Powervar 3200 Series User manual

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A55-00033 Rev. E December 2015
3200 Series User’s Manual

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A55-00033 Rev. E December 2015

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A55-00033 Rev. E December 2015
Table of Contents
1. Introduction and Safety
Important Safety Instructions……………………………………………………………………5-7
Note to Users…………………………………………………………………………………….8-9
2. Installation
UPS Unpacking Instructions………………………………………………………………….10-12
UPS Installation…………………………………………………………………………………13
Clearance Guide……………………………………………………………………………........14
Wiring Guide…………………………………………………………………………..……….,15
UPS Connector Terminals and Lug locations……………………………………………….16-19
3. Product Specifications
3200 Series Product Specifications…………………………………………………………..21-22
4. Operation
UPS Operational Overview………………………………………………………………….23-24
UPS Operation: Normal Mode………………………………………………………………….24
UPS Operation: Battery Mode………………………………………………………………….25
UPS Operation: Bypass Mode………………………………………………………………….26
UPS Operation: Emergency Bypass………………………………………………………........27
UPS Operation: Manual Maintenance Bypass Mode……………………………………..........28
Touch Screen Description, Calibration, Using the Touch Screen.......…………………………29
Touch Screen Descriptions (Monitoring)………………………………………………………30
UPS Startup Sequence………………………………………………………………………31-35
UPS Shutdown Sequence…………………………………………………………………...36-38
UPS Maintenance Bypass Sequence………………………………………………………..38-45
Monitor Functions…………………………………………………………………………..46-47

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A55-00033 Rev. E December 2015
Control Functions………………………………………………………………………….48-62
Touch Screen Menu’s………………………………………………………………..…….63-80
5. Maintenance
UPS Maintenance…………………………………………………………………………..82
Battery Maintenance………………………………………………………………………..83
Battery Replacement…………………………………………………………………….....84-97
6. Warranty
Product Warranty…………………………………………………………………………..99-100
7. Service and Troubleshooting
Alarm Severity Definitions…………………………………………………………….......102
Alarms Messages…………………………………………………………………………..103-106
8. Drawings
UPS Outline Drawings………………………………………………………………………108
Block Diagram (UPS + External Battery Cabinet)………………………………………….109
Block Diagram (UPS + Input Transformer Cabinet)………………………………………..110
Block Diagram (UPS + Output Transformer Cabinet)………………………………...........111
Block Diagram (UPS + Input/Output Transformer)……………………………………..….112
Block Diagram (UPS + 3 Breaker MBS)……………………………………………….…...113
Block Diagram (UPS + 3 Breaker MBS + Input Step-Down Transformer)………….…….114
Block Diagram (UPS + 3 Breaker MBS + Output Isolation Transformer)………………....115
Block Diagram (UPS + 3 Breaker MBS + Input/Output Transformers)……………............116
Facility Data Planning Guide………………………………………………………………..118

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A55-00033 Rev. E December 2015
1. Introduction and Safety

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A55-00033 Rev. E December 2015
****IMPORTANT SAFETY INSTRUCTIONS****
****SAVE THESE INSTRUCTIONS****
This manual contains important instructions to be followed during installation and maintenance of the
UPS and batteries.
Please read all instructions before installing or operating the described equipment and
PLEASE SAVE THIS MANUAL FOR FUTURE REFERENCE!
SPECIAL SYMBOLS: The following are examples of symbols used on the UPS, or within this manual to
alert you to important information. Please familiarize yourself with these symbols.
Risk of Electric Shock- observe the warnings associated with the risk of electrical
shock.
CAUTION: HOT SURFACE – Do not touch! Risk of burn hazard.
CAUTION: REFER TO OPERATOR’S MANUAL—refer to operator’s manual for
additional information, such as specific operating and/or maintenance instructions.

