11. UPS and UPS DB

ITEM 11

PRODUCT DESCRIPTION:

UPS and UPS DB

M0703_NX_Series_Operators_Manual V1.25 2012-06-12

NX-Series Three Phase UPS System

GES-103NX – GES-1603NX 10 kVA – 160 kVA

Operators Manual

Always On UPS Systems

M0703_NX_Series_Operators_Manual V1.25 2012-06-12 i


M0703_NX_Series_Operators_Manual V1.25 2012-06-12 ii

Dear Customer, We Thank You for selecting our NX Series UPS system as your power quality solution, and we are pleased to include you as one of our valued customers at Always On UPS Systems Inc. We are confident that this Always On NX Series Uninterruptible Power Supply system, developed and manufactured in our ISO 9001 Certified facilities will provide the quality and satisfaction you demand. Please read the Operators Manual carefully as it contains the necessary information required to extend the life of this UPS to its fullest and this manual will also inform you as to how to use this UPS. Thank you for choosing us. We Are Always On!


M0703_NX_Series_Operators_Manual V1.25 2012-06-12 iii

Preface Congratulations on your choice of NX Series Uninterruptible Power Supply (UPS). This system will protect your valuable equipment from the electrical noise, spikes, surges and other power aberrations found in today’s power grids. This manual describes how to prepare the installation site and procedures for moving, installing and connecting the UPS, with detailed information of maintenance procedures suggested to allow for maximum reliability. It will also explain the function of the UPS module, the purpose and location of the switches, the meaning of system events identified on the front LCD panel and provides procedures for starting and stopping the UPS. While every care has been taken to ensure the completeness and accuracy of this manual, Always On UPS Systems Inc assume no responsibility or liability for any losses or damages resulting from the use of the information contained in this document. WARNING! Installation restrictions or additional measures may be needed to prevent specific disturbances. Ensure all local and national electrical codes are followed during installation and connection. The information contained in this manual is to be used as a guideline and recommendation only. We recommend that this manual be kept with the UPS (Holder provided inside the front door) for future reference. If any problems are encountered with the procedures contained in this manual, please contact our Service Center before proceeding. This document shall not be copied or reproduced without the explicit written permission of Always On UPS Systems Inc. Due to technical advancements and improvements, some of the information contained in this manual may be changed or modified without prior notice. Safety Instructions Read the safety instructions contained on the following pages carefully before the installation, start-up of the UPS its options and batteries. Also refer to this manual before any maintenance procedures are undertaken Please pay particular attention to the text in the rectangular boxes as below: They contain important information or warnings concerning electrical connections and personnel safety.


M0703_NX_Series_Operators_Manual V1.25 2012-06-12 iv

TABLE OF CONTENTS 1 IMPORTANT SAFETY INSTRUCTIONS.................................................................................. 1 2 INTRODUCTION....................................................................................................................... 3

2.1 System Description.........................................................................................................................3 2.2 Definitions........................................................................................................................................3

3 THEORY OF OPERATION ....................................................................................................... 5 3.1 General Topology............................................................................................................................5 3.2 Normal Operation Mode..................................................................................................................6 3.3 Back-Up Mode: ................................................................................................................................6 3.4 Reserve Mode:.................................................................................................................................7 3.5 Maintenance Bypass Mode: ...........................................................................................................7 3.6 Features and Advantages...............................................................................................................8 3.7 Rectifier ..........................................................................................................................................10 3.8 Inverter ...........................................................................................................................................11 3.9 Static Switch ..................................................................................................................................12 3.10 Maintenance Bypass Switch ........................................................................................................12

4 INTER-PCB DIAGRAM........................................................................................................... 13 5 DIMENSIONS & DRAWINGS ................................................................................................. 14 6 INSTALLATION ...................................................................................................................... 18

6.1 Transport........................................................................................................................................18 6.2 Delivery...........................................................................................................................................18 6.3 Storage ...........................................................................................................................................19

6.3.1 STORAGE OF THE UPS............................................................................................................19 6.3.2 STORAGE OF BATTERY...........................................................................................................19

6.4 Site & Environment Consideration..............................................................................................20 6.5 Unpacking ......................................................................................................................................21 6.6 Cable Selection..............................................................................................................................23

6.6.1 CURRENT RATING FOR INPUT ...............................................................................................23 6.6.2 CABLE SIZE FOR INPUT & OUTPUT .......................................................................................23 6.6.3 FUSE RATING & CABLE SIZE FOR BATTERY BANKS...........................................................27

6.7 Terminal Connection.....................................................................................................................28 7 FRONT PANEL....................................................................................................................... 29 8 OPERATION ........................................................................................................................... 34

8.1 Switch On Procedure (Authorized Trained Personnel ONLY) ..................................................34 8.2 Shutdown Procedure ....................................................................................................................35 8.3 From Inverter To Manual Bypass Procedure..............................................................................36 8.4 From Manual Bypass To Inverter Procedure..............................................................................37

9 THE LCD DISPLAY ................................................................................................................ 38 9.1 Menu 0 – Main Menu .....................................................................................................................38 9.2 Menu 1 – Select Menu...................................................................................................................39 9.3 Menu 2 – Status Warning Menu ...................................................................................................40


M0703_NX_Series_Operators_Manual V1.25 2012-06-12 v

9.4 Menu 3 – Real Time Data Menu....................................................................................................41 9.5 Menu 4 – Historical Event Menu ..................................................................................................42 9.6 Menu 5 – Parameter Setting Menu...............................................................................................43 9.7 Menu 6 – Rectifier Data Menu ......................................................................................................44 9.8 Menu 7 – Reserve Data Menu.......................................................................................................44 9.9 Menu 8 – Output Data Menu.........................................................................................................45 9.10 Menu 9 – Other Data Menu ...........................................................................................................45 9.11 Menu 10 – Boost Charge Setting Menu.......................................................................................46 9.12 Menu 11 – Data Time Setting Menu .............................................................................................48 9.13 Menu 12 – Other Setting Menu.....................................................................................................48

10 INTERFACE CONNECTIONS ................................................................................................ 49 10.1 Dry Contacts ..................................................................................................................................49 10.2 Software for PC Monitoring..........................................................................................................50 10.3 Emergency Power Off Connection ..............................................................................................50 10.4 DB9 Connectors ............................................................................................................................50 10.5 Web Monitoring Module (SNMP Module) ....................................................................................50

11 OPTIONS ................................................................................................................................ 51 11.1 Battery Cabinet..............................................................................................................................51 11.2 Battery Runtime Charts ................................................................................................................52 11.3 Emergency Stop Switch ...............................................................................................................53 11.4 Remote Display Panel...................................................................................................................53 11.5 Isolated Parallel Redundant Operation (IPRO)...........................................................................53 11.6 12-Pulse Rectifier ..........................................................................................................................53 11.7 5th Harmonic Filter.........................................................................................................................53 11.8 External Wrap Around Bypass ....................................................................................................53

12 TECHNICAL SPECIFICATION............................................................................................... 54 12.1 NX Series – 10kVA to 60kVA UPS 3Ø Input ................................................................................54

13 CONTACT INFORMATION..................................................................................................... 60


M0703_NX_Series_Operators_Manual V1.25 2012-06-12 1

1 IMPORTANT SAFETY INSTRUCTIONS

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 NX Series UPS 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 to protect themselves and the equipment being installed. GENERAL - Move the UPS 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 UPS equipment carefully. If visible damage is evident, do not attempt to install or start the UPS. Contact the transport

delivery company immediately, file a claim with the transport company and inform Always On directly.

- Do not use outdoors - The use of accessory equipment not recommended by Always On 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 UPS may contain its own energy source, (batteries) which can be dangerous to the untrained person. This UPS contains potentially hazardous voltages

- The field-wiring terminals may be electrically live, even when the UPS 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 of 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.



INSTALLATION - This UPS is intended for use in a controlled indoor environment free of conductive

contaminants and protected against any type of intrusion. - Do not install the UPS in an excessively humid environment or near water. - Avoid spilling liquids and/or dropping any foreign object(s) onto the UPS. - 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 UPS does not isolate the UPS 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 UPS 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 IS APPARENTLY NOT OPERATING. OBSERVE ALL CAUTIONS AND WARNINGS IN THIS 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 UPS, 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 UPS input or output power cables.

READ AND FOLLOW ALL SAFETY INSTRUCTIONS. SAVE THESE INSTRUCTIONS.



2 INTRODUCTION

2.1 System Description The NX Series (UPS) continually monitors and provides conditioning to the incoming electrical power removing surges, spikes, sags, over-voltages, and other irregularities that are inherent in commercial utility power. This UPS system supplies clean, consistent power at the rated voltage with low wave distortion to your sensitive electronic equipment. Blackouts, brownouts and other power interruptions regardless of duration can be protected against with additional optional battery cabinets to provide the necessary emergency power to safeguard your operation. Always On UPS Systems Inc. believes that product reliability is first and foremost in acquiring the confidence of the industry. Our Quality Control Standards ensures that testing at the component level, board level, function level and completed stage level as specified by our ISO9001 Certification allows us to gain this confidence and sets us apart as one of the leading UPS manufacturers in this industry. Always On maintains reliability by incorporating conservatively rated components minimizing transfers to bypass, which eliminates over working many components. Always On provides a truly isolated output (no common neutral from input to output) to eliminate all types of power aberrations as well as Common and Normal Mode noise increasing the reliability and life of the loads connected.

2.2 Definitions UPS Module: That portion of the UPS system which contains the rectifier/charger, inverter, static bypass switch, maintenance bypass switch, controls, monitoring, and indicators. Rectifier/Charger: That portion of the UPS module, which converts the normal source AC input power to DC power for the inverter input and for charging the battery. Inverter: That portion of the UPS module, which converts DC bus power to regulated and filter AC power that is then supplied to the critical loads. Static Bypass Switch: That portion of the UPS module which automatically transfers the critical loads, without interruption, from the inverter output to the bypass AC power source in the event of an overload or degradation of the inverter’s performance. Maintenance Bypass Switch: That portion of the UPS module which is used to connect the bypass AC power source to the critical loads while electrically isolating the static bypass switch, rectifier/charger and inverter for maintenance purposes. Battery: The battery system provides DC power to the inverter input when the normal AC input power to the UPS fails or in the event that the rectifier/charger failure. Critical Loads: These are loads that require clean, regulated and continuous AC power and which are connected to the output of the UPS module.



Key features:

0.9 power factor, the Always On NX Series delivers more real power than other manufactured UPS’s. With today’s trend toward power factor corrected loads, the NX Series can support more total load than any other UPS, of similar size, allowing you to support a greater number of today’s Power Factor Corrected (PFC) equipment.

Isolated Parallel Redundancy Operation (IPRO) is exclusive Always On technology. With IPRO the NX Series UPS’s are controlled in a true peer-to-peer configuration where all critical elements and functions (including bypass) being redundant. The NX Series is designed to be the most reliable power protection system available on the market today.

IGBT technology and new triggering technology allows the NX Series to offer efficiencies up to 94%.

Digital Signal Processor (DSP), Flash memory and user compatibility are the technology corner stones of our New Age of power quality and reliability.

Custom made power protection and tailored to meet your individual requirements, the NX Series offers user selectable options. I.e. Input harmonic filters, comprehensive shutdown software suite for mission control and data protection needed to facilitate all your needs.



3 THEORY OF OPERATION 3.1 General Topology

UPS Module Components: The UPS module consists of the following major components: - Input, Reserve and Bypass circuit breakers - Rectifier / Charger - Inverter - Microprocessor controlled logic and control panel with alarm indicators and digital

metering display - External battery connection - Static bypass - Full maintenance bypass - Emergency power off (EPO) connection - Communications interface - Input power walk-in - Front cable connections - Output isolation transformer - Optional Features:

- 5th harmonic filter to reduce input harmonic content. - SNMP Adapter for network communications and monitoring - Additional battery modules for extended runtime - Top cable entry - Remote display panel - Emergency power off switch - External maintenance bypass cabinet - Isolated parallel redundant operation (IPRO)

Generally, there are four modes of operation for a UPS system, NORMAL MODE, BACK-UP (BATTERY) MODE, RESERVE MODE and MAINTENANCE BYPASS MODE.

Figure 3.1.1 General Block Diagram



3.2 Normal Operation Mode

The rectifier/charger converts the supplied AC power into DC (bus) power, which is then supplied to the inverter and the battery charger. The DC to AC inverter then supplies continuous, noise free AC power to the critical loads. The inverter output is synchronized with the bypass AC power source provided that the bypass AC power source is within the specified frequency range.

