Mitsubishi Electric 9800A Series User manual

UNINTERRUPTIBLE POWER SUPPLY SYSTEM
MODEL
9800A SERIES
OWNERS / TECHNICAL MANUAL
(For parallel operation possible model only)
MITSUBISHI
ELECTRIC

Preface
MITSUBISHI ELECTRIC CORPORATION
Revision
3
.
0
3
Mar
.
2
4
, 0
8
ALN-H0776

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TABLE OF CONTENTS
LIST OF TABLES ................................................................................................ ii
LIST OF FIGURES .............................................................................................. iii
HOW TO USE THIS MANUAL ............................................................................ iv
1.0 INTRODUCTION ........................................................................................ 1-1
1.1 SAFETY PRECAUTION ............................................................................. 1-2
1.2 GENERAL ................................................................................................... 1-5
1.3 DEFINITIONS ............................................................................................. 1-6
1.4 OPERATION OVERVIEW .......................................................................... 1-7
1.5 SPECIFICATIONS ...................................................................................... 1-15
2.0 OPERATION CONTROLS AND INDICATORS ......................................... 2-1
2.1 LED DISPLAY ............................................................................................. 2-2
2.2 EPO BUTTON ............................................................................................. 2-2
2.3 LIQUID CRYSTAL DISPLAY ...................................................................... 2-3
2.4 EXTERNAL SIGNAL TERMINAL BLOCK .................................................. 2-8
2.5 EXTERNAL COMMUNICATION CONNECTOR ........................................ 2-12
3.0 INSTALLATION AND OPERATION .......................................................... 3-1
3.1 TRANSPORTATION AND INSTALLATION ............................................... 3-1
3.2 INSTALLATION PROCEDURE .................................................................. 3-1
3.3 PROCEDURE FOR CABLE CONNECTIONS ........................................... 3-2
3.4 OPERATING PROCEDURES .................................................................... 3-24
4.0 RESPONSE TO UPS FAILURE ................................................................. 4-1
5.0 PARTS REPLACEMENT ........................................................................... 5-1
6.0 FAULT CODES .......................................................................................... 6-1
7.0 WARRANTY & OUT OF WARRANTY SERVICE ..................................... 7-1

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LIST OF TABLES
Table 1.1 UPS Installation Environment....................................................... 1-2
Table 1.2 Rating of Bypass Input Circuit Breaker ....................................... 1-4
Table 1.3 Power Specifications .................................................................... 1-15
Table 1.4 UPS Module Information............................................................... 1-15
Table 1.5 Detail of Specifications ................................................................. 1-16
Table 1.6 Rating of Contactor and Fuses..................................................... 1-17
Table 3.1 How to Transport and Install the System ..................................... 3-1
Table 3.2 List of UPS Weights (lb.)............................................................... 3-1
Table 3.3 Maximum Permitted Fault Current................................................ 3-2
Table 3.4 Recommended Cable Sizes......................................................... 3-5
Table 3.5 Crimp Type Compression Lug...................................................... 3-6
Table 6.1 Fault Code .................................................................................... 6-2

