Online Power Protector 3 User manual

Price $50.0
0
Protector 3
Three Phase Uninterruptible Power System
10 – 62.5 kVA
User Manual
Installation
Operation
Maintenance
Doc #. 6002-1874
Rev. B
$50.00

OnLine Power
a
TABLE OF CONTENTS
SECTION PAGE
REVISION HISTORY c
PROPRIETARY d
SECTION 1 - SAFETY 1-1
SECTION 2 - OVERVIEW 2-1
2.1 INTRODUCTION 2-1
Illustration 2.1: Protector 3 `2-1
2.2 BENEFITS 2-2
2.3 PRODUCT FEATURES 2-2
Illustration 2.2: Unit Component Layout 2-4
Illustration 2.3: Sub Assembly Component Location 2-5
2.4 FUNCTIONAL DESCRIPTIONS 2-6
Illustration 2.4: Functional Block Diagram for Single Input Power System 2-7
Illustration 2.5: Functional Block Diagram for Dual Delta Input Power System 2-8
Illustration 2.6: Functional Block Diagram for Dual Wye Input Power System 2-8
2.5 THEORY OF OPERATION 2-9
2.6 OUTPUT LOADS 2-10
2.7 OPTIONS (See more detail on Section 6) 2-10
SECTION 3 - INSTALLATION 3-1
3.1 SITE PLANNING AND PREPARATION 3-1
Table 3-A: Site Planning Specifications 3-1
Illustration 3-1: Cable Access and Mounting 3-2
3.2 EQUIPMENT UNPACKING 3-3
Illustration 3.2: Fork lifting 3-3
3.3 UNIT INSTALLATION 3-4
Illustration 3-3: Protector Customer’s Connection 3-5
3.4 REMOTE SIGNALLING CONNECTIONS (OPTIONAL) 3-6
3.5 STORAGE 3-7
SECTION 4 - OPERATION 4-1
4.1 START-UP PROCEDURES 4-1
4-2 OPERATION 4-3
4.3 FIELD REPLACEABLE UNITS 4-3
Illustration 4-1: Heat Sink Assembly (FRU) 4-4
4.4 RENEWAL PARTS 4-5
SECTION 5 - MAINTENANCE 5-1
5.1 SAFETY PRECAUTIONS 5-1
5.2 WHEN TO CALL 5-3
5.3 STEPS TO TAKE 5-3
5.4 PREVENTIVE MAINTENANCE 5-3
5.5 ONLINE POWER CUSTOMER SERVICE AND SUPPORT 5-6

OnLine Power
b
SECTION PAGE
SECTION 6 – SYSTEM OPTIONS 6-1
6.1 MAINTENANCE BYPASS SWITCH 6-2
Illustration 6-1: External Maintenance Bypass Switch Diagram 6-2
Illustration 6-2: Maintenance Bypass Switch 6-3
6.2 AUDIO ALARM WITH SILENCE SWITCH 6-5
6.3 REMOTE UPS STATUS PANEL 6-5
6.4 FORM “C” CONTACTS FOR ALARMS 6-5
6.5 TRANSIENT VOLTAGE SUPPRESSOR SYSTEM 6-6
6.6 NORMALLY ON/OFF NORMALLY OUTPUT AUX. CIRCUIT BREAKERS 6-6
6.7 EXTERNAL OUTPUT AUX. CB’S IN PANEL BOARD 6-6
6.8 10% INPUT CURRENT HARMONIC FILTER 6-7
6.9 5% INPUT CURRENT HARMONICS FILTER 6-7
6.10 EMI FILTER 6-7
6.11 HIGHER KAIC NORM ON/OFF OUTPUT CB 3 AND 3-PHASE 6-7
6.12 DUAL INPUT SYSTEM WYE/WYE 6-8
6.13 DUAL INPUT SYSTEM DELTA/WYE 6-8
6.14 DUAL INPUT SYSTEM DELTA/DELTA 6-8
6.15 SEISMIC MOUNTING BRACKET 6-8
6.16 STACKABLE RACK 6-8
6.17 POWER FLOW MIMIC 6-8
Illustration 6-3: Power Flow Mimic 6-8
6.18 GLOBAL MONITORING SYSTEM 6-9
6.18.1 Local on UPS - Event Log 6-9
Illustration 6-4: Logged Events 6-9
Illustration 6-5: Status Screen 6-9
Illustration 6-6: System Info 6-10
6.18.2 Local on UPS – Aux.CBs Trip Monitor with Event Log 6-10
Illustration 6-7: Auxiliary CB Trip 6-10
6.18.3 Local on PC via RS 232 6-11
Illustration 6-8: Sample PC Screen 6-11
6.18.4 Local on PC via RS 485 6-11
6.18.5 Gms Remote dial up Monitor 2000 6-12
Illustration 6-9: Monitoring 2000 Front View 6-12
Illustration 6-10: Manager 2000 Screen 6-12
6.18.5.2 GMS Operation, Status, Alarm, Events Log, E-mail 6-13 to 6-18
6.18.6 GMS WEB/SNMP (GWS)Status , Event log 6-19 to 6-38
6.19. ECC – EMERGENCY CIRCUIT CONVERTER 6-39
6.20 ECC – EMERGENCY CONTROL MODULE 6-40
6.21 EVENT LOG WITH 1625-344-01 PCBD ASSY. 6-41 TO 6-46
APPENDICES
APPENDIX A – SPECIFICATIONS A-1
APPENDIX B – BATTERY CONNECTIONS B-1
APPENDIX C - LCD DISPLAY MENU & TROUBLESHOOTING GUIDE C-1
APPENDIX D – INPUT & OUTPUT AMPACITY FOR VARIOUS MODELS D-1
APPENDIX E – DRAWINGS & TABLES, REQUEST FOR TURN ON E-1

