Schrack Technik AVARA Multi USMLT60 User manual

USER MANUAL
UNINTERRUPTIBLE POWER SUPPLY
Series AVARA Multi
USMLT 60 - 125 kVA
3 phase input / 3 phase output
On Line / Double Conversion (VFI) Technology

2
INTRODUCTION
Thank you for choosing our product.
Our company is highly specialised in the development and production of uninterruptible power supplies (UPS).
The UPS device described in this manual is a high quality product that has been carefully designed and manufactured to
guarantee optimal performance.
This manual contains detailed instructions for product use and installation.
This manual must be stored in a safe place and CONSULTED BEFORE DEVICE USE for proper usage instructions
as well as maximum performance from the device itself.
NOTE: Some images contained in this document are for information purposes only and may not faithfully demonstrate the
parts of the product they represent
ENVIRONMENTAL PROTECTION
Our company devotes abundant resources to analysing environmental aspects in the development of its products. All our
products pursue the objectives defined in the environmental management system developed by the company in compliance
with applicable standards.
Hazardous materials such as CFCs, HCFCs or asbestos have not been used in this product.
Packaging is composed of RECYCLABLE MATERIALS. Dispose of all material in compliance with applicable standards in the
country in which the product is used. Refer to the following table to identify materials:
DESCRIPTION
MATERIAL
Pallet
Wood
(FOR)
Package box
Corrugated cardboard
(PAP)
Protective bag
High density polyethylene
(PE-HD)
Adhesive buffers
Low density polyethylene
(PE-HD)
Bubble wrap
DISPOSING OF THE PRODUCT
The UPS contains internal material which (in case of dismantling/disposal) are considered TOXIC AND HAZARDOUS
WASTE, such as electronic circuit boards and batteries. Treat these materials according to the laws in force, contacting
qualified centres. Proper disposal contributes to respect for the environment and human health.
© The reproduction of any part of this manual, even in part, is prohibited unless authorised by the Manufacturer.
The manufacturer reserves the right to change the product described at any time without prior notice for improvement purposes.

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CONTENTS
PRESENTATION 5
UPS VIEWS 6
FRONT VIEW 6
COMMUNICATIONS AREA VIEW 7
SWITCHES VIEW 8
REAR VIEW 9
CONTROL PANEL VIEW 10
UPS CONNECTIONS VIEW 11
USMLT60-80-100 CONNECTIONS 11
USMLT125 CONNECTIONS 12
SEPARATE BYPASS INPUT (OPTIONAL FOR USMLT60-80-100) 13
INSTALLATION 15
INSTALLATION SET-UP 15
UPS STORAGE 15
PRELIMINARY INFORMATION 15
ELECTROMAGNETIC COMPATIBILITY 16
INSTALLATION ENVIRONMENT 16
REMOVING THE UPS FROM THE PALLET 17
CONTENT CHECK 18
UPS POSITIONING 18
ELECTRICAL CONNECTIONS 19
CONNECTION CABLES SECTION 19
ARRANGEMENT OF THE CABLES AND INSERTION OF THE FERRITE TOROIDS 19
PRELIMINARY OPERATIONS FOR CONNECTION 20
HOOKUP INSTRUCTIONS 21
ELECTRICAL SYSTEM CONNECTION DIAGRAMS 22
PROTECTION DEVICES 25
SHORT-CIRCUIT PROTECTION 25
PROTECTION AGAINST BACK-FEED 25
INPUT LINE THERMAL MAGNETIC SWITCHES 25
BATTERY LINE 25
DIFFERENTIAL 26
OUTPUT LINE FUSES/THERMAL MAGNETIC SWITCHES 27
R.E.P.O. 27
EXTERNAL SYNC 28