3.3 Back-Up Mode:

As the batteries are connected to the DC bus they supply energy to the inverter via this DC bus, the AC power will remain constant and continuous without interruption to the loads when the AC fails or falls out side of the operating parameters. Upon return of the supplied AC input power the UPS the rectifier will automatically assume the DC load (charger, inverter) from the batteries. The UPS will simultaneously supply power to the inverter and the battery charger to replenish the batteries.

Figure 3.2.1 Normal Mode Operation

Figure 3.3.1 Back-up Mode Operation



3.4 Reserve Mode: If the inverter is placed into an abnormal condition, such as over temperature, short circuit, abnormal output voltage or is overloaded for a period which exceeds the inverter’s limits, the inverter will automatically shutdown in order to protect itself. If the AC utility power is within the normal parameters, the static switch will automatically transfer the load to the reserve (utility) source without interruption of the AC output.

3.5 Maintenance Bypass Mode: During UPS maintenance procedures or battery replacement, the loads cannot be interrupted, and as such the technician needs to turn off the inverter switch, close the bypass breaker and then open the rectifier and reserve (utility) breakers. The UPS is now running in Maintenance By-pass mode supplying utility AC to the loads. The AC output will not be interrupted during the manual bypass transfer procedure because the maintenance bypass switch is designed to supply continuous power to the loads.

Figure 3.4.1 Reserve Mode Operation

Figure 3.5.1 Maintenance (Manual) Bypass Mode Operation



3.6 Features and Advantages

a. Reliable input protection: Circuit breakers are in each input loop to ensure power can continue through the other loops in the event of a breaker trip caused by abnormal conditions in either the rectifier or the load. b. Input surge protection: Input surge protection is added at the input to provide enhanced protection to both the UPS and the load and also protects against lightning effects and/or surges caused by large cycling loads or those that are being turned on and/or off. c. EMI suppression: An EMI filter is added to meet the international EMC limits to ensure that No noise will effect or interfere with other equipment connected to the same AC source. d. Ruggedness: The rectifier employs phase control technology to regulate the DC bus voltage allowing the batteries to be charged while supplying DC power to the inverter. This has been proven to be the most efficient method to control and regulate the charge on the batteries. The SCR technology and PFC circuit also assist in maintaining the input waveform. e. High frequency design: The inverter design incorporates high frequency, highly efficiency Insulated Gate Bi-polar Transistors (IGBT). A PWM wave, synchronized to the bypass input, triggers the IGBT’s, which invert the DC into AC power required by the loads. This design decreases the number of required components, increases reliability and performance while decreasing acoustic noise, size and weight. f. True galvanic isolation: The isolation transformer addresses ground differentials between the input and output, and prevents ground leakage current problems, common mode and normal mode noise. This transformer is located on the output side of the UPS system providing isolation under every mode of operation. g. PNP modular design: The circuit boards are designed into several modules, which are plugged into slots in the UPS. These plug-able modules allow for easy replacement in the field when necessary and eliminate field diagnostics. h. Cold start function: The UPS can be started without the utility AC supply being activated. Or present at the input terminal strip because our designed system is designed with current limiting circuitry, which allows Startup of the UPS on battery DC power. i. Multi-CPU design: Several CPU’s are designed into the control circuit. These critical functions are designed with multi-level redundancy increasing reliability and up-times by eliminating field problems. j. Protection against possible operator error: The UPS is designed with breaker on/off sensors and power supply sensors. These sensors prevent potential operational mistakes from interfering with the start –up operation causing possible damage. k. Wide input range: The components are overrated by designed to handle high input voltages and currents without harm to the system, ensuring that Always On UPS’s remain one of the most reliable UPS Systems available in today’s market. l. Harsh environment: Each component of the UPS is chosen with the highest degree of safety margins allowing for wider environmental parameters and specifications related to temperature, humidity, altitude, surge or noise.



m. Intelligent charger: The UPS will automatically recharge (boost charge) the batteries when the battery voltage level decreases to approximately 2V/Cell or to a user specified level. To prevent the over-charging of the battery, the boost charge will stop when batteries achieve a 90% charged level or the ambient temperature reaches 35oC (95oF) at which point the float charging begins. n. Intelligent battery test: The batteries are tested after every boost charge whether the charge has been initiated by a battery discharge state (2V/Cell) or by the regular battery test preformed by the UPS (monthly test). When an abnormal condition (low charge rating, or bad battery) is found the user will be informed immediately through alarms on the UPS system. o. Charging rate: The charging rate is selectable (L/M/H) according to Ah ratings of the batteries. The charger is designed to charge the larger battery banks without adding an additional charger (up to 8hr. back-up). p. MTBF of cooling fans: Long cycling fans will operate at variable speeds necessary which is dependent on the ambient temperature of the UPS system increasing the life expectancy of the fan motors. q. Redundant power supply: Redundant power supplies have been installed to allow for worry free operation of the system. r. Intelligent interface: One remote control panel (or one PC) can monitor and control up to ninety-nine UPS’s. The communication allows for N+1 redundancy, whereby if one system encounters an emergency or fault condition, it will warn the user immediately and the load is automatically transferred to the other UPS systems. The UPS status, data or commands are transmitted to external modules through four RS-485 ports. s. Data log capability: All abnormal conditions will be stored within the UPS control interface board for further reference by the user. Each abnormal condition is time and date stamped (real-time clock) as the event occurs. This history is stored and cannot be removed even if or when the UPS is turned off for servicing. t. Convenient front panel design: The LCD display and control switches are accessible through the up, down, and enter switches below the front panel window. All the viewable parameters can be read without opening the front door. The inverter on/off switch is protected from accidental operation by being located behind the locked front door although the inverter can still be switched on and off via the control switches on the front panel but this feature is password protected. u. Emergency stop: In the event of an emergency the UPS can be shutdown (no AC at the output) either through a switch (optional) or through a smoke detector signal (optional).



3.7 Rectifier

The main function of a rectifier is to convert the AC input power to DC power. The DC power is then used to charge the batteries, supply the DC bus, which in turn supplies the inverter. The rectifier design used in the 10kVA to 60kVA UPS’s include a 6-pulse full controlled rectifier. Power Factor Correction (PFC) has been added to maintain a high input power factor, independent of the load power factor. This 6 pulse rectifier smoothes the current waveform and reduces the harmonic content reflected back to the utility. The control circuit regulates the DC bus to within 1% of the nominal voltage. Soft walk-in circuitry (approximately 20 seconds) and current limiting circuitry are used to prevent over current or surge currents from affecting any part of the UPS system. Additionally, over and under-voltage protection is added to improve reliability and to shutdown the rectifier in the event of abnormal conditions. The DC bus is adjustable to allow for different types and capacities of batteries. The power components used within the rectifier are specially designed and selected to handle extreme ranges of high voltage and high current (–25% to +25%). In order to further improve the power factor and reduce harmonic current drawn by the rectifier, Always On UPS’s above 80kVA incorporate a 12-pulse full controlled rectifier (also available as an option on the 10 to 60kVA UPS’s) to reduce the total harmonic current to less than 12%. A phase shift transformer is added with input inductors to achieve this higher level of performance while maintaining our high input power factor. An optional 5th harmonic filter can be added to further reduce the total harmonic distortion current to less than 9%. The total harmonic current can be decreased to less than 7% with the inclusion of the 18-pulse full controlled rectifier. This option is recommended for the larger (80kVA and up) UPS systems.



3.8 Inverter The inverter is composed of IGBT’s, inductors, capacitors, highly efficient filters, control circuitry and protection circuitry. This inverter inverts the DC power received on the DC bus to isolated, noise-free AC power, which is then supplied to the critical loads. Our PWM wave generator is switching at a higher frequency well above the human audible range. The Voltage regulating circuitry limits the output voltage variation to within 1% of the nominal voltage and special compensation circuitry has been added to eliminate output distortion. Every component is oversized to accept a wide DC input range (from 285 to 420VDC), allowing the output waveform to remain sinusoidal throughout the entire range. With the aid of dynamic feedback loop circuits the inverter maintains a true sine wave output, even if non-linear loads are connected. The system is designed and incorporates an independent inverter per phase. These inverters are totally independent of each other preventing the possibility of cascading failures while allowing the user to connect loads to adjacent inverters without affecting the other inverters. This connectivity provides high-end voltage regulation under a 100% unbalanced load situation. The IGBT is operated in its optimal condition to obtain maximum efficiency, keeping electrical costs to a minimum. Usually, most UPS failures are a result of inverter failures. To prevent this occurrence, Always On has included redundant protection circuitry to protect the inverter and increase its reliability. To enhance this protection we have also added a high efficiency filter designed to suppress the spikes and noise that can be reflected from the attached loads back into the UPS system. Specifying oversized and high quality components, additional semi-conductor fuses and allowing for good ventilation systems within further increase reliability.

Figure 3.8.1 Inverter Layout



3.9 Static Switch The static switch is composed of two pairs of back to back naturally commutated SCR’s, which moves the load from inverter to reserve (utility) or from reserve to inverter without interruption of power to the load. Detection circuitry is included in the control circuit to achieve “0” dead time transfer. Additional detection is employed to control the static switch transfer. Dead Short: If a dead short circuit was to occur under normal mode operation, the UPS would detect the short circuit and immediately stop the inverter until the problem has been rectified. Due to the large amount of current a dead short requires, the static switch will not transfer to reserve preventing the tripping of the reserve breaker. Overload condition: The UPS will transfer the load to reserve (utility) path. The static switch is designed to handle 110% of the capacity of the system but will switch to the reserve path if the overload continues for any length of time. The load will still be operational, but the load system will not be protected from a utility failure, as it has no battery capability until the overload is removed. The static switch will only be activated if the input levels are within parameters to ensure the load is only supplied with acceptable power to protect against damage that may be caused to the critical load. The system performs numerous checks on the transfer from inverter to bypass and visa versa to ensure the exchange is smooth.

3.10 Maintenance Bypass Switch

The maintenance bypass switch is a function of Always On UPS’s, which is open under normal operation, and closed for maintenance service. All power supplied to the UPS should be disconnected before service begins. The maintenance bypass is switched seamlessly to supply utility AC power to the loads during UPS maintenance and servicing. If the bypass breaker is closed (by mistake) under normal operations, the inverter will stop and the load will be transferred to reserve (utility) power. The inverter cannot be turned on when the maintenance bypass breaker is in the closed position. (The operation of the maintenance bypass breaker is explained later in this manual)

Figure 3.9.1 Static Bypass



4 INTER-PCB DIAGRAM

RectifierDriver

RectifierControl

RectifierDriver

RectifierControl

Switch

LED

Display

Controller

Power Supply

BattRelay

SS Drive

R Phase

S Phase

T Phase

InverterDriver

InverterDriver

InverterDriver

CallService

Remote ControlPanel

PCCommunications

SNMP (Web)Monitoring

Battery Monitoring

LCD

Optional CommunicationFeatures

6 Pulse Rectifier

12 Pulse Rectifier

DryContact

Figure 4.1 Block Diagram For Component And Feature Layout



5 DIMENSIONS & DRAWINGS

559mm [22”]

815m

m [3

2"]

1600

mm

[63"

]

95m

m [3

3/4

"]

Figure 5.1 10kVA to 60kVA Dimensional Drawing



1. Turn off the INVERTER module byP pressing & on the LCD panelP simultaniously.P2. Open theBATTERY breaker/P fuses.P3. Open the RECTIFIERbreaker.P4. Wait 5 minutes for DC Pc apacitor todischarge.P5. Open the RESERVE breaker. P6. Openthe INPUT breaker. P7. Lock the door.

1. Close the INPUT breaker.P2. Close the RESERVEbreaker.P3. Close the RECTIFIER breaker.P4. Wait 30secound for the DC bus P vo ltage to rise .The warningLEDsP "BAT LOW" and 'BAT LOW STOP"P on the frontpanel will turn off.P5. Close the BATTERY breaker/P fuses.P6. Start t he INVERTER module byP pressing & on the LCD panelP simultaniously.P7. The load willtransfer to inverterP output in approximately 7seconds. P8. Lock the door.

Operating Proced ure

Warning: For Installa tion & First Time Startup, Please Se

St artup Proc edure Shutdown Proc edure

Inverter to Manual Bypass Procedure Manual Bypass to Inv er terP Proc edure

1. Turn off the INVERTER module byP pressing & on the LCD panelP simultaniously.P2. Open theBATTERY breaker/P fuses.P3. Open the RECTIFIERbreaker.P4. Wait 5 minutes for DC c apacitorsP todischarge.P5. Close the bypass breaker. P6. Openthe Reserve breaker. P7. The UPS is now in manualbypass.