OnLine Power
c
REVISION HISTORY
REV DATE PRIMARY REASON FOR CHANGE
A Mar. 05, 2007 Production Release.
B Jan 19, 2009 Production Release.
LIST OF EFFECTIVE PAGES
PAGE REV PAGE REV PAGE REV PAGE REV PAGE REV
Title Page B
a to e B
1-1 to 1-4 B
2-1 to 2-10 B
3-1 to 3-7 B
4-1 to 4-5 B
5-1 to 5-6 B
6-1 to 6-14 B
A-1 to A-3 B
B-1 to B-5 B
C-1 to C-2 B
D-1 to D-1 B
E-1 to E-24 B

OnLine Power
d
OnLine Power, Inc.
Reproduction or Distribution forbidden
NOTICE: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION
This document contains proprietary and confidential information of
OnLine Power, Inc. (”OnLine Power”). In consideration of the receipt of
this document, the recipient agrees not to copy any of its contents, nor to
disclose them to or allow them to be used by any person not currently an
OnLine Power employee or an employee of the recipient having a need to
know, without the express written consent of OnLine Power, and further
agrees to surrender this document to OnLine Power when the reason for
its receipt has terminated.
© 2007 OnLine Power, Inc. – All rights reserved

OnLine Power
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Congratulations on selecting one of the fine products from OnLine Power, the leader in power
protection technology. Our wide product offering includes UPS (Uninterruptible Power Systems), power
conditioners, automatic voltage regulators and specialty transformers (e.g., computer-grade, medical-
grade). Since our founding in 1972, OnLine Power has shipped many of these fine products to
discerning customers around the world for use on sensitive equipment and in critical applications.
One of our goals is to make our manuals both comprehensive and easy to use. The new format of our
user manual is the result of ideas and inputs from customers like you who have taken an active interest
in our continued success. We invite and appreciate your feedback on our products and documentation
via e-mail, fax, mail, or telephone.
HEADQUARTERS
OnLine Power
5701 Smith Street
Commerce, CA 90040
SALES
Phone: [phone]
FAX No: [phone]
E-mail: [email protected]
Office Hours are 7:00 AM to 5:30 PM PST
SERVICE
If you require assistance, please call our 24-hour toll free hot line 800-PWR-SRVC (800-797-
7782). Please have the following information from your unit’s nameplate available to speed
assistance:
Serial Number:
kVA/Power Rating:
Input Voltage:
Output Voltage:
Manufacturer Date:

OnLine Power
1-1
SECTION 1 - SAFETY
Following safety precautions is important when operating or servicing electrical
equipment. The symbols shown are used extensively throughout this manual.
Always heed these precautions since they are essential to the safe operation and
servicing of this product.
Boxes labeled with the “Danger!” symbol indicate that there is a high risk of
personal injury or death if instructions are not followed.
Warnings labeled with the symbol indicate that there is a high
probability of equipment failure, damage, or destruction if instructions are not
followed.
If you require assistance, call toll free 800-PWR-SRVC (800-797-7782). Please have the
following information from your unit’s nameplate available to speed assistance:
Serial Number:
kVA/Power Rating:
Input Voltage:
Output Voltage:
Manufacturer Date:
Danger!
READ THIS MANUAL IN ITS ENTIRETY BEFORE PERFORMING THE
INSTALLATION, START-UP, OPERATION, OR MAINTENANCE OF THE UPS
(Uninterruptible Power System) OR BATTERY SYSTEMS. FAILURE TO DO SO
COULD RESULT IN ELECTROCUTION, FIRE, EXPLOSION, OR EQUIPMENT
FAILURE.
Danger!
ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT
TO INSTALL OR REPAIR THE UPS OR ITS BATTERY SYSTEM. IMPROPER
INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT
CAUSE OF START-UP PROBLEMS. HIGH AC AND DC ELECTRICAL
VOLTAGES ARE PRESENT THROUGHOUT THE UNIT(S) AND INCORRECT
INSTALLATION OR SERVICING COULD RESULT IN ELECTROCUTION, FIRE,
EXPLOSION, OR EQUIPMENT FAILURE.
Caution

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1-2
Danger!
ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED
ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT.
WIRING MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE
NATIONAL AND LOCAL ELECTRICAL CODES. IMPROPER WIRING MAY
CAUSE DAMAGE TO THE EQUIPMENTS, INJURY OR DEATH OF PERSONNEL.
VERIFY THAT ALL HIGH AND LOW VOLTAGE INPUT POWER CIRCUITS ARE
DE-ENERGIZED AND LOCKED OUT BEFORE INSTALLING CABLES OR
MAKING ANY ELECTRICAL CONNECTIONS.
Danger!
EXERCISE EXTREME CARE WHEN HANDLING UPS AND BATTERY
CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL.
CABINETS WEIGH SEVERAL HUNDRED POUNDS.
Danger!
TEST LIFT AND BALANCE THE CABINETS BEFORE MOVING. MAINTAIN
MINIMUM TILT FROM VERTICAL AT ALL TIMES. THE BOTTOM STRUCTURE
WILL SUPPORT THE UNIT ONLY IF THE FORKLIFT FORKS ARE
COMPLETELY UNDERNEATH THE UNIT.
Danger!
OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION
OR SERVICE OF THE UPS OR BATTERIES. EVEN WITH THE BATTERY
CIRCUIT BREAKER IN THE OFF POSITION, THE DANGER OF
ELECTROCUTION MAY STILL BE PRESENT. THE BATTERY POWER TO THE
UNIT MUST BE LOCKED AND TAGGED “OFF” BEFORE PERFORMING ANY
SERVICE OR WORK ON THE UNIT. THE BATTERY MANUFACTURER’S
SAFETY INFORMATION AND MATERIAL SAFETY DATA SHEET IS LOCATED
IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UPS.
FAILURE TO FOLLOW THOSE INSTRUCTIONS AND THE INSTRUCTION
LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN
EXPLOSION, FIRE, EQUIPMENT FAILURE, OR ELECTROCUTION.

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1-3
Danger!
ALL POWER TO THE UNIT MUST BE LOCKED AND TAGGED “OFF” BEFORE
PERFORMING ANY SERVICE OR WORK ON THE UNIT. FAILURE TO DO SO
COULD RESULT IN ELECTROCUTION.
Danger!
EXTREME CAUTION IS REQUIRED WHEN PERFORMING MAINTENANCE.
LETHAL VOLTAGES EXIST WITHIN THE EQUIPMENT DURING OPERATION.
OBSERVE ALL WARNINGS AND CAUTIONS IN THIS MANUAL. FAILURE TO
COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH. OBTAIN QUALIFIED
SERVICE FOR THIS EQUIPMENT AS INSTRUCTED.
Danger!
BE CONSTANTLY AWARE THAT THE UPS SYSTEM CONTAINS HIGH DC AS
WELL AS AC VOLTAGES. WITH INPUT POWER OFF AND THE BATTERY,
DISCONNECTED, HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER
CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS. HOWEVER, POWER
CIRCUIT FAILURES CAN OCCUR, SO YOU SHOULD ALWAYS ASSUME THAT
HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN. VERIFY THAT
POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING
CONTACT.
Danger!
IN CASE OF FIRE INVOLVING ELECTRICAL EQUIPMENT, ONLY CARBON
DIOXIDE FIRE EXTINGUISHERS, OR THOSE APPROVED FOR USE ON
ELECTRICAL EQUIPMENT, SHOULD BE USED. USE OF WATER ON FIRES
INVOLVING LIVE HIGH VOLTAGE ELECTRICAL CIRCUITS COULD PRESENT
AN
ELECTROCUTION
HAZARD.
Danger!
SOME COMPONENTS WITHIN THE CABINETS ARE NOT CONNECTED TO
CHASSIS GROUND. ANY CONTACT BETWEEN FLOATING CIRCUITS AND
THE CHASSIS IS A LETHAL SHOCK HAZARD.