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AUXILIARY CONTACTS 28
EXTERNAL TEMPERATURE SENSOR (OPTIONAL) 29
REMOTE PANEL (OPTIONAL) 29
AUXILIARY SOCKETS (OPTIONAL) 29
ENERGYSHARE 29
AUX OUTPUT 29
REMOTE MAINTENANCE BYPASS 30
USE 31
DESCRIPTION 31
FIRST START-UP AND ADDITIONAL SETTINGS 32
SWITCHING ON FROM THE MAINS 34
SWITCHING ON FROM THE BATTERY 34
SHUTDOWN 34
GRAPHIC DISPLAY 35
DISPLAY MENU 37
OPERATING MODE 38
MANUAL BYPASS (SWMB) 38
REDUNDANT AUXILIARY POWER ADAPTER FOR AUTOMATIC BYPASS 39
POWER WALK-IN 39
DERATING OF POWER FOR 200/208V NEUTRAL-PHASE LOADS 39
UPS CONFIGURATION 40
COMMUNICATION PORTS 42
RS232 AND USB CONNECTORS 42
COMMUNICATION SLOT 42
AS400 PORT 43
ACOUSTIC SIGNAL (BUZZER) 44
SOFTWARE 45
MONITORING AND CONTROL SOFTWARE 45
CONFIGURATION SOFTWARE 45
TROUBLESHOOTING 46
STATUS /ALARM CODES 50
TECHNICAL DATA 54

5
PRESENTATION
USMLT60 –80 –100 - 125 series UPS have been designed using currently available state of the art technology to ensure
maximum performance. The use of new control boards based on multiprocessor architecture (DSP + P) and of special
circuit solutions employing the latest generation of components has enabled us to achieve high performance such as:
➢ZERO IMPACT SOURCE: ensures low input distortion, power factor close to one and maximum compatibility with
the generator
➢BATTERY CARE SYSTEM: allows custom handling of batteries for different topologies and continuous monitoring
of the same, thus increasing efficiency and duration
➢SMART INVERTER: provides extraordinary efficiency even at low load rates and a stable output voltage and low
distortion even in the most extreme operating conditions

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UPS VIEWS
FRONT VIEW
Control panel with graphic display
Wheels for UPS handling
Front door with lock
Parking brakes

7
COMMUNICATIONS AREA VIEW
“R.E.P.O.” Remote Emergency Power Off
“COLD START” battery start-up button
“AS400” Contacts port
“USB” communication port
“RS232” communication port
“UPS Parallel Board” housing (optional)
Slot for communication accessory boards

8
SWITCHES VIEW
“SWIN” Input switch
“SWOUT” Output switch
“SWBYP” Separate bypass switch (optional)
“QN” Switch for service personnel use only
“SWMB” Manual bypass switch
Terminal cover (USMLT60-100) / bar cover
(USMLT125)

9
REAR VIEW
“EnergyShare / Aux Output” sockets (10A max.)
and relative protection (optional)
Power board fans
“MultiCOM 382 contacts board” accessory
housing
Battery charger fan

10
CONTROL PANEL VIEW
Mains operation LED
•On steady: mains operation with good bypass line and synchronised inverter
•Flashing: mains operation with bad or disabled bypass line and/or non-synchronised inverter
•Flashing in standby: programmed restart function active and mains present
Battery operation LED
•On steady: battery operation
•Flashing: battery operation with early low battery or imminent shutdown warning
•Flashing in standby: programmed restart function active and mains absent
Load on bypass LED
•On steady: load powered from bypass line
Standby/alarm LED
•On steady: alarm present
•Flashing: standby mode
Replace batteries LED
•On steady: replace batteries
•Flashing: batteries overvoltage alarm
ECO mode LED
•On steady: ECO mode configuration active
Graphic display
F1, F2, F3, F4 = FUNCTION KEYS. Each key's task can be found on the lower part of the display and varies
according to menu.