1. Close a ll fuses behind the controlP module door.P2.Close the RESERVE breaker.P3. Open the BypassbreakerP4. Close the RECTIFIER breaker.P5. Wait 30seconds for the DC bus P voltage to rise .The warningLEDsP "BAT LOW" and 'BAT LOW STOP"P on the frontpanel will turn off.P6. Close the BATTERY breaker/ P fuses.P7. Start t he INVERTER module byP pressing & on the LCD panelP simultaniously.P8. The load willtransfer to inverterP output in approximately 7seconds. P9. Lock the door.

Before Maintenanc e beginsPOn UPS

1. Open all fuses behind the controlP moduledoor.

WARNING!

Da ngerous AC & DC PHIGHVOLTAGE !

INPUT RECTIFIER RESERVE BYPASS

Table 5.1 Weight, Dimensions and Loading of the 10 to 60kVA UPS systems.

UPS Rating Dimensions Weight (kVA) W (Width) D (Depth) H (Height) UPS Floor Loading

10 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 250kg (550lbs) 625kg/sq.m (124lbs/sq.ft.) 20 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 300kg (660lbs) 750kg/sq.m (149lbs/sq.ft) 30 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 400kg (880lbs) 1,000kg/sq.m (198lbs/sq.ft.)40 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 480kg (1,056lbs) 1,200kg/sq.m (238lbs/sq.ft.)50 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 550kg (1,210lbs) 1,375kg/sq.m (273lbs/sq.ft) 60 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 680kg (1,496lbs) 1,700kg/sq.m (337lbs/sq.ft.)

Figure 5.2 10kVA to 60kVA Interior Layout



Figure 5.3 80kVA to 160kVA Dimensional Drawing



FROM INVERTER TO BYPASS PROCEDURE: 1. PUSH THE INVERTER OFF SWITCH (RIGHT & MIDDLE OF INVERTER SWITCH). 2. OPEN THE BATTERY BREAKER. 3. OPEN THE RECTIFIER BREAKER. 4. WAI T 5min FOR DC CAPACITOR INSIDE TO DISCHARGE. 5. CLOSE THE BYPASS BREAKER. 6. OPEN THE RESERVE BREAKER. 7. LOCK THE DOOR.

SHUTDOWN PRO CEDURE: 1. PUSH THE INVERTER OFF SWITCH (RIGHT & MIDDLE OF INVERTER SWITCH). 2. OPEN THE BATTERY BREAKER. 3. OPEN THE RECTIFIER BREAKER. 4. WAI T 5min FOR DC CAPACITOR INSIDE TO DISCHARGE. 5. OPEN THE RESERVE BREAKER. 6. LOCK THE DOOR.

START PROCEDURE: 1. CLOSE THE RESERVE BREAKER. 2. CLOSE THE RECTIFIER BREAKER. 3. WAI T 30sec FOR DC VOLTAGE RISE UP. 4. CLOSE THE BATTERY BREAKER. 5. PUSH INVERTER ON SWITCH (LEFT & MIDDLE OF INVERTER SWITCH). 6. THE LOAD WILL TRANSFER TO INVERTER OUTPUT AFTER 7sec . 7. LOCK THE DOOR. FROM BYPASS TO INVERTER PROCEDURE: 1. CLOSE THE RESERVE BREAKER. 2. OPEN THE BYPASS BREAKER. 3. CLOSE THE RECTIFIER BREAKER. 4. WAI T 30sec FOR DC VOLTAGE RISE UP. 5. CLOSE THE BATTERY BREAKER. 6. PUSH INVERTER ON SWITCH (LEFT & MIDDLE OF INVERTER SWITCH) . 7. THE LOAD WILL TRANSFER TO INVERTER OUTPUT AFTER 7sec . 8. LOCK THE DOOR.

Table 5.2 Weight, Dimensions and Loading of the 80 to 160kVA UPS systems

UPS Rating Dimensions Weight (kVA) W (Width) D (Depth) H (Height) UPS Floor Loading

80 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 820kg (1,804lbs) 932kg/sq.m (185lbs.sq.ft.) 100 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 950kg (2,090lbs) 1,080kg/sq.m (214lbs/sq.ft.)120 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 1,180kg (2,596lbs) 1,340kg/sq.m (266lbs/sq.ft.)160 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 1,450kg (3,190lbs) 1,648kg/sq.m (327lbs/sq.ft.)

Figure 5.4 80kVA to 160kVA Interior Layout



6 INSTALLATION 6.1 Transport The UPS is packaged on a pallet, suitable for handling with a forklift. Pay strict attention to the center of gravity. The UPS must be moved in upright position. Do not tilt cabinets more than +/- 10° during handling. Move the UPS in its original package to the final destination site. Do not stack other packages on top. If the UPS must be lifted by crane, use suitable lifting straps and spreader bars.

6.2 Delivery Upon receiving the UPS system, inspect the packaging integrity and the physical condition of the cabinets carefully. In the event that physical damage is visible, the carrier must be informed immediately and a claim filed with them. Inform Always On as soon as the claim has been filed and a copy of claim should be faxed to Always On at (250) 491-9775. A detailed report of the damage is necessary for carrier insurance claim. WARNING A damaged UPS system must never be installed or connected to the utility or batteries without written instruction from Always On Engineering.



6.3 Storage 6.3.1 STORAGE OF THE UPS

The UPS is carefully packed for transport and storage. Never leave a UPS outside the building exposed to the elements and do not place other packages on the top of the UPS. Storing: It is recommended to store the UPS in its original package in a dry, dust-free room, away from chemical substances, and with a temperature range of -25°C (-13°F) to 55°C (131°F). Exceeding this temperature range may cause damage. Important functions of the UPS, are defined by parameters stored in a RAM memory. The RAM is supplied by a small backup battery located on the Controller board. If the storage time of the UPS exceeds 1 year, these functions should be verified by an Always On Service Center before putting the UPS into operation.

6.3.2 STORAGE OF BATTERY

Although this system includes maintenance free batteries, keep in mind that they are subject to self-discharge and therefore must be recharged. The storage time without battery recharge depends on the temperature of the storage site. The optimal temperature for battery storage is 20°C (68°F) to 25°C (77°F). Recharge of the stored maintenance free battery every: 6 months when the ambient storage temperature is 20°C (68°F) 3 months when the ambient storage temperature is 30°C (86°F) 2 months when the ambient storage temperature is 35°C (95°F)



6.4 Site & Environment Consideration The designed function of the UPS is to provide a safe, clean and independent electrical supply free from random variations, disturbances or interruptions of the utility mains. The UPS will provide a constant power source, which is regulated in both voltage and frequency. When the utility mains are not available, the UPS will provide optimal back-up time depending on the capacity connected battery bank. Usually the life expectancy of the UPS is 8 to 10 years. The optimal life expectancy of the UPS can be achieved by careful consideration of the site and environment. The following precautions and recommendations should be checked when considering the site and environment for the UPS: a. The UPS should be located in a place with adequate ventilation (refer to the specification of

the heat dissipation of the UPS). Should the UPS be installed in a sealed room, care must be taken to ensure adequate heat evacuation is provided.

b. Void space is not required on all sides of the UPS system, but adequate space, a minimum of 1m (3’), should be allowed at the front for the door to open and a minimum of 60cm (2’) should be allowed on the right side to allow for the door to open and removal of the side panels for operation or maintenance purposes. Adequate space, a minimum of 60cm (2’) [recommended 1m (3’)], should also be allowed at the top of the UPS system to allow for proper heat dissipation and ventilated through the top openings (optional ventilation booth is available upon request).

c. The battery banks require access to front only. A minimum of 1m (3’) should be allowed at

the front to allow for the door to open and removal of the side panels for operation or maintenance purposes.

71"

35"

25"

76"

52"

34"

2'3'

Figure 6.4.1 Minimum Spacing Requirements



d. Do not place any objects on the top of the UPS that might obscure the ventilation. Do not

place the UPS near any heat source, or machinery, which may produce metallic particles, dust or powder. Do not place the UPS near equipment that will produce corrosive substances or vapor.

e. Do not place the UPS below the shower of a fire extinguishing system (optional drip shield available). Abnormal conditions of the UPS should be protected by a cutoff from the power supply.

e. The user is required to guarantee the temperature and humidity values of the site into which the UPS will be installed meet the required and published manufacturer specifications. The UPS should be installed within the range allowed by these specifications. The UPS is capable of continuous normal operation within a temperature range of 0°C (32°F) to 40°C (104°F). For optimal performance and reliability the recommended environment temperature is best at 25°C, with humidity < 80% non-condensing.

f. The floor loading capacity should be sufficient to endure the weight of the UPS and battery

bank. Four right-angled steel feet attached restrainers are included with the UPS system, which should be inserted into the floor for securing the UPS system, when the location has the potential to experience vibrations. (e.g.: earthquake, moving vehicles, or tanker.) See Addendum if applicable.

h. Walls, ceilings, floors or anything near to the UPS should be constructed of non-

combustible materials. A portable fire extinguisher should be accessible nearby.

i. Avoid accumulating litter or trash of any sort in or around the UPS system. The floor area surrounding the UPS should be kept clean, free from metallic powder and/or filings.

j. Access to the UPS room should be limited to operation and maintenance personnel. The doors should be kept locked and the keys should be available only to authorized personnel.

k. Personnel who operate or maintain the UPS system should be proficient in normal and emergency operational procedures. New personnel should be trained and qualified prior to operation of the equipment.

l. Although the UPS has passed the international EMC tests, it is not recommended to install the UPS near to any equipment that is susceptible to electro-magnetic interference, such as computer systems, monitors, radios etc.

6.5 Unpacking

Carefully remove all the packaging material of the UPS, then carefully place the UPS at the final destination site. This UPS system has passed all stages of production testing and final stage QC testing prior to shipment from the factory (report enclosed). The UPS should be in full operating condition upon receipt. Upon receiving visually check the UPS for any physical damage that may have occurred during transport. If damage is notice file a damage report immediately with the



transport company and inform Always On. Also check to ensure all of the accessories/options ordered are received. • DOOR KEY • OPERATOR’S MANUAL • BATTERY FUSE (FOR BATTERY CABINET ONLY)

Check and verify the specifications of the UPS are identical to the specifications of the system ordered. The key items in the specifications you must check are: • RATED POWER OF THE UPS • INPUT VOLTAGE & FREQUENCY • OUTPUT VOLTAGE & FREQUENCY • BATTERY RUNTIME Check that the necessary documentation located inside the front door of the UPS, is included: • OPERATORS MANUAL • TEST AND WARRANTY INFORMATION • SERVICE MANUAL (If purchased)



6.6 Cable Selection

The cabling of the UPS system has to be sized according to the UPS power rating. Sizing of circuit breakers, fuses and cables for input utility, output load and battery must meet the requirements of local and national electrical codes.

The following tables list the information between kVA of the UPS and the current requirements of the systems. WARNING Inadequate cable size and over sized breakers can increase the risk of fire or damage connection cables and internal components. The following tables can be used to determine the input circuit breaker rating and the size of cable for input, output and battery connections. This data is for reference only as final installation must meet the requirements of local and national electrical codes.

6.6.1 CURRENT RATING FOR INPUT

Table 6.6.1.1 Maximum Input current ratings

KVA Rating

Imax(A) 120/208VAC

3Ø Minimum

Breaker/FuseImax(A)

277/480VAC 3Ø

Minimum Breaker/Fuse

Imax(A) 347/600VAC

3Ø

Minimum Breaker/Fuse

10 45 50 20 20 16 20 15 63 70 27 30 22 30 20 83 90 36 40 30 30 30 125 125 55 60 45 50 40 160 175 70 70 56 60 50 200 200 90 90 70 70 60 250 250 110 110 90 90 80 330 350 145 150 115 125

100 415 450 180 200 145 150 120 500 500 220 225 175 175 160 660 700 290 300 230 250

When choosing a non-fused breaker (NFB) for the UPS, always choose the NFB that is closest, but not below the maximum rated input current.

6.6.2 CABLE SIZE FOR INPUT & OUTPUT NEC SECTION 210-20 (a) Table 8.3.2 (next page) shows the allowable amperage of insulated conductors rated 0 through 2000 Volts, 60°C through 90°C (140°F through 194°F) not more than three current-carrying conductors in a raceway, cable, or earth (directly buried), based on ambient temperature of 30°C (86°F).