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1-4
Danger!
LEAD-ACID BATTERIES CONTAIN HAZARDOUS MATERIALS. BATTERIES
MUST BE HANDLED, TRANSPORTED, AND RECYCLED OR DISCARDED IN
ACCORDANCE WITH FEDERAL, STATE, AND LOCAL REGULATIONS.
BECAUSE LEAD IS A TOXIC SUBSTANCE, LEAD-ACID BATTERIES SHOULD
BE RECYCLED RATHER THAN DISCARDED.
DO NOT DISPOSE OF BATTERIES IN A FIRE, THE BATTERIES MAY
EXPLODE.
DO NOT OPEN OR MUTILATE THE BATTERIES. RELEASED ELECTROLYTE
IS HARMFUL TO THE SKIN AND EYES AND MAY BE TOXIC.
A BATTERY CAN HAVE A HIGH SHORT CIRCUIT CURRENT AND PRESENT A
RISK OF ELECTRICAL SHOCK. THE FOLLOWING PRECAUTIONS SHOULD
BE OBSERVED WHEN WORKING ON BATTERIES:
1. REMOVE WATCHES, RINGS OR OTHER METAL OBJECTS.
2. USE TOOLS WITH INSULATED HANDLES.
3. WEAR RUBBER GLOVES AND BOOTS.
4. DO NOT LAY TOOLS OR METAL PARTS ON TOP OF BATTERIES.
5. DISCONNECT CHARGING SOURCE PRIOR TO CONNECTING OR
DISCONNECTING BATTERY TERMINALS.
6 DETERMINE IF BATTERY IS INADVERTENTLY GROUNDED. IF SO,
REMOVE THE SOURCE OF THE GROUND. CONTACT WITH ANY PART OF
A GROUNDED BATTERY CAN RESULT IN ELECTRICAL SHOCK. THE
LIKELIHOOD OF SUCH SHOCK WILL BE REDUCED IF SUCH GROUNDS
ARE REMOVED DURING INSTALLATION AND MAINTENANCE.
7 LEAD-ACID BATTERIES CAN PRESENT A RISK OF FIRE BECAUSE THEY
GENERATE HYDROGEN GAS. THE FOLLOWING PROCEDURES SHOULD
BE FOLLOWED:
1. DO NOT SMOKE WHEN NEAR BATTERIES.
2. DO NOT CAUSE FLAME OR SPARK IN BATTERY AREA.
8 DISCHARGE STATIC ELECTRICITY FROM YOUR BODY BEFORE
TOUCHING BATTERIES BY FIRST TOUCHING A GROUNDED SURFACE.
Danger!
INTERNAL BATTERY STRAPPING MUST BE VERIFIED BY THE CUSTOMER
PRIOR TO MOVING THIS UNIT.
THIS UNIT CONTAINS NON-SPILLABLE BATTERIES. KEEP THE UNIT
UPRIGHT. DO NOT STACK. DO NOT TIP. ALWAYS FOLLOW THE BATTERY
MANUFACTURER’S SAFETY INFORMATION LOCATED IN A POCKET
ATTACHED TO THE INSIDE OF THE LEFT DOOR OF YOUR UPS TO PREVENT
AN ACCIDENT THAT COULD RESULT IN INJURY OR DEATH.