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A55-00033 Rev. E December 2015
Do Not Discard--this equipment utilizes components that contain lead and must be
disposed of properly. For more information, contact your local recycling/refuse or hazardous waste
center.
Do Not Discard-- never discard Waste Electrical or Electronic Equipment (WEEE) in the
trash. For proper disposal contact your local recycling/refuse or hazardous waste center.
Information of Special Note--Specific handling or operational instructions may apply.
Phase--This is the electrical symbol for the word “phase”.
Recycle—equipment or components are made of recyclable material, please contact
your local recycling center for proper disposal.

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A55-00033 Rev. E December 2015
NOTE TO USERS
To ensure correct operation of the UPS, please read this instruction manual carefully. Please
keep this manual handy for future reference.
IMPORTANT INFORMATION FOR USERS OF
THIS UNINTERRUPTIBLE POWER SUPPLY
1. Before operating the UPS or connecting any load equipment, please ensure the UPS
is connected to a properly grounded electrical supply.
2. This UPS has dangerously high voltages on both its input and output connections.
Contact with these voltages may be life threatening.
3. Please do not disassemble the covers. There is a risk of electric shock.
4. In an emergency, immediately turn off the circuit breaker for the circuit supplying
power to the UPS. Also immediately turn off the battery circuit breaker.
5. This UPS has two power sources. One is the circuit supplying the UPS with input
power. The other is the UPS battery. Prior to any maintenance, both of these power
sources must be disconnected to ensure that the UPS is de-energized. If only the
input power is disconnected, the UPS can still operate from the battery, and
hazardous voltages may still exist.
6. To prevent damage or a safety hazard, keep the UPS away from open flame and
any other devices that may cause sparks.
7. Do not open or damage individual battery cases as spillage of caustic electrolyte
may occur resulting in danger to life, safety, and the environment.
8. The charging characteristics of UPS batteries vary by both brand and type. For this
reason, replacement batteries should be of the same brand and type as those
specified by the manufacturer. Using batteries other than the brand and type
specified by the manufacturer may affect the performance of the UPS. Before
installing batteries of different brand or type, please consult with the manufacturer.
9. The UPS has an internal EMI filter for purposes of enhancing electromagnetic
compatibility with the input mains supply. This filter produces leakage current to
earth on the input mains. When selecting a circuit breaker for the branch circuit
This UPS has dangerously high voltages on both its Input
and output connections. Contact with these voltages may
be life threatening. Please follow the operating instructions
carefully. Please give close attention to the warnings in this
manual and those posted on the UPS. There are no user
serviceable parts inside the UPS. Disassembly and/or
maintenance should only be done by authorized personnel.

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A55-00033 Rev. E December 2015
supplying power to the UPS, ensure that the breaker selected is not an ELCB type
circuit breaker that detects earth leakage current.
10. Please contact the manufacturer or an authorized distributor for any assistance
with troubleshooting.
11. The UPS should only be serviced or maintained by a factory authorized service
technician.
12. This UPS meets FCC Class A electromagnetic compatibility requirements.
13. Depleted batteries must be disposed of in a proper manner. Contact your local
recycling or hazardous waste center or the UPS manufacturer for instructions
concerning proper disposal.

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A55-00033 Rev. E December 2015
2. Installation