Table 2 (See rules 4-004, 8-104, 12-012, 12-2212, 26-000, 26-742, 42-008, and 42-016 and Tables 5A, 5C, 19, and D3)

Allowable Ampacities for Not More Than 3 Copper Conductors in Raceway or Cable Based on Ambient Temperature of 30°C

Allowable Ampacity 60°C 75° 85-90°C 110° 125° 200°

Types R90, RW90 T90 NYLON

Paper Types TW

Types RW75 TW75

Mineral-InsulatedCable**

See Note (1)

See Note (1)

See Note (1)

Size AWG kcmil

COPPER 14 15 15 15 30 30 30 12 20 20 20 35 40 40 10 30 30 30 45 50 55 8 40 45 45 60 65 70 6 55 65 65 80 85 95 4 70 85 85 105 115 120 3 80 100 105 120 130 145 2 100 115 120 135 145 165 1 110 130 140 160 170 190 0 125 150 155 190 200 225 00 145 175 185 215 230 250

000 165 200 210 245 265 285 0000 195 230 235 275 310 340 250 215 255 265 315 335 300 240 285 295 345 380 350 260 310 325 390 420 400 280 335 345 420 450 500 320 380 395 470 500 600 355 420 455 525 545 700 385 460 490 560 600 750 400 475 500 580 620 800 410 490 515 600 640 900 435 520 555

1000 455 545 585 680 730 1250 495 590 645 1500 520 625 700 785 1750 545 650 735 2000 560 665 775 840 Col.1 Col.2 Col.3 Col.4 Col.5 Col.6 Col.7

CORRECTION FACTORS Ambient Temp. (°C)

For ambient temperatures other than 30°C (86°F), multiply the allowable amperage shown above by the appropriate factor below

21 - 25 1.08 1.05 1.04 1.08 1.05 1.04 26 - 30 1.00 1.00 1.00 1.00 1.00 1.00 31 - 35 0.91 0.94 0.96 0.91 0.94 0.96 36 - 40 0.82 0.88 0.91 0.82 0.88 0.91 41 - 45 0.71 0.82 0.87 0.71 0.82 0.87 46 - 50 0.58 0.75 0.82 0.58 0.75 0.82 51 - 55 0.41 0.67 0.76 0.41 0.67 0.76



Table 4 (See rules 4-004, 8-104, 12-2212, 26-000, 26-742, 42-008, and 42-016 and Tables 5A, 5C, and D3)

Allowable Ampacities for Not More Than 3 Aluminum Conductors in Raceway or Cable Based on Ambient Temperature of 30°C

Allowable Ampacity 60°C 75° 85-90°C 110° 125° 200°

Types TW

Types RW75 TW75

Types R90,RW90

T90 NYLON Paper

See Note

See Note

See Note

Size AWG kcmil

COPPER

12 15 15 15 25 30 30 10 25 25 25 35 40 45 8 30 30 30 45 50 55 6 40 50 55 60 65 75 4 55 65 65 80 90 95 3 65 75 75 95 100 115 2 75 90 95 105 115 130 1 85 100 105 125 135 150 0 100 120 120 150 160 180 0 115 135 145 170 180 200 0 130 155 165 195 210 225 0 155 180 185 215 245 270

250 170 205 215 250 270

300 190 230 240 275 305

350 210 250 260 310 335

400 225 270 290 335 360

500 260 310 330 380 405

600 285 340 370 425 440

700 310 375 395 455 485

750 320 385 405 470 500

800 330 395 415 485 520

900 355 425 455

1000 375 445 480 560 600

1250 405 485 530

1500 435 520 580 650

1750 455 545 615

2000 470 560 650 705 Col.1 Col.2 Col.3 Col.4 Col.5 Col.6 Col.7



Table 5A (See rules 4-004(8), 12-2212, and Tables 1,2,3,4,57,58, and D3)

Correction Factors Applying to Tables 1,2,3, and 4 Ampacity Correction Factors for Ambient Temperatures Above 30°C

(These correction factors apply, column for column, to Tables 1,2,3, and 4. The correction factors in column 2 also apply to Table 57.)

Correction Factor

60°C 75° 85-90°C 110° 125° 200°

Ambient Temperature °C

60°C Types

TW

75°C Types RW75 TW75

85-90°C Types

R90,RW90 T90 NYLON

Paper

110°C See

Note(2)

125°C See

Note(2)

200°C See

Note(2)

40 0.82 0.88 0.90 0.94 0.95 1.00 45 0.71 0.82 0.85 0.90 0.92 1.00 50 0.58 0.75 0.80 0.87 0.89 1.00 55 0.41 0.65 0.74 0.83 0.86 1.00 60 0.58 0.67 0.79 0.83 0.91 70 0.35 0.52 0.71 0.76 0.87 75 0.43 0.66 0.72 0.86 80 0.30 0.61 0.69 0.84 90 0.50 0.61 0.80

100 0.51 0.77 120 0.69 140 0.59

Col.1 Col.2 Col.3 Col.4 Col.5 Col.6 Col.7 NOTES:

(1) The ampacity of a given conductor type at these higher ambient temperatures is obtained by multiplying the appropriate value from Table 1,2,3, or 4 by the correction factor for that higher temperature. (2) These ampacities are only applicable under special circumstances where the use of insulated conductors having this temperature rating are acceptable.



6.6.3 FUSE RATING & CABLE SIZE FOR BATTERY BANKS

Table 6.6.3.1 Recommended Fuse and Cable Size for the Battery Banks KVA Rating Imax(A) FUSE(A) CABLE(mm²) CABLE (AWG)

10 60 70 22 #6 15 60 70 22 #6 20 60 70 22 #6 30 90 100 38 #3 40 120 125 38 #2 50 150 175 50 0 60 180 200 80 00 80 240 125*2 38*2 #2

100 300 175*2 50*2 0 120 360 200*2 80*2 00 160 480 200*2 80*2 00 240 720 200*4 80*4 00 320 960 200*4 80*4 00

*THE BATTERY VOLTAGE IS 295 – 410V **LEAD ACID BATTERY – 174 CELLS



6.7 Terminal Connection

Different models of UPS’s may have different cable connection terminals. UPS connection terminal configurations fall into one of the following types:

RR RS RT IN IR IS IT OR OS OT ON B+ B-

RESERVEINPUT

RECTIFIERINPUT

UPSOUTPUT INPUT

BATTERY

INPUTRECTIFIER & RESERVE

IN IR

UPSOUTPUT

ORITIS OS OT

BATTERYINPUT

B-ON B+

3 PHASE INPUT / 3 PHASE OUTPUTTERMINAL WITH TWO SOURCE

3 PHASE INPUT / 3 PHASE OUTPUTTERMINAL WITH SINGLE SOURCE

Figure 6.7.1 Terminal Strip Layout for Dual in Single input UPS systems



7 FRONT PANEL C

A

B

R QP ONM

L K

J

I

H

G

F

E

D

Figure 7.1 Front Panel Display



The front panel is located behind the glass window on the front of the UPS system. It displays the real time information and status of the UPS and battery system. It also provides for user interface for controlling and setting the UPS operating status. This panel also allows the user to operate and monitor the system with ease. The panel is explained below: A: LCD display- Real time status, data and historical events are displayed on the LCD. The

UPS parameters, real time clock, inverter, and buzzer can also be set through this LCD. The LCD is back lit by LED’s for a sharper display, but in order to lengthen the LED’s life time, the LED will automatically shut off 3 minutes after a key has been pressed, and will light up again when one of the up/down/enter keys are pushed.

B: Warning LED’s-When an abnormal condition occurs, these LED’s will illuminate allowing

the user to identify the fault. This will also allow the service personnel the ability to troubleshoot the system. These LED’s are described below:

• RECT AC FAIL – when the supply to the rectifier is outside of the operating

parameters. This not only applies to voltage range but also when phase rotation is incorrect or the rectifier has been shutdown (refer to C: Status LED’s).

• RES AC FAIL – supply to the reserve is outside of the operating parameters. Supply voltage or frequency out of range (refer to C: Status LED’s).

• FUSE/TEMP – inverter has shutdown due to inverter fuse open or heat sink temperature above operating parameters.

• OVERLOAD – an overload condition has occurred on the output. • HIGH DC – this LED will be lit as long as the DC voltage exceeds 430VDC. • BAT LOW – this LED will be lit as long as the DC voltage is lower than

320VDC. • BAT LOW STOP – the LED will be lit as long as the DC voltage is lower

than 295VDC. The inverter will not activate until the DC voltage is above this level.

• FAULT – the inverter has shutdown because an abnormal condition has occurred. Possible conditions include overload, short circuit, high DC shutdown, fuse/over temperature, bypass breaker on or emergency stop (refer to C: Status LED’s).

C: Status LED’s- 24 LED’s represent the real-time information regarding the status of the UPS system. These LED’s will aid in diagnosing and trouble shooting abnormal conditions. The 24 LED’s represent the following:

• INVERTER ON – inverter is running. • INV STATIC SWITCH ON – inverter static switch is active. • OUTPUT SHORT CIRCUIT – UPS output is in a short circuit state. • FUSE/TEMP INV SHUTDOWN – inverter has shutdown due to inverter fuse

open or heat sink temperature above operating parameters.



• INVERTER FAIL INV SHUTDOWN – inverter has shutdown due to inverter

output voltage below tolerances. • BYPASS ON INV SHUTDOWN – inverter has shutdown because the

bypass breaker has been activated while the inverter is supplying power to the load.

• HIGH DC BUSS INV SHUTDOWN – inverter has shutdown because the DC Bus voltage is outside of operating parameters while the inverter is operating.

• INV OVERLOAD INV SHUTDOWN – inverter has shutdown because an overload condition has been detected on the output. The inverter will automatically restart after the condition has been removed for a period of seven seconds.

• 70% LOAD – load connected to the output is over 70% of the UPS rating. • 110% LOAD - load connected to the output is over 110% of the UPS rating. • 125% LOAD - load connected to the output is over 125% of the UPS rating. • 150% LOAD - load connected to the output is over 150% of the UPS rating. • RESERVE AC FAIL – supply voltage to the Reserve is outside of operating

window. • RESERVE FREQ FAIL – supply frequency to the Reserve is outside of

operating window. • BATTERY LOW – the DC bus (or battery) voltage is lower than 320VDC.

Low battery shutdown is approaching. • BATTERY LOW SHUTDOWN – the inverter has shutdown because the DC

bus (or battery) voltage is below operating level (lower than 295VDC). • RECTIFIER AC FAIL – supply to rectifier is outside of operating window. • �ROTATION ERROR – supply phase rotation is outside of operating

window. • RECTIFIER SHUTDOWN – the rectifier has shutdown because the DC bus

voltage has exceeded maximum operating level (over 445VDC). The rectifier will automatically restart 30 seconds this abnormal condition has been cleared.

• RECTIFIER HIGH DC – the DC voltage has exceeded maximum operating level (over 430VDC). The bus voltage is limited to this voltage.

• BOOST CHARGE – the batteries are being boost charged by the rectifier. • BATTERY TEST – batteries are being tested. • EMERGENCY STOP – the inverter has shutdown because the emergency

stop switch has been activated. • COMM. ACTIVE – blinks when data is being transmitted or received via the

communication port.



D: Buzzer outlet: There is a buzzer located behind the LCD Display. The buzzer will allow for audile notification during an abnormal condition. The buzzer will be activated under one of the following conditions: (The frequency of the buzzer is also described for your reference.)

• INVERTER IS OVERLOADED >110%, beep once / 3 seconds

>125%, beep once / second >150%, beep twice / second

• BACK-UP >320VDC, beep once/ 3 seconds <320VDC, beep twice / second <295VDC, no beeping

• INVERTER IS SHORT CIRCUITED beep continuously • FUSE BROKEN beep continuously • HEAT SINK OVER TEMPERATURE beep continuously • HIGH DC SHUTDOWN beep continuously • BYPASS ON STOP beep continuously • EMERGENCY STOP beep continuously

The buzzer will beep once every time the inverter is switched on or off. This will allow for the user to be sure the operation was preformed correctly.

E. Bypass LED: This LED is lit when the maintenance bypass breaker is closed leaving the

inverter in the off mode. If the inverter is active when the bypass breaker is closed the inverter will shutdown immediately.

F. Reserve LED: This LED is lit when the reserve breaker is closed, and the supply is within

operating parameters. G. Rectifier LED: This LED is lit when the rectifier is operating, the supply is within operating

parameters, the rectifier breaker is closed and the DC bus voltage is within operating parameters.

H. Battery LED: This LED is lit while the UPS is in back-up mode. This LED also indicates the

results of battery test. If the battery pack does not pass the test, this LED will flash prompting the user to change the battery pack.

I. Inverter LED: This LED is lit when the inverter is supplying power to the load. J. Inverter Static Switch LED: This LED is lit when the inverter static switch is operating and

the reserve static switch is turned off. When this LED is on, the load is supplied from the inverter. Usually this LED will stay lit for 7sec. after the inverter is switched on.

