYPASS ................................................................................................... 20
4.2.5 Shut down procedure......................................................................................................... 21
4.2.6 Startup procedure for parallel system ........................................................................ 21
4.3 The Display....................................................................................................................................... 22
4.3.1 System LCD dispay............................................................................................................. 22
4.3.2 UPS Module LCD display................................................................................................ 28
4.4 Display Messages/Troubleshooting........................................................................................... 34
4.5 Options.............................................................................................................................................. 39
Appendix 1 Specifications.....................................................................................................42
Appendix 2 UPS message table ...........................................................................................44
Appendix 3 Problems and Solution.....................................................................................48
Appendix 4 RS232 communication port definition .........................................................50
Appendix 5 USB communication port definition..........................
錯誤
!
尚未定義書籤。
Appendix 6 RS485 communication port definition .........................................................51
Appendix 7 REPO instruction...............................................................................................52

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1
．
Safety
Important safety instructions – Save these instructions
There exists dangerous voltage and high temperature inside the UPS. During the
installation, operation and maintenance, please abide the local safety instructions and relative
laws, otherwise it will result in personnel injury or equipment damage. Safety instructions in this
manual act as a supplementary for the local safety instructions. Our company will not assume the
liability that caused by disobeying safety instructions.
1.1 Safety notes
1．Even no connection with utility power, 220/230/240VAC voltage may still exist at UPS outlet！
2．For the sake of human being safety, please well earth the UPS before starting it.
3．Don’t open or damage battery, for the liquid spilled from the battery is strongly poisonous and
do harmful to body！
4．Please avoid short circuit between anode and cathode of battery, otherwise, it will cause
spark or fire！
5．Don’t disassemble the UPS cover, or there may be an electric shock！
6．Check if there exists high voltage before touching the battery
7．Working environment and storage way will affect the lifetime and reliability of the UPS.Avoid
the UPS from working under following environment for long time
◆Area where the humidity and temperature is out of the specified range(temperature 0
to 40℃, relative humidity 5%-95%)
◆Direct sunlight or location nearby heat
◆Vibration Area with possibility to get the UPS crashed.
◆Area with erosive gas, flammable gas, excessive dust, etc
8．Keep ventilations in good conditions otherwise the components inside the UPS will be
over-heated which may affect the life of the UPS.
1.2 Symbols used in this guide
WARNING!
Risk of electric shock
CAUTION!
Read this information to avoid equipment damage

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2
．
Main Features
2.1 Summarization
Our UPS is a kind of three-in- three -out high frequency online UPS, it provides four
specifications: The 200kVA/320kVA/400kVA and 320kVA. The products are modularized and
adopt the N+X redundancy. It can flexibly increase the number of the UPS modules according to
the load capacity which is convenient for flexible allocation and gradually investment.
The UPS can solve most of the power supply problems, such as blackout, over-voltage,
under-voltage, voltage sudden drop, oscillating of decreasing extent, high voltage pulse, voltage
fluctuation, surge, inrush current, harmonic distortion (THD), noise interference, frequency
fluctuation, etc..
This UPS can be applied to different applications from computer device, automatic equipment,
communication system to industry equipment
2.2 Functions and Features
◆Digital control
◆
19-inch standard cabinet
1.6-meter and 2-meter high cabinets are provided according to the user’s requirement.
◆
Modularized design
◆
High power-density design
The height of the single module is 3U, a standard 1.6m cabinet can hold 5 pieces modules
and a standard 2M cabinet for 8 modles and can a standard 2M cabinet for 13 modles reach
maximum as below:
200kVA cabinet: 5 x 40k modules
320kVA cabinet: 8 x 40k modules
400kVA cabinet: 10 x 40k modules
520kVA cabinet: 13 x 40k modules
◆
N+X parallel redundancy
This series UPS adopts N+X parallel redundancy design, user can set different redundancy
according to the importance of the load. While the redundancy modules are set more than two,
the availability of UPS system will achieve 99.999%, which may satisfy the required reliability of
the critical load connected. Through LCD display setting, you may configure the required
quantity of the redundancy unit. When the load connected is over the number of the
redundancy, the UPS will alert right away. The design of the MTBF(Meantime before Failure) is
up to 250,000 hours.
This series can set the number of redundancy modules. When the load exceeds the
redundancy setting, the UPS can still work normally and simultaneously send out corresponding
warning as long as the load doesn’t exceed the total capacity of modules.
◆
Parallel Redundant control system
◆
Optimizing distributed convergence for the cabinet
◆
Separated Bypass
◆
Common Battery
◆
Automatic charge current adjustment according to battery capacity connected.
◆
3-Stage Intelligent charging
◆
Touch-screen Super-large LCD display(Optional)
◆
Each module with indiviaul LCD display