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UPS CONNECTIONS VIEW
USMLT60-80-100 CONNECTIONS
Removing the terminal cover panel to access the UPS terminal board:
BATT (+ -)
Power connections: (+) and (-) BATTERY
INPUT (L1 L2 L3)
Power connections: INPUT PHASES
BYPASS (L1 L2 L3)
Power connections: SEPARATE BYPASS PHASES (optional)
OUTPUT (L1 L2 L3)
Power connections: OUTPUT PHASES
N
Power connections: N BATTERY, N INPUT, N BYPASS, N OUTPUT
PE
Power connections: GROUND
A1 - A2
Connection for external synchronization signal
A3 - A4
Connection for remote auxiliary maintenance bypass
A5 - A6
Connection for remote auxiliary output switch
EXT BATT TEMP
Connection for external battery temperature probe

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USMLT125 CONNECTIONS
Remove the bar cover to access the UPS's connections:
BATT (+ -)
Power connections: (+) and (-) BATTERY
INPUT (L1 L2 L3)
Power connections: INPUT PHASES
BYPASS (L1 L2 L3)
Power connections: SEPARATE BYPASS PHASES
OUTPUT (L1 L2 L3)
Power connections: OUTPUT PHASES
N
Power connections: N BATTERY, N INPUT, N BYPASS, N OUTPUT
PE
Power connections: GROUND
EXT SYNC [A1 –
A2]
Connection for external synchronization signal
SERVICE BYP
Connection for remote auxiliary maintenance bypass
AUX SWOUT
Connection for remote auxiliary output switch
EXT BATT TEMP
Connection for external battery temperature probe

13
SEPARATE BYPASS INPUT (OPTIONAL FOR USMLT60-80-100)
THE "DUALINPUT" UPS SERIES VERSION PRESENTS THE BYPASS LINE SEPARATE FROM THE INPUT LINE.
The UPS series with Separate Bypass allows a separate connection between the input line and the bypass line.
The UPS output will be synchronized to the bypass line in such a way that there will not be any incorrect switching between
push-pull voltages in the event of automatic bypass intervention or manual bypass (SWMB) closing.
THE USMLT125 CAN BE CONFIGURED EITHER AS DUAL INPUT OR WITH BYPASS CONNECTED TO THE INPUT
LINE.
See the followingimages for how to hook it up in either case
USMLT125 - BYPASS CONNECTED TO INPUT LINE
USMLT125 –DUAL INPUT

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15
INSTALLATION
INSTALLATION SET-UP
ALL OPERATIONS DESCRIBED IN THIS SECTION MUST BE PERFORMED BY QUALIFIED
PERSONNEL ONLY.
Our Company assumes no liability for damages caused by incorrect connections or operations not
contained in this manual.
UPS STORAGE
The storage site must meet the following requirements:
Temperature:
-25°÷60°C
Degree of relative
humidity:
30÷95% max
PRELIMINARY INFORMATION
UPS Models
USMLT60
USMLT80
USMLT100
USMLT125
Nominal power
60kVA
80kVA
100kVA
125kVA
Operating temperature
0 - 40 °C
Max relative humidity in operation
90 % (without condensation)
Max installation height
1000 m at nominal power
(-1% power for every 100 m above 1000 m)
max 4000 m
Net dimensions
(W x D x H)
500 x 850 x 1600 mm
650 x 830 x 1600 mm
Shipping
dimensions
625 x 900 x 1720 mm
780 x 945 x 1745 mm
Net weight
190 kg
200 kg
220 kg
250 kg
Shipping weight
214 kg
224 kg
244 kg
274 kg
Power loss at nominal resistive
load (pf=0.9) and with charged
batteries (1)
2.61 kW
2245 kcal/h
8910 B.T.U./h
3.65 kW
3140 kcal/h
12460 B.T.U./h
4.75 kW
4074 kcal/h
16170 B.T.U./h
5,32 kW
4575 kcal/h
18160 B.T.U./h
Installation site fan flow rate for
heat removal (2)
1400mc/h
2000 mc/h
2600mc/h
3100 mc/h
Current dispersed to ground (3)
< 300 mA
Degree of protection
IP20
Cable input
at bottom rear
(1) 3.97 B.T.U./h = 1 kcal/h
(2) Use the following formula to calculate air flow: Q [mc/h] = 3.1 x Pdiss [kcal/h] / (ta - te) [°C]
Pdiss is power dissipation expressed in kcal/h in the installation site for all installed equipment.
ta= room temperature, te=external temperature. Increase the value derived by 10% to account for losses.
An example of flow is shown in the table, with (ta - te)=5°C and with nominal resistive load (pf=0.9).
Notes: The formula applies when ta > te ; if not, the installation requires a conditioner).
(3) The load dispersion current is added to that of the UPS on the ground protection conductor.