K. Reserve Static Switch LED: This LED is lit when the reserve static switch is operating and

the inverter static switch is turned off. When this LED is on, the load is being supplied by the reserve. Since the reserve static switch and inverter static switch will never operate simultaneously, the Inverter Static Switch LED and the Reserve Static Switch LED will never be lit at the same time.

L. Output LED: This LED is lit when there is AC power present at the output terminals. M. Up key: This is an LCD control key. It moves the cursor one field upward when items



are being selected or changes the number/character forward when data or parameters of the UPS are being set.

N. Down key: This is an LCD control key. It moves the cursor one field downward when

items are being selected or changes the number/character backward when data or parameters of the UPS are being set.

O. Enter key: This is an LCD control key. It returns to the previous page, and also confirms

the number/character/item selected. P. Inverter “On” Switch: This is an inverter control switch. When this switch is pushed

simultaneously with the control key, the inverter will switch on. Q. Inverter “Control” Switch: This is an inverter control switch. When this switch is

pushed in conjunction with the inverter “On” switch the inverter will activate. Similarly, when this switch is pushed with the inverter “Off” switch the inverter will shutdown. This switch acts as a safety switch to prevent accidental operation of the inverter.

R. Inverter “Off” Switch: This is an inverter control switch. When this switch is pushed

simultaneously with the control switch the inverter will be turned off.



8 OPERATION

After all the cables have been connected and power is present at the input terminal, the UPS is ready to operate. Before initial start-up, re-check the following: a. Make certain there is no foreign material left on, inside or around the UPS b. Ensure all breakers and the battery disconnect switches are opened c. Ensure all loads are switched off. d. Check that the input frequency matches the UPS’s rated input frequency e. Check that the input voltage matches the UPS’s rated input voltage

8.1 Switch On Procedure (Authorized Trained Personnel ONLY) These start-up procedures can be preformed with the AC utility source connected to or with only the batteries connected. a. Close the input breaker – Energize the transformer. b. Close the reserve breaker – The reserve and output LED on the status panel will light up,

indicating the reserve static switch loop is energized and there is power on the output terminals. The power supplies within the UPS will energize and the internal fans will rotate.

c. Close the rectifier breaker - The rectifier will automatically start if the AC utility power connected is within operating parameters. The DC voltage will slowly rise (15 – 30 sec.) until the designated voltage is reached. The DC voltage is now ready for the inverter and battery bank.

d. Close the battery breaker - A breaker between the battery to the DC bus is used for safety purposes. The batteries will start charging once the breaker is closed. This breaker can be located within the UPS system or within the battery cabinets depending on rating.

e. Push inverter on switch – To turn on the inverter simultaneously press the inverter on switch (׀) and the control switch (◄►). The inverter will begin to function with inverter output within 4 sec. The load will automatically transfer to the inverter 3 sec. later. The UPS is now operating in normal mode.

f. Check the status panel for correctness as shown in the diagram on the next page. All warning LED’s on the right hand side are off, two LED’s: ‘INVERTER ON’ and ‘INVERTER STATIC SWITCH’ on the left hand side should be lit, and the LED’s circle should also be lit. If the load is over 70%, the ‘70% LOAD’ LED will also be lit.



8.2 Shutdown Procedure To completely shutdown the UPS, please follow the following steps. a. Switch off the inverter – The inverter can be switched off by simultaneously pressing the

inverter off switch (O) and the inverter control switch (◄►). The load will be automatically transferred to reserve without interruption.

b. Open the battery fuse holder – This will disconnect the batteries from the DC bus and the UPS no longer has back up available. This fuse holder can be located within the UPS system or within the battery cabinets.

c. Open the rectifier breaker – Opening the rectifier breaker will remove the power source from the DC bus. The DC bus will start to drop slowly until it reaches a save level of approximately 20VDC. WARNING! Completing the next step will turn off the power to the loads. Make sure all loads have been turned off before proceeding or the external wrap-around bypass has been initiated.

d. Open the reserve breaker – Before opening the reserve breaker you must make sure there is no critical load connected to the UPS that requires power. NO OUTPUT POWER WILL BE SUPPLIED FROM THE UPS ONCE THE RESERVE (UTILITY) BREAKER IS OPENED.

e. Open the input breaker – transformers will de-energized.

Figure 8.1.1 Status Panel Display Under Normal Operation

Circles represent LED’s that are on.



f. Now that all power has been cut off within the UPS system. All LED’s, displays and fans

should be off.

CAUTION! Terminal strip and breakers may still be energized if the main input breaker feeding the UPS system is not turned off or open.

8.3 From Inverter to Manual Bypass Procedure

The following procedures will allow the service personnel to switch the UPS system to maintenance bypass mode without interrupting the output power to the loads. a. Switch off the inverter – The inverter can be switched off by simultaneously pressing the

inverter off switch (O) and the inverter control switch (◄►). The load will be automatically transferred to reserve (utility) supply without interruption.

b. Open the battery fuse holder – This will disconnect the batteries from the DC bus and the UPS no longer has back up available. This fuse holder can be located within the UPS system or within the battery cabinets.

c. Open the rectifier breaker – Opening the rectifier breaker will take the power source away from the DC bus, therefore, the DC bus will start to drop slowly. After 5 min., the DC bus will drop to a safe level (approx. 20VDC).

d. Close the bypass breaker – The reserve breaker and reserve static switch are still conducting. When the maintenance bypass breaker is closed, power will flow through the bypass loop instead of the reserve loop because the impedance of the bypass loop is lower.

e. Open the reserve breaker – You can now open the reserve breaker to cut off any power within the UPS electronics.

NOTE: To place the unit into Maintenance Bypass mode the fuse holders behind the control module (where all control PCB’s are stored) must be opened. The system is now in Manual Bypass mode (or Maintenance Bypass mode).

CAUTION! If fuse holders have not been opened power still present and fans will be turning. If fuse holders open power is still present at the terminal strip and several terminals on the PCB’s.



8.4 From Manual Bypass To Inverter Procedure After the maintenance procedures and testing are complete you will need to restore the UPS back to its normal mode of operation without interrupting the power to the loads. The following procedures need to be followed. a. Close all fuse holders – ensure all fuse holders behind the control module are closed. Fans

will start spinning. b. Close the reserve breaker – Wait 15 seconds for the reserve and output LED on the status

panel to light up, indicating the reserve static switch loop is energized and there is power on the output terminals. The power supplies within the UPS will also energized and the internal fans will rotate.

c. Open the bypass breaker – The inverter cannot be switched on when the maintenance bypass breaker is closed (because the CPU will sense the breaker and prevent the inverter from connecting directly to the AC source). The reserve breaker is already closed so power goes through the reserve loop if the bypass breaker is open. AC power at the output will not be interrupted.

d. Close the rectifier breaker - The rectifier initiates automatically if the AC utility power connected is with in operating parameters. The DC voltage will slowly rise (15 – 30 sec.) until the designated voltage is reached. The DC voltage is now ready for the inverter and battery cabinets.

g. Close the battery fuse holder - A fuse holder is employed from the battery to the DC bus for safety purposes. The batteries will start charging once the fuse door or breaker is closed. This fuse holder can be located within the UPS system or within the battery cabinets.

h. Push inverter on switch – To turn on the inverter simultaneously press the inverter on switch (׀) and the control switch (◄►). The inverter will start working and the inverter output will be established in 4 sec. The load will automatically transfer to the inverter 3 sec. later. The UPS is now operating in normal mode.

e. Check the status panel is correct, as shown in the diagram on the previous page. All warning LED’s on the right hand side are off, two LED’s: ‘INVERTER ON’ and ‘INVERTER STATIC SWITCH’ on the left hand side should be lit, and the LED’s circle should also be lit. If the load is over 70%, the ‘70% LOAD’ LED will also be lit.



9 THE LCD DISPLAY

The LCD displays Real Time information as to the status and operation characteristics of the UPS system and battery banks. In order to make the display sharp and readable, the LCD is back-lit by LED’s. To prolong the life of the LED, the CPU will cut off the power of the LED 3 minutes after the last key has been pressed. The backlight will illuminate whenever a key has been pressed. This screen will pop up once the system power is enabled (i.e. the default screen).

9.1 Menu 0 – Main Menu

The first row will display the greeting content set by the factory. The model no. (MODEL), serial no. (S/N), and the identification no. (ID) are displayed in the second row. The third row will display the kVA rating, input rating and output rating of the UPS. The serial no. is set by the factory for the convenience of maintenance personnel who may need to refer to the serial number for the correct spare parts and testing procedures. The identification no. is set only when multiple UPS systems are connected in parallel. Each UPS must have a unique number to identify itself, and will be set by a factory trained technician after installation. The YEAR/MONTH/DATE, DAY OF THE WEEK, HOUR, MINUTE and AM/PM from the real time clock inside the UPS are displayed in the fourth row for user’s reference and for stamping the date and time in the historical data when an abnormal conditions occurs. By pressing one of the UP(↑), DOWN(↓) or ENTER(↵) keys, the LCD will change to another screen.

W E L C O M E T O A L WA Y S O N U P S S Y S T E M S I N C

M O D E L : N X - S E R I E S S / N : 3 4 5 6 7 8 9 0 I D : 0 15 0 K V A I : 1 2 0 2 0 8 V 6 0 H Z O : 1 2 0 2 0 8 V 6 0 H Z

2 0 0 2 0 2 0 1 T U E 0 8 : 0 0 A M Figure 9.1.1

Main Menu Display



9.2 Menu 1 – Select Menu

MENU 1 is reached by pressing any button on the opening screen and is also the default menu. From this menu the personnel can select STATUS WARNING FAULT (MENU 2 – Section 10.3), REAL TIME DATA (MENU 3 – Section 10.4), HISTORICAL DATA (MENU 4 – Section 10.5) and PARAMETER SET (MENU 5 – Section 10.6). To select an option move the cursor (→) by pressing the UP (↑) key, or the DOWN(↓) key. Selections are confirmed by pressing the ENTER (↵) key. The user will be sent to the menu the cursor is pointing to. If the item ‘PARAMETER SET’ is selected, the LCD will jump into a screen that will prompt the user for a password. See the figure below.

The numbers are changed by pressing the UP (↑) or the DOWN(↓) key respectively and is confirmed by the ENTER(↵) key. When the four-digit password has been entered successfully you will proceed to the selected area. If the password has been entered incorrectly three times the display will revert to the default menu (MENU 0). The password for entering the < PARAMETER SET > menu is 1-2-3-4. To change the password, please review MENU 12 (Section 10.13). To return to MENU 0 select the ‘EXIT’ option (blinking instead of pointed by cursor).

S E L E C T M E N US T A T U S W A R N I N G F A U L T P A R A M E T E R S E T

R E A L T I M E D A T A H I S T O R I C A L D A T A E X I T

P A S S W O R D : 1 2 3 4

Figure 9.2.1 Select Menu Display

Figure 9.2.1 Password Menu Display



9.3 Menu 2 – Status Warning Menu

The Status/Warning menu is accessed through MENU 1 by selecting STATUS WARNING FAULT. The left-hand side of this menu shows the real time status of the rectifier, inverter and static switch, while the right hand side shows the warning or fault condition if any. Under normal condition, the LCD display should be exactly the same as the figure shown above. When abnormal conditions occur it will be shown under the title < WARNING >, but this will be overridden by a “fault” message if more serious abnormal conditions occur and the title < WARNING > will then change to < FAULT >. For example, if a short circuit has occurred, this screen will display as follows:

The inverter will automatically shut off under a short circuit fault. The CPU is designed to detect short circuits and in order to avoid unnecessary tripping of the reserve (utility supply) breaker, the static switch will remain open or inactive. (There will be no output power present) Listed below are all the warning conditions that can be displayed (they are arranged in order of priority, starting with the highest priority): 1st row: BYPASS ON – Output is being supplied by the reserve RECT AC FAIL – AC utility source failure

RECTIFIER PHASE ERROR – AC utility phase loss or one phase out of operating parameters RESERVE FREQ. ERROR – AC utility frequency is out of parameters and reserve has been disabled until error is corrected

2nd row: 170% OVERLOAD – over 170% maximum capacity for the UPS system. 150% OVERLOAD – over 150% maximum capacity for the UPS system. 125% OVERLOAD – over 125% maximum capacity for the UPS system. 110% OVERLOAD – over 110% maximum capacity for the UPS system. 3rd row: BATTERY LOW STOP – Battery have been exhausted.

BATTERY LOW – Batteries have passed the low voltage level and will soon be exhausted.

BATTERY BAD – One or more cells have tested faulty. BATTERY GND FAULT – Battery cabinet not grounded properly. BATTERY TESTING – performing test on the batteries.