OnLine Power
2-1
SECTION 2 – OVERVIEW
2.1 INTRODUCTION
The Protector 3 UPS system is designed for switch mode power supplies, computer loads, with no
derating, drawing sine-wave input current that is power factor corrected. The Protector 3 meets or
exceeds life safety codes of UL1778. These codes were established to allow the UPS to provide power
during a power failure.
When input power to the Protector 3 is lost during a power outage, the system will automatically draw
power from its internal battery supply without any interruption. The critical load will receive only clean
sine wave power. The optional output transformer allows multiple output voltages as well as input
voltages that are different than output voltages. The internal VRLA (valve regulated lead-acid),
maintenance-free batteries provide specified time of backup power.
Upon restoration of input power, the Protector 3 automatically resumes normal operation, and
immediately begins to recharge the batteries.
The Protector 3 has an internal bypass circuit, which maintains the power to the load in case of internal
UPS failure.
The Protector 3 provides comprehensive monitoring capabilities. In addition to the LCD display, it
provides five dry relay contacts for remote monitoring capabilities. The Protector 3 contains, as standard
features, an AS 400, RS 232 protocol interface, RS485 data transmission ports and many other
communication options.
The Protector 3 is an on-line three phase PWM inverter available in output rating of 10, 15, 20, 25, 30, 40,
50, and 62.5 kVA. The Protector 3 is listed for compliance to UL1778, UL924A and CSA107.1 Standards.
The Protector 3 is available with an input or output voltages of 480Y/277 or 208Y/120 VAC, three phase.
This information is provided on the nameplate located on the inside front door of the UPS. See Appendix
A for a complete listing of the Protector 3 specifications.
ILLUSTRATION 2-1 PROTECTOR 3

OnLine Power
2-2
2.2 BENEFITS
Electrical disturbances can come from practically anywhere: from the incoming power lines and even from
within a building. Outside electrical disturbances include lightning strikes, utility switching, brown-outs,
and accidents. Electrical disturbances in a facility can be caused by load cycling (elevators, HVAC
systems, etc.), fault conditions, welders, and other electrically noisy equipment. Whether the electrical
disturbances are generated outside or within the facility, the following power problems can occur:
Complete power outages;
Brown-outs including momentary sags;
Voltage surges;
Transients including common-mode and transverse-mode noise;
Frequency shifts and fluctuations.
Sensitive equipment needs protection from power problems. Without power protection, users of sensitive
equipment may experience:
Loss of data;
Database corruption;
Rebuilding of files;
Equipment and component deterioration;
Premature equipment failures;
Unexpected equipment malfunctions;
Missed deadlines, especially during batch processing;
Loss of real time transaction processing;
Loss of employee productivity
It offers significant advantages over other alternatives.
The convection cooled, OnLine PWM inverter system, is virtually silent and can be installed anywhere.
On-line PWM technology provides switchover from utility to battery power without any interruption.
The Protector 3 is designed to fit the needs of virtually all power conditioning and UPS applications. It
has been designed to power all forms of modern data processing, communication, and process control
equipment. The Protector 3 does not require any de-rating, as other UPS products may, when powering
100% electronic loads including switching mode power supplies.
The Protector 3 protects sensitive electrical equipment, such as computer servers, telecommunication
networks, LANs, multi-user, and instrumentation systems from electrical interference including problems
associated with poor quality AC power sags and complete power outages.
2.3 PRODUCT FEATURES
The following describes the major blocks within the Protector 3. Please refer to Illustration 2-3
Subassembly Component Location to find specific items.