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LIST OF FIGURES
Figure 1.1 Single Line Diagram-Normal Operation ................................................... 1-5
Figure 1.2 Single Line Diagram-Bypass Operation................................................... 1-6
Figure 1.3 Single Line Diagram-Battery Operation.................................................... 1-7
Figure 1.4 UPS Parts Location .................................................................................. 1-8
Figure 1.5 UPS Parts Location (Continued) .............................................................. 1-11
Figure 1.6 External I/F circuit PCB IOAU-04 ............................................................ 1-11
Figure 2.1 Operation/Display Panel........................................................................... 2-1
Figure 2.2 Main Screen.............................................................................................. 2-3
Figure 2.3 Start/Stop Screen...................................................................................... 2-4
Figure 2.4 PIN Protection Screen.............................................................................. 2-4
Figure 2.5 Bypass Voltage Abnormal Message Screen............................................ 2-4
Figure 2.6 Measurement Screen ............................................................................... 2-4
Figure 2.7 Setup Screen............................................................................................ 2-5
Figure 2.8 Log Select Screen..................................................................................... 2-5
Figure 2.9 Event Log Screen..................................................................................... 2-5
Figure 2.10 Battery Log Screen ................................................................................. 2-6
Figure 2.11 Main Screen (Battery Operation) ............................................................ 2-6
Figure 2.12 Measurement Screen (Battery Operation) ............................................... 2-6
Figure 2.13 Main Screen (Fault Indication) ................................................................ 2-7
Figure 2.14 Message Screen ..................................................................................... 2-7
Figure 2.15 External Signal Terminal Block................................................................. 2-8
Figure 2.16 Control Wiring for External Contacts........................................................ 2-10
Figure 2.17 Remote "Start" Contact Connections ....................................................... 2-11
Figure 2.18 External communication connector .......................................................... 2-12
Figure 3.1 UPS Terminal Designation ...................................................................... 3-6
Figure 3.2 Diagram of input/output bus bars and terminal blocks ........................... 3-7
Figure 3.3 Diagram of Rectifier Cabinet & Inverter Cabinet Inter-connect .............. 3-19
Figure 3.4 Diagram of Power and Control Wire Connect (Parallel Connection)....... 3-21
Figure 3.5 Operation Procedures: Start Up/Shut Down Procedure........................... 3-24

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HOW TO USE THIS MANUAL
This manual is designed for ease of use, giving the user easy and quick reference to
information.
This manual uses notice icons to draw attention to the user important information regarding the
safe operation and installation of the UPS. The notice icons used in this manual are explained
below, and should be taken into account and adhered to whenever they appear in the text of
this manual.
Warning: A warning notice icon conveys information provided to protect
the user and service personnel against hazards and/or possible equipment
damage.
Caution: A caution notice icon conveys information provided to protect
the user and service personnel against possible equipment damage.
Note: A Note notice icon indicates when the user should make a reference of
information regarding the UPS operation, load status and display status.
Such information is essential if Mitsubishi field service group assistance and
correspondence is required.
Safety Recommendations: If any problems are encountered while following this manual,
Mitsubishi field service group assistance and correspondence is recommended.

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1.0 INTRODUCTION
Your Mitsubishi Uninterruptible Power Supply System (UPS) is designed to provide many
years of reliable protection from power failure, brown-outs, line noise, and voltage transients.
To ensure optimum performance of the equipment, follow the manufacturer's instructions. This
manual contains descriptions required to operate the UPS. Please read this manual carefully
and retain it for future reference.
This manual contains important instructions for the 9800A SERIES Uninterruptible Power
Supply Systems that should be followed during installation and maintenance of the UPS and
batteries.
Lethal voltages exist within the equipment during operation. Observe all
warning and cautions in this manual. Failure to comply may result in
serious injury or death. Obtain qualified service for this equipment as
instructed.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
WARNING 1

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In no event will MITSUBISHI be responsible or liable for either indirect or
consequential damage or injury that may come from the use of this equipment.
Any modifications without authorization by MITSUBISHI could result in personal injuries,
death or destruction of the UPS.
1.1 SAFETY PRECAUTIONS
APPLICATION
This UPS shall NOT be applied to support equipment (*) that could affect
the human lives.
Special considerations are required when applying this UPS to the
equipment (**) that affect human safety and/or maintain public services.
Be sure to contact/inform MITSUBISHI if it is such a case. The application
without special consideration may cause serious accidents.
*Medical operation room equipment
Life support equipment (artificial dialysis, incubators, etc.)
Toxic gas or smoke eliminators
Equipment that must be provided under fire laws, construction standards
or other ordinances
Equipment equivalent to the above
** Equipment to supervise or control airways, railways, roads, sea-lanes
or other transportation.
Equipment in nuclear power plants.
Equipment to control communications.
Equipment equivalent/similar to the above mentioned.
WARNING 2