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◆
Remote Monitoring via SNMP
◆
OptionalAccessories available such as Isolation transformer, Distribution Panel, SNMP Card,
Relay Contact Board, etc..
◆
Equip with Maintenance Bypass Switch for easy maintenance purpose.
◆
Superior MTTR(Meantime to repair) & Short shutdown time in maintenance
◆
Centralized monitoring module is also available
◆
EPO and REPO function
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．
Installation
3.1 Unpack checking
1. Don’t lean the UPS when moving it out from the packaging
2. Check the appearance to see if the UPS is damaged or not during the transportation, do
not switch on the UPS if any damage found. Please contact the dealer right away.
3. Check the accessories according to the packing list and contact the dealer in case of
missing parts.
3.2 The appearance of the product
200kVA cabinet:
Front View Side View Rear View

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Front View
（
internal
）
Rear View
（
internal
）
320kVA cabinet:
Front View Side View Rear View

6
Front View
（
internal
）
Rear View
（
internal
）
520kVA cabinet:
Front View Side View Rear View

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Front View
（
internal
）
Rear View
（
internal
）
(1) LCD panel : LCD and LED display
(2) Front lock
(3) Lightning arrester cover plate : Remove cover plate to replace lightning arrester
(4) Bypass switch cover plate : Remove cover to operate bypass switch
(5) Fuse box : Input fuse board and Battery fuse board inside, fuse box 1 connect ot module 1
(6) Communication module
(7) I/P Switch
(8) Maintenance switch
(9) Maintenance switch cover : Remove cover UPS transfers to Maintenance
(10) Input/Output Terminal cover : Remove cover to operate wire
(11) O/P Switch
(12) Lightning arrester
(13) Parallel port 1/2
(14) The input filter capacitor switch : connect capacitor or not
(15) Bypass Switch
(16) LBS port

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Fuse box
(17) Update RS485 port : use to update UPS software
(18) Battery Switch : Optional
(19) Power Module 1
(20) Power Module 2
(21) Power Module 3
(22) Power Module 4
(23) Power Module 5
(24) Power Module 6
(25) Power Module 7
(26) Power Module 8
(27) Power Module 9
(28) Power Module 10
(29) Power Module 11
(30) Power Module 12
(31) Power Module 13
(1) Fuse Box 1 : input fuse and battery fuse inbuilt, connect to module 1
(2) Fuse Box 2 : input fuse and battery fuse inbuilt, connect to module 2
(3) Fuse Box 3 : input fuse and battery fuse inbuilt, connect to module 3
(4) Fuse Box 4 : input fuse and battery fuse inbuilt, connect to module 4
(5) Fuse Box 5 : input fuse and battery fuse inbuilt, connect to module 5
(6) Fuse Box 6 : input fuse and battery fuse inbuilt, connect to module 6
(7) Fuse Box 7 : input fuse and battery fuse inbuilt, connect to module 7
(8) Fuse Box 8 : input fuse and battery fuse inbuilt, connect to module 8
(9) Fuse Box 9 : input fuse and battery fuse inbuilt, connect to module 9
(10) Fuse Box 10 : input fuse and battery fuse inbuilt, connect to module 10

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200/320kVA Terminal Block:
400/520kVA Terminal Block:
3.3 UPS module appearance
Front View
Rear View
(11) Fuse Box 11 : input fuse and battery fuse inbuilt, connect to module 11
(12) Fuse Box 12 : input fuse and battery fuse inbuilt, connect to module 12
(13) Fuse Box 13 : input fuse and battery fuse inbuilt, connect to module 13

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Side View
(1) Module left switch screw
(2) Module right switch screw
(3) Module fixed screw
(4) handle
(5) LCD display
(6) INV fan
(7) PFC fan
(8) Module output connector slot
(9) Module input connector slot
3.4 UPS Module LCD control panel
LCD control panel introduction
(1) LED(from top to bottom: “alarm”, “bypass output”
、
“battery output”
、
“mains output”)
(2) LCD display
(3) scroll button
(4) Off button
(5) On button
3.5 Installation notes
Note: Consider for the convenience of operation and maintenance, the space in