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2-3
2.3.1 Input Contactor K1 (Illustration 2-3, Item 20)
The input contactor is multifunctional. First, it provides connections for the input power to the UPS.
Secondly, the contactor disconnects the input line when an outage occurs so that there is no back feeding
of power into the power line. Finally, the contactor allows for automatic UPS operation upon a complete
discharge of the batteries. No operator intervention is required when power to the UPS is restored after a
complete battery discharge.
2.3.2 Input Transformer (T3) (Illustration 2-2, Item 2)
The input transformer adjusts the input voltage for proper rectifier DC voltage, depending on UPS rated
power and back-up capacity.
2.3.3 Battery Charger (Illustration 2.3, Electronics Tray)
The battery charger maintains the batteries at full charge. After a battery discharge, the charger will
automatically recharge the batteries upon restoration of input power. This circuit is on the Power Board.
2.3.4 Power Board Assembly with IGBT’s (Illustration 2.3, Item 3)
The Power Board is bolted onto the IGBT (Insulated Gate Bipolar Transistor) blocks that are mounted on a
heat sink. The complete Heat Sink Assembly with IGBTs and Power Board is replaceable as a single part.
This FRU (Field Replaceable Assembly) converts all the power, i.e. input AC power converted to DC bus,
battery power boosted to DC bus, and finally DC bus power converted to output AC power using PWM
technology for a smooth AC sine wave. In case of a catastrophic failure, the complete Heat Sink Assembly
is easily replaceable using only a screwdriver. The Power Board also contains the housekeeping power
supplies and drivers for the IGBTs. The entire assembly provides the landing place for all internal input,
output, DC cables and metering devices for control and monitoring of the unit input and output currents.
2.3.5 Control Board (Illustration 2.2, Item 10)
The microprocessor with unit specific firmware and control circuitry is located on the Control Board. The
Control Board is mounted on the cabinet door and communicates with the Power Board (A2) via a ribbon
cable. It monitors the input and output voltages and generates the command to close or open the input
contactor and to sense and change the status of the bypass static switch. The Control Board sends data to
the LCD panel located on the door where actual status and parameters are displayed. It additionally has
AS400, RS232 and RS485 output capabilities and supports various communication options.
2.3.6 Output Static Switch (Illustration 2.3, Item 18)
This SCR solid-state switch connects the output of the inverter (UPS) to the load. It is connected on the
primary side of the optional output isolation transformer. This switch shuts off in case of a problem or
failure within the UPS and transfers the load directly to the utility input via the bypass static switch. It
maintains its status opposite to that of bypass switch.
2.3.7 LCD Display Panel (Illustration 2.2, Item 11)
The LCD (Liquid Crystal Display) panel provides all the input, output, battery metering and alarm data, and
UPS status for customer use on a constantly scrolling set of 2 default screens with continuous update.

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2-4
2.3.8 Output Isolation Transformer (Illustration 2.2, Item 1)
The output isolation transformer provides isolation between the inverter and protected output. The power
to the primary of this transformer is received from UPS and is transformed to required output voltage
levels.
2.3.9 Maintenance Bypass Switch (Illustration 2.2, Item 28)
The MBS (Maintenance Bypass Switch) removes the UPS from the power grid providing utility input
directly to the load in case of a problem with the UPS.
2.3.10 Battery Bank – located in External Battery Cabinet(s)
The battery bank consists of sealed, maintenance-free batteries. The batteries provide emergency power
during power outages. The battery bank includes a breaker for over current protection and DC disconnect.
2.3.11 System Component Layout
ILLUSTRATION 2-2: COMPONENT LAYOUT

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2-5
ILLUSTRATION 2-3: SUB-ASSEMBLY COMPONENT LOCATION
1. Output Transformer (T1)
2. Auto-Transformer (T3)
3. Power Board Assembly (A1)
4. Input/Output/Battery/DC Buss
Terminal Block
5. Output Inductor (L2)
6. Diode Bridge
7. DC Choke (L4)
8. Input Inductors (L1)
9. High Frequency Noise Filter
Capacitors, Output and Battery
Power
10. Control Board (A2)
11. LCD Display Board
12. Output High Frequency Filter
(Optional) (C5, C6, C7)
13. Terminal Block to remove heat
sink assembly (TB4)
14. Control Power Transformer (T2A)
15. Fan Fuse (F3 - F6)
16. IGBT Heat Sink Assembly
17. Control Fuses (F2, F1)
18. Heat Sink (Bypass SCR)
19. Fan(s) (B1 - B6)
20. Input Contactor (K1)
21. Ground Terminal
22. Input Breaker (CB1)
23. Battery Breaker (CB2)
24. Output Breaker (CB3)
25. Output Distribution Breakers
(Optional)
26. Neutral Bus
27. Customer Input/Output
Connection Terminal Blocks
28. Maintenance Bypass Switch
(SW1)
29. SCRs and Snubbers
30. Contactor Coil Transformer (T5)
31. Fan Transformer (T4)
32. Inverter Test Switch
33. RS232 (Option)
34. TVSS (Option)
35. TVSS Fuse (Option)
36. 5 Form “C” Alarm Terminal
(Option)
37. MBS S –1 Toggle Switch

