Tycor-ups Ty-borealis series User manual

Ty-Borealis Series

Three Phase ELI System

8 KW – 48 KW

OperatorsManual

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

Dear Customer,

Thank you for selecting our emergency lighting inverter (ELI). Weare

pleased to include you as one of our valued Tycor UPS customers!

Weare confident that this emergency lighting inverter system, developed

and manufactured in our ISO 9001 certified facilities, will provide the quality

and satisfaction you demand.

Please read this installation manual carefully as it contains the necessary

information required to install the ELI properly.

Thank you for choosing Tycor UPS.

NOTE

The instructions contained in this manual are not intended to cover all of the

details or variations in equipment, or to provide for every possible contingency

to be met in connection with installation, operation, or maintenance. Should

further information be desired or should particular problems arise which are not

covered sufficiently for the purchaser’s purposes, the matter should be referred

directly to Tycor UPS.

Any electrical or mechanical modifications to this equipment, without prior

written consent of Tycor UPS, will void all warranties and may void UL/cUL

listing. Unauthorized modifications may also result in personal injury, death,

and damage to the equipment.

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

Preface

Congratulations on your choice of our emergency lighting inverter (ELI).

This equipment has been manufactured and tested using methods and procedures

equivalent to

UL 924.

This manual describes the recommended procedures for installing the ELI.

While every effort has been made to ensure the completeness and accuracy of this manual,

Tycor UPS assumes no responsibility or liability for any losses or damages resulting from

the use of the information contained in this document.

We recommend that this manual be kept with the ELI for future reference. If any problems

are encountered with the procedures contained in this manual, please contact our Service

Centre before proceeding.

This document may not be copied or reproduced without the explicit written permission of

Tycor UPS.

Due to technical advancements and improvements, some of the information contained in

this manual may be changed or modified without prior notice.

iii

WARNING: This manual is intended to provide installation instructions

only. The information contained in this manual is to be used as a guideline

and recommendation only. Only qualified personnel should perform

installation and maintenance. Factory authorized personnel shall inspect

installation prior to start up and commissioning to validate warranty.

Failure to follow this directive will void the warranty.

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

Symbols

The following symbols are used through out this manual.

WarningInformation

Electrical Hazard

Electrical Symbols

Protective grounding terminal; a terminal that must be connected to ground prior to

making any other connection to the equipment.

A terminal to/from which an alternating current or voltage may be applied/supplied.

A terminal to/from which a direct current or voltage may be applied/supplied.

This symbol indicates the word “phase”.

This symbol indicates an electrical hazard may be present.

This symbol alerts you to important information.

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

SafetyInstructions

READ AND FOLLOW ALL SAFETY INSTRUCTIONS.

SAVE THESE INSTRUCTIONS.

This manual contains important safety instructions that should be followed during installation

and maintenance of the ELI system and optional packages. Before the installation

process

begins, we recommend that the installer read through the safety precautions,

operators

manual and the option installation instructions, taking all necessary safety precautions

protect themselves and the equipment being installed.

GENERAL

Move the ELI in an upright position, in its original packaging, to its final destination.

To lift the cabinets, use a forklift or lifting belts with spreader bars.

Check for sufficient floor and elevator loading capacity.

Check the integrity of the ELI equipment carefully.

If visible damage is evident, do not attempt to install or start the ELI. Contact the

transport delivery company immediately, file a claim with the transport company

and

inform Tycor UPS directly.

Do not use outdoors.

The use of accessory equipment not recommended by Tycor UPS may cause an unsafe

condition

WARNING! RISK OF ELECTRICAL SHOCK: use extreme caution when removing

covers.

All maintenance and service work should be performed by qualified and trained service

personnel. The ELI may contain its own energy source, (batteries) which can

dangerous to the untrained person. This ELI contains potentially hazardous voltages

The field-wiring terminals may be electrically live, even when the ELI is not connected to

the utility.

Use caution when servicing batteries. A battery can present a risk of electrical shock,

burn from high short-current. Battery acid can cause burns to skin and eyes. If acid is

spilled on skin or in eyes, flush with fresh water and contact physician immediately.

When replacing batteries use the same number and type (sealed-cell lead acid).

Proper disposal of batteries is required. Refer to your local codes for disposal

requirements.

Dangerous voltages may be present during battery operation. The batteries must be

disconnected during maintenance or service work. (Open battery breaker or fuses)

Be aware that the inverter can restart automatically after the utility voltage is restored.

Do not use this equipment for other than intended use.

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

INSTALLATION

This ELI is intended for use in a controlled indoor environment free of conductive

contaminants and protected against any type of intrusion.

Do not install the ELI in an excessively humid environment or near water.

Avoid spilling liquids and/or dropping any foreign object(s) onto the ELI.

The unit must be placed in a sufficiently ventilated area; the ambient temperature should

not exceed 40°C (104°F).

Optimal battery life is obtained if the ambient temperature does not exceed 25°C (77°F).

HIGH GROUND LEAKAGE CURRENT: ground connection completed before connecting

the AC voltage wires on the input!

Switching OFF the ELI does not isolate the ELI from the utility as the utility supply is still

HOT at the input terminal strip. Supply breaker needs to be opened.

It is important that air can move freely around and through the unit. Do not block the air

vents.

Avoid locations in direct sunlight or near heat sources (gas or electric heaters).

STORAGE

Store the ELI in a dry location free of contaminants;

Storage temperature must be within -25°C (-13°F) to 55°C (131°F).

If the unit is stored for a period exceeding 3 months, the batteries must be recharged

periodically (time depending on storage temperature).