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front and back of the cabinet should be left at least 100cm and 80cm respectively when
installing the cabinet .
◆Please place the UPS in a clean, stable environment, avoid the vibration, dust, humidity,
flammable gas and liquid, corrosive. To avoid from high room temperature, a system of room
extractor fans is recommended to be installed. Optional air filters are available if the UPS operates
in a dusty environment.
◆The environment temperature around UPS should keep in a range of 0 ℃～40 ℃. I f th e
environment temperature exceeds 40 ℃
, the rated load capacity should
be reduced by 12％per
5℃. The max temperature can't be higher than 50℃.
◆If the UPS is dismantled under low temperature, it might be in a condensing condition.The
UPS can't be installed unless the internal and external of the equipment is fully dry. Otherwise,
there will be in danger of electric shock.
◆Batteries should be mounted in an environment where the temperature is within the required
specs. Temperature is a major factor in determining battery life and capacity. In a normal
installation, the battery temperature is maintained between 15°C and 25°C. Keep batteries away
from heat sources or main air ventilation area, etc.
WARNING!
Typical battery performance data are quoted for an operating temperature between
20°C and 25°C. Operating it above this range will reduce the battery life while
operation below this range will reduce the battery capacity.
◆Should the equipment not be installed immediately it must be stored in a room so as to
protect it against excessive humidity and or heat sources。
CAUTION!
An unused battery must be recharged every 6months Temporarily connecting the
UPS to a suitable AC supply mains and activating it for the time required for
recharging the batteries.
◆The highest altitude that UPS may work normally with full load is 1500 meters. The load
capacity should be reduced when this UPS is installed in place whose altitude is higher than 1500
meters, shown as the following table:
(Load coefficient equals max load in high altitude place divided by nominal power of the UPS)
Altitude(m) 1500 2000 2500 3000 3500 4000 4500 5000
Load coefficient 100% 95% 90% 85% 80% 75% 70% 65%
◆The UPS cooling is depending on fan, so it should be kept in good air ventilation area.
There are many ventilation holes on the front and rear, so they should not be blocked by any exotic
obstacles.
3.6 External Protective Devices
For safety reasons, it is necessary to install, external circuit breaker at the input A.C. supply
and the battery. This chapter provides guidelines for qualified installers that must have the
knowledge of local wiring practices for the equipment to be installed.

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◆External Battery
The UPS and its associated batteries are protected against the effect of over-current
through a DC compatible thermo-magnetic circuit-breaker (or a set of fuses) located
close to the battery.
◆UPS Output
Any external distribution board used for load distribution shall be fitted with protective
devices that may avoid the risk of UPS overloaded.
◆Over-current
Protection device shall be installed at the distribution panel of the incoming main
supply. It may identify the power cables current capacity as well as the overload capacity
of the system .
CAUTION !
Select a thermo magnetic circuit-breaker with an IEC 60947-2 trip curve C (normal)
for 125% of the current as listed below.
3.7 Power Cables
◆The cable design shall comply with the voltages and currents provided in this section, Kindly
follow local wiring practices and take into consideration the environmental conditions
(temperature and physical support media) .
WARNING
！
UPON STARTING, PLEASE ENSURE THAT YOU ARE AWARE OF THE
LOCATION AND OPERATION OF THE EXTERNAL ISOLATORS WHICH ARE
CONNECTED TO THE UPS INPUT/BYPASS SUPPLY OF THE MAINS
DISTRIBUTION PANEL.CHECK TO SEE IF THESE SUPPLIES ARE ELECTRICALLY
ISOLATED, AND POST ANY NECESSARY WARNING SIGNS TO PREVENT ANY
INADVERTENT OPERATION
◆For future expansion purpose, it is economical to install power cable according to the full rating
capacity initially. The diameter of cable is shown bellow：
UPS
cabinet
Cable Dimension
AC Input
(mm2) AC Output (mm2) DC Input (mm2) Grounding (mm2)
200
150
120
120*2
70
320
120*2
95*2
150*2
120
400
150*2
120*2
185*3
150
520
185*2
150*2
185*3
185*2
CAUTION!
Protective earth cable: Connect each cabinet to the main ground system. For
Grounding connection, follow the shortest route possible。
WARNING!
FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES MAY
RESULT IN ELECTROMAGNETIC INTERFERENCE OR IN HAZARDS
INVOLVING ELECTRIC SHOCK AND FIRE
3.8 Power cable connect
Once the equipment has been finally positioned and secured, connect the power cables as