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A55-00033 Rev. E December 2015
UPS Unpacking Instructions
The POWERVAR 3200 Series comes packed in heavy cardboard with foam
dividers on a heavy wooden pallet. The unit is bolted to the skid with two metal brackets. A
wooden ramp is stored vertically in front of the UPS. This ramp is used to move the UPS off of
its shipping pallet.
Note: POWERVAR encourages the end user to retain all shipping
materials until the UPS has been inspected, installed and verified for proper operation.
The POWERVAR 3200 Series UPS utilizes internal batteries which are pre-assembled in
individual trays and shipped separately from the UPS. These trays come completely wired and
ready for connection to the internal battery harness of the UPS. A quick visual inspection is
requested to determine if any connections were unseated during the shipping process.
Unpacking the UPS requires a 19mm wrench or socket. To remove the UPS from the packing
materials:
1. Visually inspect the unit for any signs of transit damage (Fig. 2-1). Remove and retain all
associated paperwork (packing list, user’s manual etc.) that is affixed to the top of the
unit. Remove the cardboard lid from the top of the container.
2. Remove any fasteners from the lower edge of the cardboard container.
3. With the help of an assistant, carefully lift the heavy cardboard container straight up until
it is clear of the UPS. (Fig. 2-2)
4. Remove the foam dividers. (Fig. 2-3)
5. Lift the ramp clear of the alignment pin, and place it sloping downward at the front of the
UPS, using the pin to hold the back of the ramp in place.
6. Remove the protective plastic cover from the UPS.
7. The UPS is attached to the shipping pallet with two shipping brackets—one on each side
of the UPS. Using an adjustable wrench or 19mm socket, remove the three bolts that
attach the bracket to the UPS. If your location has a Seismic requirement, please contact
factory for Seismic installation instructions. (Fig. 2-4)
8. The UPS has two leveling feet. Be sure to check that the levelers are up against the
bottom of the UPS to ensure it rolls freely on the ramp.

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A55-00033 Rev. E December 2015
9. With the help of an assistant, carefully roll the UPS off the pallet and down the ramp to
the floor of your facility. If the floor at your desired UPS location is uneven, the levelers
may be used to steady the UPS, once it is in place.
Please do not install batteries in the UPS. Batteries should be installed ONLY
by factory authorized personnel once the UPS is in its final location, and at the
time of initial startup.
Fig. 2-1 Fig. 2-2 Fig. 2-3
Fig. 2-4
Shipping
bracket
bolts (3
per side)
UPS
Leveler

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UPS Installation
The installation of this UPS should be performed only by
qualified personnel who are familiar with UPS and battery systems and
the required precautions necessary for safe and proper installation.
Unauthorized and /or unqualified personnel should not attempt to install
or service this equipment. Any damage resulting from installation or
service performed by unauthorized/unqualified personnel, or non-
compliance with any pertinent local codes will void the warranty of
this equipment.
Maximum operating ambient temperature is 40°C
Storage (non-operating) ambient temperature range is -20°C to 60°C
Please consult the Facility Data Planning Guide for floor loading and unit cooling characteristics.
The levelers are not designed to support the weight of the entire unit, they are to be used when
the floor is not entirely level.
CAUTION: Please confirm that the AC Input switch and the Battery Disconnect
switch are in the “Off” position, and the Manual Maintenance Bypass is in the “Normal”
position, before making any connections to this UPS.
The POWERVAR 3200 Series requires a 208V three phase, four wire (+ ground) input for
proper operation. Input over current protection and the output disconnect are to be
provided by the user. The Facility Data Planning Guide is available as a guideline to assist with
the installation of the UPS. This document however, is not intended as a substitute or to
supersede any regional or local electrical codes. In the event of questions or controversy
regarding the installation of this equipment, the local Authority Having Jurisdiction (AHJ)
should always be consulted and will have the ultimate final approval over the installation.

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POWERVAR 3200 Series Clearance Guide
Location
Minimum Clearance (Inches)
Top (Above) of Cabinet
36
Front of Cabinet
36
Rear of Cabinet
12
Sides of Cabinet
6*
*Matching peripheral cabinets are considered to be part of the UPS system, so the 6”
spacing should be taken from the outside edge of the peripheral cabinet.
POWERVAR
3200 SERIES
UPS
12 Inches
6 Inches6 Inches
36 Inches
Front of UPS
Minimum Clearance Guidelines