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2.4 FUNCTIONAL DESCRIPTION
Illustrations 2-4 thru 2-7 depict functional block diagrams of the Protector 3. These diagrams provide an
excellent tool for identifying the major building blocks within the Protector.
2.4.1 Main input circuit breaker - optional
The main input circuit breaker provides Protector 3 with incoming power isolation and input overcurrent
protection.
2.4.2 Input Contactor
Input contactor controls power applied to the unit. The microprocessor control circuit verifies that the UPS
is in “normal” and not at a “fault” condition and that the input voltage and frequency are within an
acceptable range. Only then it energizes the contactor closing coil via control transformer and fuse.
2.4.3 Input Inductors
The input inductors are a 3 phase input filter.
2.4.4 Inverter
When the AC input power is not available to power the load, the inverter converts the energy stored in the
battery bank to AC power to supply power to the load. The pulse width modulated (PWM) inverter utilizes
high speed, high efficiency IGBTs for fast response, sinusoidal power.
2.4.5 Battery charger
The battery charger converts AC power into regulated DC power to re-charge and to maintain the charge
on the battery bank. The charger is fully automatic with a current tapering feature so that battery damage
will be prevented in case of a charger malfunction or increased battery temperature. The charger is sized
to maintain a full charge even when the input voltage is at the low line limit for indefinite periods of time.
2.4.6 Battery
The battery bank, consists of 16, 24, 26 or 46, 12 Volt batteries, providing the reserve energy to sustain
the load when suitable AC input power is not present. The batteries are sealed, maintenance-free, VRLA
(Valve Regulated Lead Acid) construction.
2.4.7 DC Choke
The DC choke helps boost battery voltage to a higher internal DC bus voltage.
2.4.8 Output AC Inductor
The Output AC Inductor acts as a filter circuit component to reduce high frequency noise to the output
transformer.
2.4.9 Output Transformer
The Output Transformer performs two critical functions. First, it provides excellent common mode and
normal mode noise isolation of the load from the input or inverter power. Secondly, it provides voltage
transformation and tight regulation of the output voltage while the Protector is operating from its internal
inverter.

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2-7
2.4.10 Inverter Test Switch
The Inverter Test Switch is a momentary push button for testing the Protector #3 and its batteries for
proper operation. With Protector 3 in operation, test switch is pushed and held, the unit will automatically
transfer to battery operation. The UPS will continue to run on batteries until the switch is released. Upon
release, the Protector 3 transfers back from battery to inverter and resumes normal operation.
2.4.11 DC Supply Transformer
The step down transformer, protected with fuse supplies DC rectifier which produces voltages for power
system boards. The primary of this transformer has various taps that need to be matched to the actual
main input voltages.
2.4.12 Maintenance bypass switch
This MBS can be used for maintenance when the inverter fails or PM is required. This MBS will transfer
the input power directly to critical load. Before switching the MBS to maintenance position, first turn on S1
(toggle switch), then switch to maintenance (MAN) position. Refer to the operation label on the unit. After
repair or PM, the MBS can be switched to UPS position. First turn-off S1 (toggle switch), then switch MBS
to UPS (AUTO) position.
INPUT
CIRCUIT
BREAKER
TVSS
INPUT
CONTACTOR
Line removed when External Reserve Input Power is in use.
Optional
NOTE: Optional External Wrap-around Bypass Switch is available.
1
2
3
4
BATTERY
CIRCUIT
BREAKER
BATTERY
CABINET
OUTPUT
STATIC
SWITCH
CIRCUIT
BREAKER
AUX OUTPUT CBs
TB10
INPUT
XFMR
INPUT
POWER
3 PHASE
1
2
3
4
TB11
INPUT
MAINT.
BYPASS
SWITCH
OUTPUT
POWER
3 PHASE
INVERTER
STATIC
SWITCH
1
Use for different Input and Output Voltage unit.
2
1
2
OUTPUT
XFMR
N
N
Batt.
Cab 1
Batt.
Cab 2
Batt.
Cab 3
Batt.
Cab 4
Batt.
Cab 5
ILLUSTRATION 2-4: FUNCTIONAL BLOCK DIAGRAM FOR SINGLE INPUT POWER