S T A T U S W A R N I N G

R E C T I F I E R = O N

I N V E R T E R = O NL O A D O N I N V E R T E R

S T A T U S F A U L T

R E C T I F I E R = O N S H O R T C I R C U I T

I N V E R T E R = O F FL O A D O N I N V E R T E R

Figure 9.3.1 Status Warning Menu Display

Figure 9.3.2 Warning Status Display with Fault Condition



Listed below are all the fault conditions that can be displayed: 1st row: HIGH DC SHUTDOWN – DC Bus voltage out of operating range. 2nd row: SHORT CIRCUIT! – a short circuit condition has occurred on the output. FUSE/OVERHEAT – a fuse has blown or the system has shutdown due to

overheating. OVERLOAD SHUTDOWN – system has exceeded the overload limit beyond the operating window.

EMERGENCY STOP – user has activated the emergency stop feature. INVERTER ABNORMAL – inverter is not operating within specified parameters. 3rd row: BYPASS ON SHUTDOWN – inverter failure, system operating in bypass mode. The UP (�) or DOWN (�) key has no function in this menu. The screen will go back to MENU 1, when ENTER(�) is pressed.

9.4 Menu 3 – Real Time Data Menu

MENU 3 is reached by selecting REAL TIME DATA on MENU 1. The cursor(→) is used to select what type of real time data the user would like to view, RECTIFIER DATA (MENU 6 – Section 10.7), RESERVE DATA (MENU 7 – Section 10.8), OUTPUT DATA (MENU 8 – Section 10.9) and OTHER DATA (MENU 9 – Section 10.10). To select one of the different menu options move the cursor(→) until it is pointing at the correct selection, by press the UP (↑) key or the DOWN (↓) key. To confirm and select the menu option press the ENTER (↵) key. Selecting the ‘EXIT’ option (blinking instead of pointed by cursor) will return you to MENU 1.

R E A L T I M E D A T A

R E C T I F I E R D A T A O T H E R D A T A

R E S E R V E D A T AO U T P U T D A T A E X I T

Figure 9.4.1 Real Time Data Menu Display



9.5 Menu 4 – Historical Event Menu

MENU 4 is reached by selecting HISTORICAL DATA on MENU 1. All abnormal events are stored on the EEPROM and viewed through this menu based on the time each event occurred. The record display starts with the date and time stamp allowing the user or maintenance personnel to trace back that occurrence. A maximum of 77 records can be stored in one EEPROM. This can be increased to 154 records with the addition of a second EEPROM. These records are hard coded onto the EEPROM and will not be erased by cutting off the power supply or during a complete shutdown of the UPS, i.e. they will be kept in the EEPROM forever until they’re overwritten by the 78th (or the 155th) events. The three most recent records are displayed at one time on the view screen. The displayed records will move one record upward when the UP (↑) key is pressed, and move one record downward when the DOWN (↓) key is pressed. Below is a list of the abnormal conditions that are stored and can be displayed: HIGH DC SHUTDOWN / SHORT CIRCUIT! / FUSE/OVERHEAT / OVERLOAD SHUTDOWN / EMERGENCY STOP / INVERTER ABNORMAL / BYPASS ON SHUTDOWN The display in the top right corner of the screen is the UPS installation time displayed in year/month. This information is provided to allow the user or the maintenance personnel to have a reference point to schedule the next preventative maintenance visit. To return to MENU 1 press the ENTER (↵) key.

D A T E T I M E E V E N T S > R U N : 2 1 Y R 0 3 M O2 0 0 2 \ 0 3 \ 2 9 0 9 : 3 22 0 0 2 \ 1 1 \ 0 1 2 2 : 1 52 0 0 3 \ 0 3 \ 1 0 1 5 : 4 7

Figure 9.5.1 Historical Event Menu Display



9.6 Menu 5 – Parameter Setting Menu

MENU 5 is reached by selecting PARAMETER SET on MENU 1 and access is only allowed if the correct password is entered. The cursor (→) is used to select which parameter the user would like to edit, such as INVERTER ON/OFF, BUZZER ON/OFF, BOOST CHARGE, DATE/TIME. To select one of the different menu options move the cursor(→) until it is pointing at the correct selection, by press the UP (↑) key or the DOWN (↓) key. To confirm and select the menu option press the ENTER (↵) key. The INVERTER ON/OFF option allows the user to activate or deactivate the inverter. When selected the blinking display (ON or OFF) indicates the current status of the inverter. To change the state of the inverter press the UP (�) or the DOWN (↓) key and confirm selection by pressing the ENTER (↵) key. ‘INVERTER = ON’ will be displayed if ‘ON’ is selected or ‘INVERTER = OFF’ will be displayed if ‘OFF’ is selected. To control the state of the buzzer select the BUZZER ON/OFF option. Again the current status of the buzzer is indicated by the blinking ON or OFF. To change the state of the buzzer press the UP (↑) or the DOWN (↓) key and confirm selection by pressing the ENTER (↵) key. ‘BUZZER = ON’ will be displayed if ‘ON’ is selected or ‘BUZZER = OFF’ will be displayed if ‘OFF’ is selected. Selecting the BOOST CHARGE option will bring you to MENU 10 (Section 10.11). Selecting the DATE/TIME option will bring you to MENU 11 (Section 10.12). Selecting the ‘EXIT’ option (blinking instead of pointed by cursor) will return you to MENU 1.

P A R A M E T E R S E T T I N GI N V E R T E R = O N / O F F D A T E T I M E

B U Z Z E R = O N / O F FB O O S T C H A R G E E X I T

Figure 9.6.1 Parameter Setting Menu Display



9.7 Menu 6 – Rectifier Data Menu

MENU 6 is reached by selecting RECTIFIER DATA on MENU 3. The information provided on this menu is the real time readings of the rectifier input; RECTIFIER FREQUENCY, R-N/S-N/T-N VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R VOLTAGE on delta (≥) configured systems. The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3 when the ENTER (↵) key is pressed.

9.8 Menu 7 – Reserve Data Menu

MENU 7 is reached by selecting RESERVE DATA on MENU 3. The information provided on this menu is the real time readings of the reserve input; RESERVE FREQUENCY, R-N/S-N/T-N VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R VOLTAGE on delta (≥) configured systems. The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3 when the ENTER (↵) key is pressed.

R E C T I F I E R D A T A >

R E C T I F I E R F R E Q U E N C Y = X X H Z

R - N = X X X V a c S - N = X X X V a c T - N = X X X V a c

< R E S E R V E D A T A >R E S E R V E F R E Q U E N C Y = X X H Z

R - N = X X X V a c S - N = X X X V a c T - N = X X X V a c

Figure 9.7.1 Rectifier Data Menu Display

Figure 9.8.1 Reserve Data Menu Display



9.9 Menu 8 – Output Data Menu

MENU 8 is reached by selecting OUTPUT DATA on MENU 3. The information provided on this menu is the real time readings of the inverter or reserve output (depending on what mode the system is in); OUTPUT FREQUENCY, LOAD % OF R/S/T, OUTPUT R-N/S-N/T-N VOLTAGE for wye (Y) configured systems or R- S/S-T/T-R VOLTAGE on delta (∆) configured systems. The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3 when the ENTER (↵) key is pressed.

9.10 Menu 9 – Other Data Menu

MENU 9 is reached by selecting OTHER DATA on MENU 3. The information provided on this menu is the real time readings of the UPS system; TEMPERATURE, DC VOLTAGE, CHARGE OR DISCHARGE CURRENT. When the UPS system is operating in normal mode the last line on MENU 9 will read CHARGE CURRENT and will represent the amount of current being supplied to the batteries. When the system changes to back-up mode the last line will change to DISCHARGE CURRENT displaying how much current is being supplied to the inverter from the batteries (figure below).

The UP (↑) or DOWN (↓) key has no function in this menu. The screen will return to MENU 3 when the ENTER (↵) key is pressed.

O T H E R D A T A

T E M P E R A T U R E = X X C

D C V O L T A G E = X X X V d c D I S C H A R G E C U R R E N T = X X X A

O T H E R D A T A

T E M P E R A T U R E = X X C

D C V O L T A G E = X X X V d c C H A R G E C U R R E N T = X X X A

O U T P U T D A T A

O U T P U T F R E Q U E N C Y = X X H Z

L O A D : R = X X X % S = X X X % T = X X X % R - N = X X X V a c S - N = X X X V a c T - N = X X X V a c

Figure 9.9.1 Output Data Menu Display

Figure 9.10.1 Other Data Menu Display

Figure 9.10.2 Other Data Menu Display when system in Back-up Mode



9.11 Menu 10 – Boost Charge Setting Menu Warning! These settings have been preset by the factory to optimize the battery bank requirements. Do not change settings unless factory or factory trained service personnel have been consulted.

MENU 10 is reached by selecting BOOST CHARGE on MENU 5. This option allows the maintenance personnel to select the amount of boost charge required to maintain the batteries at their optimal performance. Move the cursor (→) up or down (UP (↑) and DOWN (↓) key respectively) and select the option by pressing the ENTER (↵) key.

AUTO-BOOST (MONTH) controls the number of hours that the system will be boost charged every month. This boost charging conditions the batteries and increases the life expectancy of the batteries. Warning! These are preset options by the factory. DO NOT CHANGE without consulting factory. AUTO-BOOST (BATT LOW) controls the number of hours that the system will be boost charged after the system has reached a low battery condition. This boost charging recharges the batteries at a faster rate and will improve the conditioning of the batteries. Both of the above AUTO-BOOST selections have six options for recharge rate (04, 08, 12, 16, 20 and 24) the numbers represent the number of hours the system will perform the boost charge for. The option is selected by the number of battery bank, the number of cells per battery bank and the type of batteries used within the battery bank. The factory set value will be display or will flash if the option has been selected. To select a different option use the UP (↑) or the DOWN (↓) key to select the time and press the ENTER (↵) key to confirm.

B O O S T C H A R G E S E T T I N G

A U T O - B O O S T ( M O N T H ) = 0 4

A U T O - B O O S T ( B A T T L O W ) = 0 8C H A R G E C U R R E N T = L O E X I T


A U T O - B O O S T ( M O N T H ) = 0 4 0 8 1 2 1 6 2 0 2 4

A U T O - B O O S T ( B A T T L O W ) = 0 4C H A R G E C U R R E N T = L O E X I T

Figure 9.11.1 Boost Charge Setting Menu Display

Figure 9.11.2 Boost Charge Setting Menu Display Program Settings



CHARGE CURRENT increases the amount of charge current the rectifier/charge supplies the battery bank. There are three possible options (LO/ME/HI). The factory will set the system at the optimal charge level for the battery bank provided. To change the level of charge select the CHARGE CURRENT option then select the level of charge via the UP (↑) and DOWN (↓) keys. Once the level of charge has been selected confirm with the ENTER (↵) key. The CHARGE CURRENT can be roughly selected by the simple rule listed below: CHARGE CURRENT SETTING 10 – 30 min battery back-up LOW 30 min – 1 hour battery back-up MEDIUM > 1 hour battery back-up HIGH Selecting the ‘EXIT’ option (blinking instead of pointed by cursor) will return you to MENU 5.


A U T O - B O O S T ( M O N T H ) = 0 4

A U T O - B O O S T ( B A T T L O W ) = 0 4 0 8 1 2 1 6 2 0 2 4C H A R G E C U R R E N T = L O E X I T

Figure 9.11.3 Boost Charge Setting Menu Display Program Settings



9.12 Menu 11 – Data Time Setting Menu

MENU 11 is reached by selecting DATE/TIME on MENU 5. This menu allows the user to set the YEAR, MONTH, DAY, HOUR, MINUTE and DAY OF THE WEEK of the real time clock. The display upon selection is the current time and day (factory preset). To change any to the variables move the cursor (→) to the correct variable by pressing the UP (↑) and DOWN (↓) key, the ENTER (↵) key will confirm the selection. Below is a list of the available variables: • YEAR : 1998 – 2097 • MONTH : 01-12 • DAY : 01 – 31(internal calendar will correct it if 31 is entered to a 30day month) • HOUR : 0 – 23 • MINUTE : 0 - 59 • DAY OF THE WEEK : MON, TUE, WED, THU, FRI, SAT, SUN The values (selected value is flashing) are increased by the UP (↑) key, and can be decreased by the DOWN (↓) key and confirmed by the ENTER (↵) key. If ‘EXIT’ is selected (blinking instead of pointed by cursor), the screen will go back to the MENU 5- the PARAMETER SETTING menu.

9.13 Menu 12 – Other Setting Menu

This menu is for factory use only and is password protected.