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ELECTROMAGNETIC COMPATIBILITY
This UPS complies with applicable EMC (Category C3).
ATTENTION:
This product is designed for second environment* commercial and industrial applications - it may be necessary during
installation to introduce certain restrictions and take additional measures to prevent disturbances.
Connection to USB and RS232 connectors must be made with the supplied cables or, however, with shielded cables that
are no longer than 3 metres.
(*) Type of environment defined in EMC regulations
INSTALLATION ENVIRONMENT
When selecting the installation site of the UPS and any Battery Boxes, observe the following notes:
▪avoid dusty environments
▪ensure that flooring is flat and able to sustain the weight of the UPS (and Battery Boxes)
▪avoid environments that are too narrow which might prevent normal maintenance operations
▪relative humidity must not exceed 90%, without condensation
▪verify that the room temperature, with the UPS in operation, is maintained between 0 and 40°C
The UPS is able to operate at a temperature between 0 and 40°C. The recommended operating
temperature for the UPS and the batteries is between 20 and 25°C. The actual operating life of the
batteries is 5 years on average at an operating temperature of 20°C. If the operating temperature
reaches 30°C, the operating life is halved.
▪avoid positioning the UPS in places which are exposed to direct sunlight or to hot air
To maintain installation room temperature in the above indicated range, waste heat disposal should be provided for (the
value of kW/kcal/h/ B.T.U /h dissipated by the UPS is shown in the table on the previous page). Methods which can be used
include:
▪natural ventilation
▪forced ventilation, recommended if the external temperature is lower (e.g. 20°C) than the temperature at which you
want to operate the UPS and/or the Battery Box (e.g. 25°C)
▪air conditioning system, recommended if the external temperature is higher (e.g. 30°C) than the temperature at
which you want to operate the UPS and/or the Battery Box (e.g. 25°C)

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REMOVING THE UPS FROM THE PALLET
ATTENTION: FOLLOW THE INSTRUCTIONS BELOW TO AVOID PERSONAL INJURY
AND/OR EQUIPMENT DAMAGE.
SOME OF THE FOLLOWING OPERATIONS REQUIRE THE INTERVENTION OF TWO
PEOPLE
▪Cut straps and remove from the cardboard
box. Remove the packaging material.
▪Remove the accessories container.
NOTE: the accessories box may be located
inside the packaging or behind the UPS
door.
▪Remove the 2 brackets fastening the UPS to the pallet,
unscrewing the type A and B screws.
▪The previously removed brackets can also to be used as slides. Fasten the slides to the pallet with the use of type A
screws, taking care to align the two wheels.
▪If necessary, unblock the front wheel brakes
▪Ensure that the door is fully closed.
▪ATTENTION: it is advisable to bring the UPS down by pushing from the rear, using great care and
accompanying it as it moves down. Given the weight of the equipment, this requires the work of two people.
NOTE: retain all packaging materials for future use

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CONTENT CHECK
It is first necessary to check the contents after the packaginghas been opened:
steel slide, warranty card, instructions manuals, safety manual, inspection certificate, serial connection cable, keys for door
lock.
UPS POSITIONING
When positioning, take into account that:
▪the wheels are only to be used for accurate positioning, so for short trips
▪plastic parts and the door are not able to act as pushing points or handles
▪you will need to ensure at least enough free space in front of the equipment to allow for start/stop operations and
maintenance ( 1.5 m )
▪the upper part should be at least 50cm from the ceiling to allow for maintenance operations
▪the rear of the UPS must be placed at least 30 cm from the wall for proper air flow blown from air vents
▪no objects should rest on the upper part of the UPS
After positioning, block the device by means of the front wheel brakes (see “Removing the pallet").
In earthquake zones or on mobile systems, it is possible to reuse the brackets for pallet fastening (slides) to anchor the UPS
to the floor (see figure below). These brackets are not necessary in normal conditions.