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/ WYE
XFMR
INPUT
RESERVE
BYPASS POWER
From Internal
Transformer
RESERVE
INPUT
POWER
(plus Gnd)
GND
GND
MAIN
INPUT
DELTA
CIRCUIT
BREAKER
TVSS
INPUT
CONTACTOR
1
2
3
4
1
2
3
4
* Cabinet 1, 48 inch tall
OUTPUT
STATIC
SWITCH
CIRCUIT
BREAKER
1
2
3
4
1
2
3
4
TB10
INPUT
XFMR
1
2
3
4
TB11
INPUT
MAINT.
BYPASS
SWITCH
OUTPUT
POWER
3 PHASE
INVERTER
STATIC
SWITCH
CONTACTOR
1Optional External ∆- WYE XFMR
when the reserve is 3 wire Delta input.
OUTPUT
XFMR
1
(N)
Batt.
Cab 1
Batt.
Cab 2
Batt.
Cab 3
Batt.
Cab 4
Batt.
Cab 5
BATTERY
CIRCUIT
BATTERY
CABINET
ILLUSTRATION 2-5: FUNCTIONAL BLOCK DIAGRAM FOR DUAL DELTA INPUT POWER

OnLine Power
2-9
INPUT
CIRCUIT
BREAKER
TVSS
INPUT
CONTACTOR
Line removed when External Reserve Input Power is in use.
Optional
NOTE: Optional External Wrap-around Bypass Switch is available.
1
2
3
4
1
2
3
4
BATTERY
CIRCUIT
BREAKER
BATTERY
CABINET
OUTPUT
STATIC
SWITCH
CIRCUIT
BREAKER
AUX OUTPUT CBs
TB10
INPUT
XFMR
INPUT
POWER
3 PHASE
1
2
3
4
TB11
INPUT
MAINT.
BYPASS
SWITCH
OUTPUT
POWER
3 PHASE
RESERVE INPUT
POWER SOURCE
3
INVERTER
STATIC
SWITCH
CONTACTOR
1
Use for different Input and Output Voltage unit.
2
Reserve input voltage must be same as UPS output voltage.
3
1
2
OUTPUT
XFMR
N
N
N
Batt.
Cab 1
Batt.
Cab 2
Batt.
Cab 3
Batt.
Cab 4
Batt.
Cab 5
ILLUSTRATION 2-6: FUNCTIONAL BLOCK DIAGRAM FOR DUAL WYE INPUT POWER

OnLine Power
2-10
2.5 THEORY OF OPERATION
2.5.1 Standby Mode
After power is applied, the system is placed in STANDBY mode and a self-check starts. During this
period, the start subroutine checks for the input voltage and proper operation of the inverter and bypass
SCR’s. After the routine is completed and check confirmed OK, the system goes into the NORMAL mode.
2.5.2 Normal Mode
The input contactor K1 receives a closing signal, connecting input power to the DC supply transformer.
The DC rectifier supplies the battery charger, Control Board and the DC/AC inverter circuit. The battery
charger is then activated allowing the batteries to be continuously charged. The on-line DC/AC inverter
converts the DC voltage to a pulse-width-modulation (PWM) waveform. This waveform is filtered and
reconstructed back to a desired AC output.
2.5.3 Response To Input Power Failure
If the system controller senses a change in input frequency of more than +3 Hz or an out of range input
voltage, it will consider it an input failure and will immediately open the input contactor, isolating the UPS
from the facility. At the same time, the charger is turned off and the battery bank becomes a DC supply
source to the inverter circuit, maintaining an uninterrupted AC supply to the protected load. The LCD
screen will display a ”UPS PROBLEM” message. When the facility power returns, stabilizes and is in
phase with the backup power, the system controller closes the input contactor and the system returns to
NORMAL. If the battery voltage drops below 16% of its nominal value and the facility power remains off,
then the system will assume a FAILURE mode.
2.5.4 UPS Failure
The System controller will issue a FAILURE message on the LCD screen if any of the following conditions
happen:
•Internal failure
•System overheats
•Battery bank undervoltage
During a FAILURE, the system stops its backup operation, inverter SCRs are switched OFF, and bypass
SCRs are switched ON. A summary alarm 5V signal is sent to the hardwired interface. The system
remains in this mode until power is cycled or the system has been repaired when needed. (See page 3-6)
2.5.5 UPS Problem
The System controller will issue a UPS PROBLEM message on the LCD screen if any of the following
conditions occur:
•Input power failure
•Output overload
During a PROBLEM mode, inverter IGBs remain on and an alarm signal may be sent to the signal
interface. The system will reset itself as soon as the problem disappears.