D A T E T I M E S E T T I N G

Y E A R = X X X X H O U R ( 2 4 H ) = X X

M O N T H = X X M I N U T E = X XD A Y = X X D A Y O F T H E W E E K = M O N E X I T

O T H E R S E T T I N G T I T L E :

A L W A Y S O N U P S S Y S T M S G E S - x x x N X 3 3 M O D E L : 5 0 3 3 A S I N : 1 2 3 4 5 6 7 8 9 0 I D : 0 0 E X I T

E

Figure 9.12.1 Data Time Setting Menu Display

Figure 9.13.1 Other Setting Menu Display



10 INTERFACE CONNECTIONS All user interfaces are connected to or from PCB 3R, see the figure below.

10.1 Dry Contacts

Eight, normally open, dry contact terminals are provided. Maximum rating of each relay is 16A/250VAC or 16A/30VDC. Definitions: • INVON – Closed when inverter is on. • OVL – Closed when load exceeds overload limits. • FAULT – Closed when system encounters a fault condition such as: Rectifier high DC

shutdown, output short circuit, inverter fuse or over temperature condition, inverter overload shutdown, emergency stop activation, inverter abnormal, and bypass on shutdown. The contact is latched until it is manually reset (off switch) or the fault has been cleared for 30 seconds.

• SS – Closed when the inverter static switch is active, open when the reserve static switch is

active. The two static switches will never conduct simultaneously. • BYPASS – Closed when the manual bypass breaker is closed, open when the manual bypass

breaker is opened. • BACK-UP – Closed while the system is in back-up mode (batteries supplying DC Bus). • BATL – Closed when low battery condition occurs and the batteries are about to be exhausted.

Figure 10.1.1 3R PCB Layout



• COM – This contact is the OR result of the signals described above. That is, if any other contact closes, this contact will close too. The signal to be read is selectable through SWR2. See the figure below.

10.2 Software for PC Monitoring The monitoring software allows for a server or workstation to monitor the UPS operation. When the software is installed on a PC it can monitor 1-99 UPS’s connected in series via a DB9 connection. The connector on the UPS side is RS-485 (for long distance transmission) therefore a RS-485 RS-232 adapter (hardware) is required to modify the signal (not included with UPS system).

10.3 Emergency Power Off Connection Two pairs of terminals (CNR 3) are provided to allow the user to shutdown the UPS system in an emergency situation (e.g. fire, short circuit, etc.). A minimum of 10mA is needed for activate the photo-coupler.

10.4 DB9 Connectors Four RS-485 and one RS-232 are provided to communicate with more sophisticated optional communication modules. Each connector is dedicated to one type of external module. Below is a list of some of the optional features available: Software for PC monitoring or SNMP (web monitoring) card Battery Monitoring Module Remote Control Panel Transferring RS-485 into RS-232

10.5 Web Monitoring Module (SNMP Module) Simple Network Management Protocol. The SNMP Card is an Interface to the Ethernet network, and provides UPS information via the standard SNMP protocol. The UPS can therefore be managed via an internet browser. This information can be used to determine the state of the UPS and guarantee safe and orderly shutdown of servers and workstations when needed.

Figure 10.1.2 Dry Contact Layout



Figure 11.1.1 D Cabinet Battery Cabinet Layout

Figure 11.1.2 E Cabinet Battery Cabinet Layout

Figure 11.1.3 K Series 3 Phase Battery Cabinet Layout

11 OPTIONS

Warning! Similar products from other manufacturers will not fit into our UPS systems. The installation of any option requires professional settings and should only be preformed by the factory or factory trained representatives.

11.1 Battery Cabinet The battery cabinets have been designed with the same style and appearance as the UPS cabinet for ease of installation and cosmetic value. Re-enforcement has been added to strengthen the cabinet for the additional weight and transportation. The Battery Banks contain the batteries and provide the runtime for the UPS system.



11.2 Battery Runtime Charts

4000W 8,000W 12,000W 16,000W 24,000W 32,000W5000VA 10,000VA 15,000VA 20,000VA 30,000VA 40,000VA

BBU-NX33D 25 mins 9 mins 4 minsBBU-NX33E 90 mins 40 mins 20 mins 15 mins 7 minsBBU-NX33KF 36 mins 23 mins 18 mins 10 mins 5 minsBBU-NX33KG 80 mins 36 mins 32 mins 17 mins 10 minsBBU-NX33KH 108 mins 76 mins 46 mins 28 mins 19 minsBBU-NX33KI 105 mins 81 mins 40 mins 24 minsBBU-NX33KJ 108 mins 72 mins 38 mins

Load

Model

40,000W 48,000W 64,000W 80,000W 96,000W 128,000W 160,000W50,000VA 60,000VA 80,000VA 100,000VA 120,000VA 160,000VA 200,000VA

BBU-NX33KG 6 minsBBU-NX33KH 12 mins 10 minsBBU-NX33KI 21 mins 18 mins 12 mins 8 mins 5 minsBBU-NX33KJ 33 mins 23 mins 18 mins 13 mins 10 mins2 X BBU-NX33KI 66 mins 40 mins 24 mins 21 mins 18 mins 12 mins 8 mins2 X BBU-NX33KJ 92 mins 72 mins 38 mins 33 mins 23 mins 18 mins 13 mins

Load

Model

Model Cabinet Style Dimensions Weight

BBU-NX33D D Cabinet 235 (9.25") W x 546 (21.5") D x 552 (21.75") H 117 kg (258 lbs)BBU-NX33E E Cabinet 400 (15.75") W x 682 (26.75") D x 1,008 (39.75") H 511 kg (1,126 lbs)BBU-NX33KF KF Cabinet 1,314 (51.5") W x 850 (33.5") D x 1,945 (76.5") H 814 kg (1,791 lbs)BBU-NX33KG KG Cabinet 1,314 (51.5") W x 850 (33.5") D x 1,945 (76.5") H 1,024 kg (2,258 lbs)BBU-NX33KH KH Cabinet 1,314 (51.5") W x 850 (33.5") D x 1,945 (76.5") H 1,204 kg (2,649 lbs)BBU-NX33KI KI Cabinet 1,314 (51.5") W x 850 (33.5") D x 1,945 (76.5") H 1,398 kg (3,076 lbs)BBU-NX33KJ KJ Cabinet 1,314 (51.5") W x 850 (33.5") D x 1,945 (76.5") H 1,764 kg (3,881 lbs)

Warning! If system is shutdown after low battery and utility, or the input power source, does not return within 48 hours, please shutdown the UPS system completely (Open all breakers including the battery breaker). If not, battery damage may occur.



11.3 Emergency Stop Switch This switch is used to immediately remove power from the load in the event of an emergency condition e.g. electrical shock, burning of the load or water located around the UPS. When the emergency stop button is pushed, the inverter will stop running immediately and the static switch does not activate. There will be no AC supply at the output. This shutdown condition is latched until a manual reset has been preformed. Manual reset is preformed by pressing the inverter off switch (O) and the inverter control switch ( ) simultaneously. Once the system is reset follow the Start-up procedure discussed earlier to turn the system back on.

11.4 Remote Display Panel The remote panel is a display module with LCD and LED’s that can monitor 1 – 99 UPS’s via a DB9 connected in series from distance < 1000m. It allows for remote monitoring of the UPS status and alarms.

11.5 Isolated Parallel Redundant Operation (IPRO) Two or more UPS systems can be paralleled to improve the overall reliability of an UPS system. The outputs of parallel units are connected to a common power bus, and in normal operation the units connected on the parallel bus share the load equally. The modular design of NX Series allows parallel operation, without using paralleling switchgear, external bypass circuits or common control circuitry. The output power rating of the redundant paralleled systems must be equal to or greater than the power required by the load in order to function properly. The output power will be equally divided among the paralleled UPS system connected. Should one of the paralleled systems be shutdown or shutdown unexpectedly, the remaining system will automatically assume the load, maintaining conditioned and backed-up power to the critical load. This results in higher reliability, security of the loads, and a substantially increased MTBF (Mean Time Between Failures).

11.6 12-Pulse Rectifier Located inside the UPS system cabinet. The 12-pulse rectifier is a standard feature for all UPS systems, but a 6-pulse rectifier is optional for systems smaller than 80kVA. The 12-pulse rectifier is designed to reduce the input harmonic distortion to less than 12%.

11.7 5th Harmonic Filter Located inside the UPS system cabinet. This filter is designed to reduce the input harmonics from 12% to 9%. This will allow for less reflected harmonics from the UPS system to the utility.

11.8 External Wrap Around Bypass A separate cabinet that allows for complete removal of the UPS system from the load, while still supplying the load with conditioned power. Systems can include isolation transformer for different voltage configurations, distribution panels and Kirk-Key interlock protection to ensure proper operation.



12 TECHNICAL SPECIFICATION 12.1 NX Series – 10kVA to 250kVA UPS 3Ø Input

GENERAL DATA

Topology True On-Line, Dual Conversion

Nominal output at PF=0.8 kVA 10 15 20 30 40 50 60 80 100 120 160 250 100% load, 0.9

PF % 91 91 91 91 91.5 92 92 92.5 92.5 93 93 93 Overall efficiency

50% load, 0.9 PF % 89 89 89 89 89 91 91 91 91 92 92 92

True galvanic isolation from input to output Yes

Heat rejection at 100% load, 0.9PF and charged battery

BTU/hr (kW)

3,070 (0.9)

3,510 (1.0)

4,440 (1.3)

6,480 (1.9)

8,870 (2.6)

10,200 (3.0)

11,900 (3.5)

15,700 (4.6)

18,400 (5.4)

22,200 (6.5)

29,700 (8.7)

44,360 (13)

Audible noise level (at 1 m) dB (A) < 65 at 1m maximum < 67 at 1m maximum

UPS 0oC to 40oC (32oF to 104oF) Operating temperature range Battery Optimum 20oC to 25oC (68oF to 77oF) Higher temperatures reduce battery life expectancy

UPS -15oC to +50oC (5oF to 122oF)

Battery 0oC to 40oC (32oF to 104oF) Storage temperature range

(VRLA) Storage time is 6 months at 25oC (77oF) Higher temperatures reduce battery storage time

Relative Humidity 0% to 90%, non-condensing

Maximum Altitude Without Derating <1,500m (5,000ft.) No derating

Type Indoor (NEMA 1) [Optional drip shield available] [other configurations available]

Safety Internal dead front construction

Cooling Forced air (bottom to top) Enclosure

Colour Manufacturer colour (ivory)

Installation Rigging Suitable for handling by forklift

Mounting Casters and Floor mounting brackets

Installation and maintenance access Front access required for normal maintenance

Conduit access Bottom entry standard [Optional top entry]



Standards CSA 22.2 – 107.1, UL 1778, IEC 62040, FCC Part 15 Class A, EN50091-1, -2

Electrostatic discharge immunity 4kV contact / 8kV air discharge

Standard Stand-alone Configuration

Optional IPRO - up to 8 units may be paralleled for redundancy or capacity

RECTIFIER

Configuration Standard 12 pulse with filter [Optional 6 pulse] Standard 12 pulse with filter

Voltage Standard 208VAC, 3 phase, 4 wire + ground (-20% to +15% without battery discharge) [Optional transformers to change voltage to 480 or 600VAC systems and 3 wire systems]

Frequency 45 to 65 Hz

Power Factor < 1 (typical)

Inrush current Limited by soft-start circuit

Input

Power walk-in: 20 seconds

Output Voltage tolerance +/- 1%

DC ripple voltage +/- 0.5% Output

DC ripple current Max. 5% of battery capacity expressed in amps

Full load input current (A) (Based on 208VAC) 22 33 44 67 89 111 133 178 222 395 355 555

Maximum input current (A) (Based on 208VAC) 33 50 67 100 133 167 200 267 333 500 533 833

Output current limit (A) (Based on 208VAC) 18 27 36 53 71 89 107 142 178 324 284 444

Maximum Current THD 12 Pulse with filter: 9%; 6 Pulse: 30%

BATTERY

Nominal output at PF=0.8) kVA 10 15 20 30 40 50 60 80 100 120 160 250

Battery compatibility Sealed lead-acid [Optional NiCD or flooded]

Number of cells 174 Cells

Voltage range 295 - 410VDC

Float voltage at 20oC (68oF) 396VDC

Low voltage level 320VDC



Minimum discharge voltage 295VDC

Boost charge voltage 410VDC

Maximum Charge Current (ADC) 10 10 10 15 20 25 30 40 50 60 80 80

Recharge time for 30 minute battery to 95% capacity 10 times the discharge time (15 times for 40kVA)