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described in the following procedure.
Verify the UPS is totally isolated from its external power source and also all power isolators of
the UPS are open. Check to see if they are electrically isolated, and post any necessary warning
signs to prevent their inadvertent operation .
Open the UPS terminal panel, remove the cover of terminals for wiring easily.
200/320kVA Terminal Block:
Terminal sequence from left to right:input phaseA(L1),input phase B(L2),input phase C(L3),input
Neutral line, output Neutral line,output phase A(L1), output phase B(L2), output phase C(L3);battery
positive, battery Neutral, battery negative,Ground,bypass input phaseA(L1),bypass input phase
B(L2),bypass input phase C(L3)。
400/520kVA Terminal Block:
Terminal sequence from left to right:input phaseA(L1),input phase B(L2),input phase C(L3),input
Neutral line, output phaseA(L1), output phase B(L2), output phase C(L3);battery positive, battery
negative, output and battery Neutral,Ground,bypass input phase A(L1), bypass input phase
B(L2),bypass input phase C(L3)。
Choose appropriate power cable.（Refer to the table above）and pay attention to the
diameter of the connection terminal of the cable that should be greater than or equal to that of
the connection poles;
Wiring

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WARNING!
If the load equipment is not ready to accept power on the arrival of the
commissioning engineer then ensure that the system output cables are
safely isolated at their ends
Connect the safety earth and any necessary bonding earth cables to
the copper earth screw located on the floor of the equipment below the
power connections. All cabinets in the UPS must be grounded properly.
CAUTION!
The earthing and neutral bonding arrangement must be in accordance
with local and national codes of practice.
3.9 Battery connection
The UPS adopts positive and negative double battery framework, total 32(optional 34/36/38/40)
in series.Aneutral cable is retrieved from the joint between the cathode of the 16th (17th/18th/19th/20th)
and the anode of the 17th (18th/19 th/20th/21 th) of the batteries. Then the neutral cable, the battery
Positive and the battery negative are connected with the UPS respectively. The battery sets between
the Battery anode and the neutral are called positive batteries and that between neutral and cathode
are called negative ones. The user can choose the capacity and the numbers of the batteries
according to their desire.

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Note
：
The BAT+ of the UPS connect poles is connected to the anode of the positive
battery, the BAT-N is connected to the cathode of the positive battery and the anode
of the negative battery, the BAT- is connected to the cathode of the negative battery。
Factory setting of the long-run unit is battery quantity---32pcs, battery
capacity---12V65AH. When connecting 32/34/38/40 batteries, please re-set desired
battery quantity and its capacity after UPS starts at AC mode. Charger current could
be adjusted automatically according to battery capacity selected. All related settings
can be done through LCD panel or monitoring software.
CAUTION!
Ensure correct polaritybattery string seriesconnection. i.e. inter-tier
and inter block connections are from (+) to (-)terminals.
Don’t mix batteries with different capacity or different brands, or
even mix up new and old batteries, either.
WARNING!
Ensure correct polarity of string end connections to the Battery
Circuit Breaker and from the Battery Circuit Breaker to the UPS
terminals i.e. (+) to (+) / (-) to (-) but disconnect one or more battery cell
links in each tier. Do not reconnect these links and do not close the
battery circuit breaker unless authorized by the commissioning
engineer.

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3.10 Online UPS Modules Replacement
For the UPS, modules must be inserted to make a complete UPS system。
The replacement of UPS module is very simple and can be operated online.The control
system of the UPS can detect the inserted or removed module(s) automatically. The user
may operate easily by following the steps mentioned below.
◆NOTE: The UPS module is rather heavy, please move it by two people!
◆Insert module
(1) Remove decorated panel;
(2) Put the UPS module in the cabinet module slot. Push the module along the slot into the
cabinet until the module is inserted properly.
(3) Fix the module with screws (M5) at the positioning screw holes;
(4) Open input switch at modules’ rear panel, and output switches accordingly. (From top to
bottom, the order is 1-5 or 8)
(5) After the modules start up , the system will detect the modules inserted automatically,
and parallel up the modules into whole system.
◆Remove UPS module
Remove the coronal screws on the left side of the module to stop the module
running completely and remove the module after fan stop spinning.
WARNING!
(1) Make sure the LCD screen is totally off before removing the module; otherwise, electric sparks
will occur at the connection of module and system cabinet.
(2) The coronal screw at left side of the module controls the operation of the module. Only after the
screw is tightened, the module can start running. When insert new module, make sure the screw is
tightened properly.
(3) When insert the module under battery mode, please press “ON” button at module’s LCD panel
until the module starts.
3.11 UPS Multi
－
Module Installation
The basic installation procedure of a parallel system comprising of two or more UPS modules is