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The UPS is to be installed in a controlled environment.
Improper storage and installation environment may deteriorate
insulation, shorten component life and cause malfunctions.
Keep the installation environment per standard described as follows:
TABLE 1.1 UPS Installation Environment
No. Item Environment standard
1 Installation
location
Indoors
2 Ambient
temperature Minimum temperature: 32F(0C), Maximum temperature: 104F(40C) The
average temperature over any 24-hour period must be in the range 41F (5C)
to 95F(35C).
3 Relative
humidity The relative humidity must be held between 5 and 95%. There must be no condensation due to temperature changes.
4 Altitude This equipment must not be applied at altitude that exceeds 2743m(9000ft)
above seal level.
5 Dust Dust in the room where the UPS is installed must not exceed normal
atmospheric dust levels. In particular, that dust shoud not include iron particles,
oils or fats, or organic materials such as silicone.
There should be no inflammable/explosive gas.
Hydrogen sulfide (H2S) No more than 0.0001 PPM
Sulfurous acid gas (SO2) No more than 0.05 PPM
Chlorine gas (Cl2) No more than 0.002 PPM
Ammonia gas (NH3) No more than 0.1 PPM
Nitrous acid gas (NO2) No more than 0.02 PPM
Nitrous oxides (NOx) No more than 0.02 PPM
Ozone (O3) No more than 0.002 PPM
6 Inflammable gas
Hydrochloric acid mist (HCl) No more than 0.1 mg/m3
WARNING 3

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This UPS does not include a Bypass input circuit breaker (MCCB) to
protect bypass circuit. The Bypass input circuit breaker (MCCB) is to be
field supplied and installed. Recommended Breaker (MCCB)'s
Specifications are as follows:
TABLE 1.2 Rating of Bypass Input Circuit Breaker
Capacity (kVA) Bypass Voltage (Vac) Bypass Rating (Aac) Breaker (A)
100 480 120 150
600 96 125
150 480 180 225
600 144 200
225 480 271 350
600 217 300
300 480 361 500
600 289 400
375 480 451 600
600 361 500
500 480 602 800
600 482 600
750 480 902 1200
600 722 900
AC input and AC output overcurrent protection and disconnect devices shall be field
supplied and installed. The DC output breaker (MCCB) shall be field supplied and
installed. The overcurrent protection device should be installed in the Battery cabinet
and rated as indicated in TABLE 1.6.
WARNING 4

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1.2 GENERAL
The Mitsubishi 9800A SERIES UPS is designed to provide continuous and clean electrical
power to a critical load. Additionally the UPS monitors power conditions affecting the load.
In the event of an input power failure, the UPS will supply power to the critical load for the
specified battery time.
If the input power is not restored promptly, back up power from the UPS battery permits
the orderly shutdown of equipment supported by the UPS. The UPS is simple to start-up,
operate and maintain.
The 9800A SERIES UPS is available in seven kVA sizes-100, 150, 225, 300, 375, 500 and
750kVA. Specifications for each kVA model appear in Section 1.5. The principles of
operation described herein are applicable to all models.
This manual provides an overview of the 9800A SERIES components and their functions.
The appearance and purpose of operator controls and indicators is described with
procedures for operation, start-up, shutdown and basic maintenance included.