Internal Batteries Available Not Available

Battery ground fault detection Standard

Automatic and manual battery test Standard Self Test and Conditioning

INVERTER

Nominal output at PF=0.8) kVA 10 15 20 30 40 50 60 80 100 120 160 250

DC voltage input range 285 - 415VDC

Nominal output voltage 208/120VAC, 3 phase, 4 wire + ground [480/277 and 600/347VAC configurations are available]

Maximum output wattage (kW) 8 12 16 24 32 40 48 64 80 96 128 200 Full load output current (A) – Single Phase Output 26 40 54 80 107

Full load output current (A) – Three Phase Output 18 26 35 53 71 89 106 142 178 316 284 444

Maximum output peak current (A) (Based on Single Phase 120/240V) 79 121 162 241 323

Maximum output peak current (A) (Based on Three Phase 120/208V) 53 80 106 159 214 267 320 428 533 948 852 1332

Inverter bridge IGBT technology via Pulse Width Modulating

Output isolation transformer Standard

Output power factor 0.8

Frequency lock range 45 - 55Hz / 55 - 65Hz

Output waveform True Sine Wave

Static +/- 1%

Load step 0% - 100% - 0% +/- 3%, recovering to within +/- 1% in 1 cycle

Output voltage tolerance

Load step 0% - 50% - 0% +/- 2%, recovering to within +/- 1% in 1 cycle



100% unbalanced load (Ph-N) +/- 3%

100% linear load < 2% THD maximum Output voltage distortion 100% non-linear load < 3% THD maximum

Crest factor capability Greater than 3:1

100% balanced load 120o +/- 1% Phase displacement 100% unbalanced load 120o +/- 2.5% Output frequency Free running 50 / 60Hz, +/-0.1% Synchronized with utility

< 110% Continuous

110 - 125% 15 minutes

125 - 150% 5 minutes

Overload capability (on

inverter)

> 150% 30 seconds

Efficiency (100% Load) 92.5% 93.0% 93.0% 93.0% 93.5% 93.5% 94.0% 94.5% 94.5% 95.0% 95.0% 94.5%

BY-PASS

Input configuration Common to rectifier (standard) or dual input (optional)

Primary components Full load rated static switch, back-feed protection and internal maintenance by-pass

Voltage range +/- 20% of input voltage (line to neutral)

Frequency range 45 - 55Hz / 55 - 65Hz

Efficiency 99.50%

Inverter to bypass 0 ms Transfers time

Bypass to inverter 0 ms

200% of UPS rating 30 seconds Overload capability

400% of UPS rating 1 second

Short circuit capability (on by-pass) 1000% for 1/2 cycle (non-repetitive)

Isolation transformer Yes



EXTERNAL INTERFACE

Alarm contacts Standard 8 pre-defined contacts (consult user manual)

Serial communication RS-232

Ethernet communications SNMP standard

Emergency Power Off contacts provided (optional switch) Input signals

Status displayed on LCD Panel

FRONT PANEL CONTROLS, SIGNALS & ALARMS

Active mimic Diagram Represents the operational status of the UPS, with integrated LED's and power flow indicators.

LED display Displays operational and fault conditions

Audile alarm audible signal active when any alarm condition is present.

LCD Display Display of UPS metering functions and event history (multi-language)

Push-Buttons Inverter On, Inverter Off, Inverter Control, Up key, Down key, Enter key

OPTIONAL FEATURES

IPRO Isolated Parallel Redundant Operation

Remote status Panel Active mimic diagram w/ Stop Operation and Summary Alarms.

Fire suppress protection Drip shield

Dust protection Air filters

Battery Cabinets Additional matching battery cabinets to extend runtime

MECHANICAL DATA



UPS Rating Dimensions Weight

(kVA) W (Width) D (Depth) H (Height) UPS Floor Loading 10 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 380kg (838lbs) 864 kg/sq.m (177 lbs/sq.ft.) 15 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 415kg (915lbs) 943 kg/sq.m (193 lbs/sq.ft) 20 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 450kg (992lbs) 1,023 kg/sq.m (210 lbs/sq.ft) 30 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 580kg (1,279lbs) 1,318 kg/sq.m (270 lbs/sq.ft.) 40 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 650kg (1,433lbs) 1,477 kg/sq.m (303 lbs/sq.ft.) 50 559mm (22.0") 815mm (32.0") 1,600mm (63.0") 710kg (1,565lbs) 1,614 kg/sq.m (330 lbs/sq.ft) 60 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 920kg (2,024lbs) 1,672 kg/sq.m (207 lbs.sq.ft.) 80 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 920kg (2,024lbs) 1,672 kg/sq.m (207 lbs.sq.ft.)

100 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 1,050kg (2,310lbs) 1,909 kg/sq.m (236 lbs/sq.ft.) 120 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 1,300kg (2,860lbs) 2,363 kg/sq.m (293 lbs/sq.ft.) 160 1,100mm (43.25") 815mm (32.0") 1,600mm (63.0") 1,600kg (3,520lbs) 2,909 kg/sq.m (360 lbs/sq.ft.) 250 2,200mm (86.6") 815mm (32.0") 1,600mm (63.0") 1,950kg (4,299lbs) 1,108 kg/sq.m (227 lbs/sq.ft.) 320 2,200mm (86.6") 815mm (32.0") 1,600mm (63.0") 2,450kg (5,401lbs) 1,392 kg/sq.m (285 lbs/sq.ft.)

All specifications mentioned above are subject to change without prior notice.



13 CONTACT INFORMATION QA / Warranty Questions Always On UPS Systems Inc. Bldg 1 – 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 209 Fax: (250) 491-9775 Email: [email protected] Website: www.alwaysonups.com Software Questions Always On UPS Systems Inc. Bldg 1 – 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 204 Fax: (250) 491-9775 Email: [email protected] Website: www.alwaysonups.com Additional Purchases or Upgrades Always On UPS Systems Inc. Bldg 1 – 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 451 Fax: (250) 491-9775 Email: [email protected] Website: www.alwaysonups.com

Class I, Division 1 and 2, Groups B, C, DClass II, Division 1 and 2, Groups E, F, GClass IIIClass I, Zone 1, Group IIB +H2NEMA 4, 4X, 7BCD, 9EFG

Applications

Features

✢

®

Standard Materials

®

Standard Finishes

Options Must be listed in alphanumeric sequence at the end of the catalog number.

BRDN

NP° V

AS1AS2

LBST

UV

★ EPD

GFI

L5

AS1AS2ST

UV

Certifications and Compliances

GFI Push-to-Test Buttons are standard with GFI or EPD options. ✢ Cutler-Hammer is a trademark of the Eaton Corporation.

APLN APPN

AGPN shown with MB and INV options

Dist

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N EQ

UIPM

ENT:

PANE

LBOA

RDS

Visit our website at www.appletonelec.com or contact us at (800) 621-1506. © October 2012

698

ALPN, AGPN and APPN Series Distribution PanelboardsExplosionproof, Dust-Ignitionproof, Watertight, Non-Factory Sealed


Select branch breakers as desired in panel. First and second digits are the quantity of breakers, third and fourth digits are ampere rating, the fifth digit is number of poles. Example: An 18-circuit 120/240 V 1-phase 3-wire 100 Amp MLO panel with 12 1-pole 20 Amp and 3 2-pole 30 Amp branch breakers should read ALPNB11A18ML100-10501GFI-

Catalog Numbering GuideALPN B 1 1 A 18 MB 100 10 50 1 GFI __

(include only if different from wiring system)

(See Options)

▲ To complete the catalog number please add the appropriate suffix for other options/features. These suffixes can be found under Options.

Distribution Equipment

DISTRIBUTION EQUIPMENT: PANELBOARDS


699

ALPN Series Lighting Distribution PanelboardsExplosionproof, Dust-Ignitionproof, Watertight, Non-Factory Sealed

Typical Panelboard Wiring Diagram

1-Phase, 3-Wire Systems 3-Phase, 4-Wire Systems

▲ To complete the catalog number please add the appropriate suffix for other options/features. These suffixes can be found under Options.

Number of

Circuits

120/240V 1-Phase 3-Wire

BAB Type

120/208V 3-Phase 4-Wire

BAB Type

240V3-Phase 3-Wire Delta

BAB TypePanel Size

Approximate Weight (lbs/kgs)

ALPNA11A12ML ▲ ALPNA12C12ML ▲ ALPNA15B12ML ▲

ALPNB11A18ML ▲ ALPNB12C18ML ▲ ALPNB15B18ML ▲

ALPNC11A24ML ▲ ALPNC12C24ML ▲ ALPNC15B24ML ▲





ALPND21A36ML ▲ ALPND22C36ML ▲ ALPND25B36ML ▲

ALPND21A42ML ▲ ALPND22C42ML ▲ ALPND25B42ML ▲

ALPNC11A12MB100 ▲ ALPNC12C12MB100 ▲ ALPNC15B12MB100 ▲


ALPND11A24MB100 ▲ ALPND12C24MB100 ▲ ALPND15B24MB100 ▲






ALPNF21A42MB225 ▲ ALPNF22C42MB225 ▲ ALPNF25B42MB2225 ▲

Note: For Back Fed main, replace ML, MB100, or MB225 in part number with BF. For 400 Amp Main Lug, contact your local representative. Standard interrupting capacity is 10,000 AIC. For higher interrupt ratings, contact your local representative.


ALPN Series Lighting Distribution PanelboardsExplosionproof, Dust-Ignitionproof, Watertight, Non-Factory Sealed

Dist

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ENT:

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RDS


700

mmiller4

Rectangle

mmiller4

Rectangle

Panel A - Front View Panel B - Front View Panel C - Front View

Panel A - End View Panel B - End View Panel C - End View

Panel Size

Mounting Dimensions in Inches/Millimeters Standard Top

Outlets Bottom

Mounting Hdw. SetA B C D E F1 F2 G H K

— AMH8

— AMH8

AMH8

All outlets are NPT.

Dist

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706

ALPN, APPN Main Lug Panelboard Dimensions and Mounting HardwareExplosionproof, Dust-Ignitionproof, Watertight, Non-Factory Sealed

mmiller4

Rectangle

mmiller4

Rectangle

Panel C - Front View Panel D - Front View Panel E - Front View

Panel C - End View Panel D - End View Panel E - End View

Panel Size

Mounting Dimensions in Inches/Millimeters Standard Top

Outlets Bottom

Mounting Hdw. SetA B C D E F1 F2 G H K

AMH8

AMH8

AMH8

All outlets are NPT.

Dist

ribut

ion

Equi

pmen

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STRI

BUTIO

N EQ

UIPM

ENT:

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LBOA

RDS


708

ALPN, APPN Main Breaker Panelboard Dimensions and Mounting HardwareExplosionproof, Dust-Ignitionproof, Watertight, Non-Factory Sealed

mmiller4

Rectangle

mmiller4

Rectangle

SCALE:

THIS DRAWING IS THE PROPERTY OF ACCURATE CONTROL CO.

LLC. ANY DRAWING MAY NOT BE COPIED OR DISCLOSED FOR

ANY REASON EXCEPT AS AUTHORIZED IN WRITING BY ACCURATE

CONTROL CO. LLC

FILE NAME:

CUSTOMER:

SHEET:

SALES ORDER #:

PRODUCTION ORDER #:

PURCHASE ORDER #:DRAFTSMAN:

SALESMAN:

DRAWING DATE:

ACCURATE CONTROL CO.

4949 BLALOCK RD

HOUSTON, TX 77041

1-800-291-7945

REV. #TIME

TITLE:

/CHECKED BY: REV. MADE BY REV. DATE APPROVED BY:

06/21/2013

T.J.

P.S.

NEMA 7/9 12 CIRCUIT PANEL BOARD

11N.T.S.

9010547

1027335

1872-KK927549D

CED-DENVER

1027335-1 #2

SCALE:

THIS DRAWING IS THE PROPERTY OF ACCURATE CONTROL CO.

LLC. ANY DRAWING MAY NOT BE COPIED OR DISCLOSED FOR

ANY REASON EXCEPT AS AUTHORIZED IN WRITING BY ACCURATE

CONTROL CO. LLC

FILE NAME:

CUSTOMER:

SHEET:

SALES ORDER #:

PRODUCTION ORDER #:

PURCHASE ORDER #:DRAFTSMAN:

SALESMAN:

DRAWING DATE:

ACCURATE CONTROL CO.

4949 BLALOCK RD

HOUSTON, TX 77041

1-800-291-7945

REV. #TIME

TITLE:

/CHECKED BY: REV. MADE BY REV. DATE APPROVED BY:

06/21/2013

T.J.

P.S.

NEMA 7/9 12 CIRCUIT PANELBOARD

11N.T.S.

9010547

1027335

1872-KK927549D

CED-DENVER

1027335-2 #2

Documents

11. UPS and UPS DB