WARNING!

LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT

APPARENTLY NOT OPERATING. OBSERVE ALL CAUTIONS AND WARNINGS IN THI

MANUAL. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR

DEATH.

REFER UNIT TO QUALIFIED SERVICE PERSONNEL IF MAINTENANCE IS REQUIRED.

NO ONE SHOULD WORK ON THIS EQUIPMENT UNLESS THEY ARE FULLY

QUALIFIED TO DO SO. AN INSTALLER SHOULD NEVER WORK ALONE.

WARNING!

WHEN REMOVING POWER FROM THE ELI, ALLOW FIVE MINUTES

FOR

CAPACITORS TO DISCHARGE BEFORE WORKING ON THE EQUIPMENT.

CAUTION!

This equipment complies with the requirements in Part 15 of FCC rules for a Class A

computing device. Operation of this equipment in a residential area may cause

interference to radio and TV reception, requiring the operator to take whatever steps

necessary to correct the interference.

CAUTION!

Do not put option control wiring in the same conduit as the ELI input or output power

cables.

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

THIS SAFETY NOTICE IS ADDRESSED TO THE TYCOR UPS

CUSTOMER ENGINEERS WHO PERFORM MAINTENANCE OF THE

UNINTERRUPTIBLE POWER SUPPLY (ELI) SYSTEMS.

Electrical Safety

•

Maintenance work to be performed by a factory trained customer engineers, or

qualified personnel. Extremely dangerous voltage levels can exist within the ELI

system. Extreme caution must be used.

Ensure system is in maintenance bypass mode or external wrap-around bypass

mode before work is started.

This manual is designed as an aid tool in diagnosing problems that may arise.

Tycor UPS does not assume responsibility if information causes injuries.

Apart from the front door, do not open any other part of the ELI without consulting the

factory first. Before removing the protection screens, be sure that the unit is

completely powered off.

Be aware that dangerous voltage can be supplied by the internal battery or

electrolyticcapacitors.

When system is in bypass mode and all fuses have been opened dangerous

voltages may exist within the ELI system. Use extreme caution when exchanging

boards and working inside the unit.

•

READ AND FOLLOW ALL SAFETY INSTRUCTIONS.

SAVE THESE INSTRUCTIONS.

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M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

Introduction........................................................................................................................................................... 1

1.1

1.2

1.3

Overview............................................................................................................................................................................... 1

Features................................................................................................................................................................................ 1

Definitions............................................................................................................................................................................ 2

Theory of Operation............................................................................................................................................. 3

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

General Topology............................................................................................................................................................... 3

Normal Operation Mode ................................................................................................................................................... 4

Backup Mode ...................................................................................................................................................................... 4

Reserve Mode ..................................................................................................................................................................... 5

Manual Bypass Mode........................................................................................................................................................ 5

Features and Advantages................................................................................................................................................ 6

Rectifier ................................................................................................................................................................................ 8

Inverter.................................................................................................................................................................................. 9

Static Switch.......................................................................................................................................................................10

Manual Bypass Switch.....................................................................................................................................................10

Inter-PCB Diagram............................................................................................................................................. 12

Physical Topology ............................................................................................................................................. 13

Installation ........................................................................................................................................................... 16

5.1

5.2

5.3

Site & Environmental Conditions..................................................................................................................................16

Cable Selection..................................................................................................................................................................18

Terminal Strip Connections............................................................................................................................................19

Front Panel........................................................................................................................................................... 20

Operation.............................................................................................................................................................. 25

7.1

7.2

7.3

7.4

7.5

7.6

Switch On Procedure (Authorized Trained Personnel Only) .................................................................................25

Shutdown Procedure .......................................................................................................................................................26

From Inverter To Manual Bypass Procedure.............................................................................................................27

From Manual Bypass to Inverter Procedure ..............................................................................................................28

Manual Battery Test..........................................................................................................................................................28

Battery Condition Test.....................................................................................................................................................28

The LCD Display................................................................................................................................................. 29

8.1

8.2

8.3

8.4

8.5

Menu 0 – Main Menu.........................................................................................................................................................29

Menu 1 – Select Menu......................................................................................................................................................30

Menu 2 – Status Warning Menu.....................................................................................................................................30

Menu 3 – Real Time Data Menu .....................................................................................................................................32

Menu 4 – Historical Event Menu....................................................................................................................................34

viii

TABLE OF CONTENTS

M4102 Ty-Borealis 8-48KW Operators Manual v1.0 2013-08-14

9 INTERFACE CONNECTIONS........................................................................................................................... 36

9.1

9.2

9.3

9.4

9.5

9.6

Dry Contacts.......................................................................................................................................................................36

Software for PC Monitoring............................................................................................................................................37

Emergency Power off Connection................................................................................................................................37

DB9 Connectors................................................................................................................................................................37

Web Monitoring Module (SNMP Module) ....................................................................................................................37

Emergency Lighting Notification..................................................................................................................................38

Battery Backup Units (BBU)............................................................................................................................ 39

10.1 Run Time Charts................................................................................................................................................................41

10.2 BBU Configurations .........................................................................................................................................................43

Options ................................................................................................................................................................. 45

11.1

11.2

11.3

11.4

11.5

Emergency Stop Switch..................................................................................................................................................45

Remote DisplayPanel......................................................................................................................................................45

12 Pulse Rectifier..............................................................................................................................................................45

External Wrap Around Bypass ......................................................................................................................................45

Normally Off Function......................................................................................................................................................45

Technical Specifications.................................................................................................................................. 46

Contact Information........................................................................................................................................... 50