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1.3 DEFINITIONS
UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS
Module Cabinet and associated batteries that function as a system to provide continuous,
conditioned AC power to a load. This is sometimes referred to as the "System".
UPS MODULE CABINET - The metal enclosure which contains the Rectifier, the Inverter,
the Chopper, the Static Transfer Switch, the Internal Bypass line, the operator controls,
and the internal control system required to provide specified AC power to a load.
UPS MODULE - The Rectifier and Inverter assemblies which, under the direction of the
internal control system and operator controls, provide specified AC power to a load.
RECTIFIER - The UPS components which contain the equipment and controls necessary
to convert input AC power to regulated DC power required for battery charging and for
supplying power to the Inverter.
INVERTER - The UPS components which contain the equipment and controls necessary
to convert DC power from the Rectifier, or the battery, to AC power required by the critical
load.
CHOPPER - The UPS components which contain the equipment and controls necessary
to charge the battery and supply power to the Inverter from battery.
STATIC TRANSFER SWITCH - The device which connects the critical load to the bypass
line when the UPS module cannot supply continuous power.
BYPASS LINE - The line which conducts electricity directly from the input power source to the
critical load during Maintenance or whenever the UPS is not completely operational.
INPUT POWER - Power provided by the electrical utility company, or auxiliary generator,
which is connected to the UPS for supplying the critical load.

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1.4 OPERATION OVERVIEW
The UPS provides two power paths between the utility source and the critical load.
Figure 1.1 shows the path for normal operation, with the load powered from the inverter.
Figure 1.2 shows the path for bypass operation, with the load supplied through the static
bypass line.
A) Normal operation: Load power supplied by each system UPS inverter.
Figure 1.1 Single Line Diagram - Normal Operation: Load powered by UPS inverters
During normal operation, the path through the UPS inverters is used to power the load.
Referring to Figure 1.1: For each system UPS, the Input AC power is converted to DC by
the Rectifier. DC power is utilized to charge the UPS battery and to provide power to the
Inverter. The Inverter converts the DC power to clean AC power to supply the critical load.
The conversion - inversion process eliminates any voltage transients or fluctuations
existing in the input power before it reaches the critical load.
The power drawn by the critical load is equally shared between all system UPS.
In the event of a UPS module failure, the critical load power will be continually supplied
and shared by all other system UPS.
In the event of a load overcurrent, all system UPS will transfer to bypass without
interruption to the critical load.
CB1
Static Transfer
Switch
AC Bypass
Input
AC input
CB
CB3
52S
52C
User supplied
MCCB
UPS ModuleBattery cabinet
CB2 Power Flow
Not in Use
RECTIFIER INVERTER
Output

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The Bypass Input circuit breaker (MCCB) for protection of the UPS and cables are field
supplied and field installed. (See WARNING 4 on page 1-4)
B) Bypass Operation: Load Power supplied through each system UPS internal static
bypass line.
FIGURE 1.2 Single Line Diagram - Bypass Operation: Load fed through Internal static
bypass line.
Referring to Figure 1.2: The Internal Static Bypass line is a Hard wired line through CB3
and contactor 52S which supplies the critical load with unconditioned input power.
Each system UPS internal static bypass line will equally share the power supplied to the
critical load.
The internal static bypass line will route power to the critical load while the UPS module is
de-energized during Start-up and before the system is fully operational.
Bypass operation will occur In the event of a load overcurrent, with all system UPS
transferring to bypass without interruption to the critical load.
The internal control system determines the operation of the two paths, with the load
powered from the inverter being the normal operation.
CB1
Static Transfer
Switch
AC Bypass
Input
AC input
CB
CB3
52S
52C
User supplied
MCCB
UPS ModuleBattery cabinet
CB2 Power Flow
Not in Use
RECTIFIER INVERTER
Output

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C) Battery operation: Load Power supplied by each system UPS battery and inverter.
FIGURE 1.3 Single Line Diagram - Battery Operation
Referring to Figure 1.3: In the event of AC input source failure or interruption, each
system UPS rectifier will de-energize and each UPS battery will immediately discharge
and supply DC power to the Inverter to maintain continuous AC power to the load. This
operation will continue until:
a) The battery capacity expires and the inverter turns off, or
b) Input power is restored after which the rectifier will power the inverter and critical load
and simultaneously recharge the batteries.
A fully charged battery will provide power for the specified time at the rated load, or longer,
at a reduced load.
When power is restored after a low battery shutdown, each system UPS Rectifier
automatically restarts operation, recharges the batteries and the Inverter is automatically
restarted without operator intervention. Load is automatically assumed by the inverter
without operator intervention.
The power drawn by the load is equally shared between all system UPS during battery
operation.
CB1
Static Transfer
Switch
AC Bypass
Input
AC input
CB
CB3
52S
52C
User supplied
MCCB
UPS ModuleBattery cabinet
CB2 Power Flow
Not in Use
RECTIFIER INVERTER
Output