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The following steps refer to bottom feed installations only.
Once the UPS has been properly unpacked (see page 9) and placed in its installation location,
the leveling feet must be lowered. These levelers are located in the front of the unit below the
door.
POWERVAR recommends the following overcurrent device (provided by customer) to be used
as the electrical supply (input) to the 3200 Series UPS:
UPS Model
(kVA)
External
Overcurrent
Protection*
Recommended
Wire Size
Terminal Wire
Range
(Min. – Max.)
Tightening
Torque
(Min. – Max.)
10 35A #8 AWG
#16 to # 0
AWG**
2.8 Nm (min) /
3.0 Nm (max)
20 70A #4 AWG
#16 to # 0
AWG**
2.8 Nm (min) /
3.0 Nm (max)
30 110A #1 AWG
#1 AWG to**
350 kcmil
#1 to 350 = 375
In-lbs.
40 150A #2/0 AWG
#2/0 AWG to**
350 kcmil
#1/0 to 350 = 375
In-lbs.
Gnd. (All
models)
#6 AWG #6 -2/0 AWG** 120 In-lbs.
* To be provided by customer ** 75°C min. rated CU conductors only
The terminals for input and output connections to the UPS are accessed by opening the hinged
front door of the UPS (Fig.2.6) Firmly grab the left hand side of the door and pull outward. The
magnetic keepers will release and the door will open exposing the flat front of the UPS (Fig.2.7).

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Fig. 2-6 Fig. 2-7
UPS-front view UPS – front view with door open
Once opened, the connection terminals can be accessed by removing the screws holding the
terminal safety cover in place (Fig 2.8). This cover is located just below the three rotating
handles used for the operation of the UPS. (Their operation is described elsewhere in this
manual)
Fig. 2-8
UPS-front view with door opened and terminal safety cover removed

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The terminals to accommodate the input and output conductors are laid out as follows (Fig. 2.9):
L1 L2 L3 N T1 T2 T3 N Pos. Batt.
Neut. Neg.
AC MAIN INPUT
TB1 UPS OUTPUT TB2 TB3
AC Input
OFF
ON
Maintenance Bypass
NORMAL BYPASS
Battery Disconnect
OFF
ON
Fig. 2-9
As shown above, the input (LINE or “L” designated terminals) conductors are connected to the
(L-R) first four terminals. This UPS will not operate without an incoming neutral conductor. The
required input phase rotation is ABC. The output (LOAD or “T” designated terminals)
conductors are connected to the (L-R) next four terminals. In all cases the conductors should
enter the enclosure from the bottom and enter the lugs or terminals from the bottom.All
conductors entering this terminal area must be kept to the left of the barrier separating terminal
TB2 from TB3.
The grounding locations are marked with the following symbols:
Protected Earth (Input) Earth (Output)

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Top side of terminal-
To Internal UPS wiring
Bottom side of Terminal-
To customer wiring
10/20kVA Terminal
30/40 kVA Lug
Care should be taken when installing these conductors so as to not confuse the
input (LINE) and output (LOAD) phase conductors. Keeping in mind this UPS requires an input
neutral for proper operation. Once all conductors are properly landed and sufficiently tightened
to their respective torque specs, the terminal safety cover may be reinstalled.

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Terminal safety cover must be installed prior to operation of the UPS.
POWERVAR recommends a disconnecting means with the following overcurrent ratings
(provided by customer) to be used as the electrical supply (output) from the 3200 Series UPS to
the critical load:
UPS Model
(kVA)
External
Overcurrent
Protection*
Recommended
Wire Size
Terminal Wire
Range
(Min. – Max.)
Tightening
Torque
(Min. – Max.)
10 35A #8 AWG
#16 to # 0
AWG**
2.8 Nm (min) /
3 Nm (max)
20 70A #4 AWG
#16 to # 0
AWG**
2.8 Nm (min) /
3 Nm (max)
30 110A #2 AWG
#4 AWG to**
350 kcmil
#1 to 350 = 375
In-lbs.
40 150A #1/0 AWG
#1 AWG to**
350 kcmil
#1/0 to 350 = 375
In-lbs.
Gnd. (All
models)
#6 AWG #6 -2/0 AWG** 120 In-lbs.
* To be provided by customer ** 75°C min. rated CU conductors only

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3. Product Specifications