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ELECTRICAL CONNECTIONS
CONNECTION CABLES SECTION
Refer to the following table for the sizing of input, output and battery cables:
Sezione cavi (mmq) (1)
INPUT
network / separate bypass (optional)
OUTPUT
EXTERNAL BATTERY (2)
kVA
PE
L1/L2/L3
N (3)
PE
L1/L2/L3
N (3)
PE
+/-
N
60
25
35
35
25
35
35
25
50
50
80
35
50
50
35
50
50
35
70
70
100
50
70
70
50
70
70
50
120
120
125
50
95
95
50
95
95
50
150
150
(1) The sections contained in the table refer to a maximum length of 10 m (cable type N07V-K in clear air)
(2) The maximum length of the connection cables to the Battery Box is 10 metres
(3) In the case of non-linear loads, oversize neutral line N by 1.7 times the phase line
Note USMLT60: the maximum section of the cables that can be inserted in the terminal board is equal to 50 mm2 (flexible
and rigid cables)
USMLT80: the maximum section of the cables that can be inserted in the terminal board is equal to 95 mm2 (flexible
and rigid cables)
USMLT100 : the maximum cross-section of the cables toinsert into the terminals is 95 mm² forthe PHASES and 150
mm² for the batteries (flexible and rigid cables).
USMLT125: the cables must be fitted with crimp headers for M8 bolts.
ARRANGEMENT OF THE CABLES AND INSERTION OF THE FERRITE TOROIDS
It is recommended to wire the power cables routing them from the back, under the UPS, tothe front of the machine, ensuring
they come up in the terminal area.
Insert the ferrite toroids supplied as shown below (NOTE: ferrites cannot be fitted to the USMLT125)
USMLT60
▪Insert 3 toroids into the cable bundle [L1, L2, L3, N] INPUT
▪Insert 3 toroids into the cable bundle [L1, L2, L3, N] OUTPUT.
▪Arrange the cables so that the toroids are positioned under the
base of the UPS or close to it.
USMLT80 –USMLT100
▪Insert 4 toroids into the cable bundle [L1, L2, L3, N] INPUT.
▪Insert 4 toroids into the cable bundle [L1, L2, L3, N] OUTPUT.
▪Arrange the cables so that the toroids are positioned under the
base of the UPS or close to it.

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At the bottom of the units is a holed bar that can be used for a steady anchor for the cables by means of appropriately
sized clamps.
Notes:
- Tighten down the clamp only after securing the cables to their terminals/bars.
- Preform the cables so that the terminals/bars are not stressed when you tighten down the clamp.
PRELIMINARY OPERATIONS FOR CONNECTION
The following operations are to be performed with the UPS disconnected from the power mains, off
and with all equipment switches open. Before making the connection, open all machine switches and
verify that the UPS is completely isolated from power sources: batteryand AC power line. In particular,
check that:
- the UPS input line is completely disconnected
- the external UPS battery line switch/fuses are open
- all UPS switches: SWIN, SWBYP, SWOUT and SWMB in the open position
- check with a millimetre that there are no dangerous voltages
The first connection to be made is the protective conductor (earth wire), to be connected to the screw
marked PE. The UPS must operate while connected to the earthing system.
The input Neutral must always be connected.
ATTENTION: a three-phase four-wire distribution system is required.
The standard UPS version must be connected to a 3 Phase + Neutral + PE (ground protection) TT, TN
or IT type power line. Comply with phase rotation
TRANSFORMER BOXES (optional) are available to convert distribution systems from 3-wire to 4-wire.
ATTENTION: in the event of non-linear three-phase loads, the Neutral conductor (N) current can reach
a value up to 1.7 times that of the phase current. Properly size the Input/output Neutral line keeping
this fact in mind.
Carefully read instructions contained in the Battery Box manual before connecting batteries.
Check that battery voltage is the same as allowed by the UPS (consult the Battery Box data plate and
the UPS manual)
ATTENTION: the maximum length of the connection cables to the Battery Box is 10 metres