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the same as that of single module system. The following sections introduce the installation
procedures specified to the parallel system.
3.11.1 Cabinet installation
Connect all the UPSes needed to be put into parallel system as below picture.
Make sure each UPS input breaker is in “off” position and there is no any output from each
UPS connected. Battery groups can be connected separately or in parallel, which means the
system itself provides both separate battery and comman battery.
WARNING!
Make sure the N、A（L1）、 B（L2）、 C（L3）lines are correct, and grouding
is well connected.
3.11.2 Parallel cable installation
Shielded and double insulated control cables available must be interconnected in a ring
configuration between UPS modules as shown below. The parallel control board is mounted on
each UPS module. The ring configuration ensures high reliability of the control.

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4
．
Operation
4.1 Operation Modes
The UPS is a double-conversion on-line UPS that may operate in the following alternative
modes：
◆
Normal mode
The rectifier/charger derives power from the AC Mains and supplies DC power to the
inverter while floating and boosting charge the battery simultaneously. Then, the inverter
converts the DC power to AC and supplies to the load.
◆
Battery mode (Stored Energy Mode)
If the AC mains input power fails, the inverter, which obtains power from the battery,
supplies the critical AC load. There is no power interruption to the critical load. The UPS will
automatically return to Normal Mode when AC recovers.
◆
Bypass mode
If the inverter is out of order, or if overload occurs, the static transfer switch will be activated
to transfer the load from the inverter supply to bypass supply without interruption to the critical
load. In the event that the inverter output is not synchronized with the bypass AC source, the
static switch will perform a transfer of the load from the inverter to the bypass with power
interruption to the critical AC load. This is to avoid paralleling of unsynchronized AC sources.
This interruption is programmable but typically set to be less than an electrical cycle e.g. less
than 15ms (50Hz) or less than 13.33ms (60Hz).
◆
Maintenance mode (Manual Bypass)
A manual bypass switch is available to ensure continuity of supply to the critical load when
the UPS is out of order or in repair. This manual bypass switch is fitted for all UPS modules and
bears for equivalent rated load.
◆
Redundancy mode
Based on different demands, The UPS can be set as N+X redundancy mode to increase the
reliability to the load connected.
4.2 Turn on/off UPS
4.2.1 Restart procedure
CAUTION!

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MAKE SURE GROUNDING IS PROPERLY DONE!
◆Set the Battery Breaker to the “ON” position according to the user’s manual.
◆Open the front and rear doors of the UPS to access to the main power switches.
During this procedure the output terminals will become alive.
CAUTION
！
Check to see if the load is safely connected with the output of the UPS. If the
load is not ready to receive power from the UPS, make sure that it is safely
isolated from the UPS output terminals
◆Turn ON the bypass and input switches of the UPS, make sure that “fuse box” insert the
cabinet, and fix with screws
When AC MAINS input voltage within the range, And the rectifiers of the UPS will be started
up in 30 seconds, then the inverter is started completely. When the output breaker is “ON”, the
inverter LED lights up.
◆Switch ON output breaker
If the rectifier of the module does not start-up, the bypass LED will light up.
When the inverter is on, the UPS will transfer from bypass mode to inverter mode,
then the bypass LED is off and the inveter LED is on.
No matter the UPS is operated normally or not, the LCD display will indicate
current status.
4.2.2 Test procedure
CAUTION!
The UPS is operating normally.
It may take 60 seconds to boost up the system and perform self-test completely.
◆Switch off the MAINS to simulate utility failure, the rectifier will turn off and the battery
should feed the inverter without interruption. At this time, the LEDs of battery should be
turned on.
◆Switch on the MAINS to simulate utility recovery, the rectifier will restart automatically
after 20 seconds and the inverter will supply to the load. It is suggested to use Dummy
loads for testing. The UPS can be loaded up to its maximum capacity during load test。
4.2.3 Black(Cold) start procedure