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FIGURE 1.4-a UPS Parts Location (100kVA, 150kVA, 225kVA)
FIGURE 1.4-b UPS Parts Location (300kVA,375kVA)
UPS module
FRONT VIEW
Inverter
Chopper
unit
DC
capacitors
52S
CB3
3. External I/F
circuit PCB
IOAU-04
52C
2. Grounding
Bar
CB1
Rectifier
unit
1.CPM
AC capacitors
AC c
apacitors
CB1
2. Grounding Bar
DC
capacitor
s
3. External I/F
circuit PCB
IOAU-04
UPS module
FRONT VIEW
1. CPM
Inverter
Chopper
unit
Rectifier unit
52S
CB3
52C

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FIGURE 1.4-c UPS Parts Location (500kVA)
UPS module
FRONT VIEW
Rectifier
unit
CB1
1. CPM
AC capacitors
2. Grounding Bar
3. External I/F
circuit PCB
IOAU-04
Inverter
Chopper
unit
CB3
AC capacitors
52C
52S
DC
Capacitors

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FIGURE 1.4-d UPS Parts Location (750kVA)
UPS modul
e
FRONT VIEW
Rectifier
unit
52C
1. CPM
2. Grounding Bar
3. External I/F
circuit PCB
IOAU-04
Inverter
Chopper
unit
DC
Capacitors
AC capacitors
CB1
CB3
52S
AC capacitors

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FIGURE 1.5 UPS Parts Location (Continued)
FIGURE 1.6 External I/F circuit PCB IOAU-04
UPS module
REAR OF FRONT DOOR (Right side)
|
FAULT
RESET
|
MAINTENANCE
SWITCH
|
TEST
SWITCH
|
BOOT
SWITCH
SYNC.LED
INVERTER
START
|
INVERTER
STOP
|
8
7910
56
IOAU-04
3. External contact signal terminal
4. RS232C D-
sub connector

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Description of Figures 1.4, 1.5, and 1.6:
1. CPM - Circuit protector for control power supply.
2. Grounding bar (G)
3. External contact signal terminal block (FIGURE 1.6) -Terminal block to connect
contact signal input/output lines to and from the external devices. Refer to Figure 2.15
section 2.4 for details.
4. RS232C communication connector (FIGURE 1.6) -Refer to Figure 2.18 section 2.5 for
details.
5. Inverter start switch - This switch is used to transfer the UPS from static bypass to
inverter during maintenance purposes. Transfers will lock-out if the bypass voltage is
more than +12%,-12% of nominal.
* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at
the time of asynchronous operation.
6. “INVERTER STOP” switch - This switch is used to transfer the UPS from inverter to
static bypass during maintenance purposes. Do not operate it under normal operation.
Transfers will lock-out if the bypass voltage is more than +12%,-12% of nominal.
* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at
the time of asynchronous operation.
7. “FAULT RESET” switch (FOR SERVICE PERSONNEL ONLY) - This switch resets
errors resulting from alarm conditions. (Do not operate this switch while inverter and
converter are in operation.)
8. Maintenance (Set) button (FOR SERVICE PERSONNEL ONLY) - This switch sets the
UPS menu parameters.
9. “Test mode” switch (FOR SERVICE PERSONNEL ONLY) - This switch changes
system operation to the test-mode. (This switch should not be operated by personnel
other than an Authorized Service Engineer).
10. “BOOT” switch (FOR SERVICE PERSONNEL ONLY) - This switch boots the
processor in the main control circuit resulting from alarm conditions. (Do not operate
this switch while inverter and converter are in operation).