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Section 2: Installation & Commissioning

Chapter 1 - Installation
1.1 Introduction .............................................................................................. 2-1
1.1.1 Equipment positioning and environmental considerations .......... 2-2
1.1.2 Raised Floor Installation .............................................................. 2-2
1.1.3 Battery Location ........................................................................... 2-2
1.2 Preliminary Checks .................................................................................. 2-4
1.3 Connecting the UPS power cables ........................................................... 2-5
1.3.1 Cable entry ................................................................................... 2-5
1.3.2 Cable rating .................................................................................. 2-5
1.3.3 Cable connections ........................................................................ 2-6
1.3.4 Safety earth .................................................................................. 2-6
1.3.5 Cabling procedure ........................................................................ 2-6
1.4 Battery Installation ................................................................................. 2-10
1.4.1 Battery circuit breaker boxes ..................................................... 2-11
Chapter 2 - Commissioning Procedure
2.1 Introduction ............................................................................................ 2-13
2.2 Procedure overview ................................................................................ 2-14
2.3 Pre-commissioning Checks .................................................................... 2-16
2.3.1 Power cable installation ............................................................. 2-16
2.3.2 Control cable installation ........................................................... 2-17
2.3.3 Battery Power Cable Installation ............................................... 2-19
2.3.4 Printed circuit board configuration jumper selection ................. 2-20
2.3.5 Pre-power checks ....................................................................... 2-26
2.3.6 Initial utility power connection .................................................. 2-28
2.4 Start-Up and software commissioning ................................................... 2-29
2.4.1 Operator Control Panel display screen ...................................... 2-29
2.4.2 Applying power to the UPS ....................................................... 2-30
2.4.3 Password protection and operation ............................................ 2-30
2.4.4 Language Selection .................................................................... 2-31
2.4.5 Selecting the UPS SETUP parameters ....................................... 2-33
Setting the basic UPS configuration ................................ 2-34
Setting the UPS working voltage parameters .................. 2-34
Setting the UPS frequency parameters ............................ 2-35
Setting the Battery parameters ......................................... 2-36
2.4.6 Selecting the UPS MAINTENANCE parameters ...................... 2-39
Accessing the maintenance menu .................................... 2-39
Entering the Serial Number ............................................. 2-39
Entering the current Date and Time ................................. 2-40
Entering the Service details ............................................. 2-40

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SECTION 2 - Installation & Commissioning

7200 Series UPS Service Manual

2.4.7 Selecting the UPS FUNCTION parameters ............................... 2-40


Accessing the function menu ........................................... 2-40
Setting the Battery Test parameters ................................. 2-42
Setting the Generator parameters ..................................... 2-43
Setting the Panel Setup selections .................................... 2-44
Setting the NEXT PAGE selections ................................ 2-46
2.5 Power checks .......................................................................................... 2-47
2.5.1 Applying power to the UPS ....................................................... 2-47
2.5.2 Monitoring & recording the UPS operating parameters ............ 2-47
2.5.3 Power module ON/OFF functional checks ................................ 2-49
Accessing the ON/OFF menu screen ............................... 2-49
Inverter test ...................................................................... 2-50
Bypass test ....................................................................... 2-50
Rectifier and battery autonomy test ................................. 2-50
2.5.4 Battery test ................................................................................. 2-51
2.5.5 Emergency remote power off check .......................................... 2-53
2.5.6 Battery boost test (if applicable) ................................................ 2-53
2.5.7 On-Generator test (if applicable) ............................................... 2-54
2.6 Commissioning conclusion (single module) ....................................... 2-55
2.7 Parallel System Start Up (1+1 System) ............................................... 2-55
2.7.1 Initialisation ............................................................................... 2-55
2.7.2 Parallel logic PCB calibration .................................................... 2-56
2.8 Testing the Complete Parallel System .................................................... 2-57
2.8.1 Module starting .......................................................................... 2-57
2.8.2 Inverter bypass re-transfer checks ............................................. 2-57
Redundant configuration system power checks ............... 2-58
Non-redundant configuration system power checks ........ 2-59
2.9 Commissioning conclusion (1+1 system) ............................................ 2-60
2.10 Voltage and Frequency Conversion ..................................................... 2-61
2.10.1 Rating considerations and battery sizing ................................. 2-61
2.10.2 Hardware conversion ............................................................... 2-61
2.10.3 Software conversion ................................................................. 2-62
Setting the UPS working voltage parameters .................. 2-63
Setting the UPS frequency parameters ............................ 2-63
Setting the Battery parameters ......................................... 2-64
2.10.4 Calibration conversions ........................................................... 2-67
Recalibrating the battery charging voltages ..................... 2-67
Completion of UPS SETUP configuration ...................... 2-68
Chapter 3 - Converting single (pre Jan 1997) units to 1+1 capability
3.1 Introduction ............................................................................................ 2-69
3.2 Conversion Procedure ............................................................................ 2-69

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Section 2:

Chapter 1 - Installation

1.1

Introduction

WARNING

Do not apply electrical power to the UPS equipment before the arrival of the commissioning engineer.

WARNING

The UPS equipment should be installed by a qualified engineer in accordance


with the information contained in this chapter and the drawing package shipped
inside the UPS cabinet.

WARNING

Battery hazards:
Special care should be taken when working with the batteries associated with this
equipment. When connected together, the battery terminal voltage will exceed
400 Vdc and is potentially lethal.
Eye protection should be worn to prevent injury from accidental electrical arcs.
Remove rings, watches and all metal objects.
Only use tools with insulated handles.
Wear rubber gloves.
If a battery leaks electrolyte, or is otherwise physically damaged, it should be
placed in a container resistant to sulphuric acid and disposed of in accordance
with local regulations.
If electrolyte comes into contact with the skin the affected area should be washed
immediately.

This chapter contains information regarding the positioning and cabling of the
UPS equipment and batteries.
Because every site has its peculiarities, it is not the aim of this chapter to provide
step-by-step installation instructions, but to act as a guide as to the general procedures and practices that should be observed by the installing engineer.
Important Note:

1+1

Options:

1+1

These instructions are written specifically for a single-module installation. If


you are installing a two-module 1+1 system you should follow the instructions
provided for the single-module installation and then complete the inter-module
control cabling to complete the installation. If you are converting an early (pre
January 1997) module for 1+1 operation then refer to Chapter 3 and carry out
the necessary modifications prior to installing the module.
There are several options available in conjunction with a 1+1 configured system, such as common battery operation. Read the instructions that accompany any
such option prior to commencing installation to understand their impact (if any)
on the following procedure.

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1.1.1

7200 Series UPS Service Manual

Equipment positioning and environmental considerations


The UPS cabinets are fitted with castors to facilitate ease of movement and positioning. When the equipment has been finally positioned ensure the adjustable
jacking feet are set so that the UPS will remain stationary and stable.
The UPS can be lifted using either a fork lift or a cradle. When lifting, take care
not to damage the castors or jacking feet located on the bottom of the unit.

WARNING

Ensure the UPS weight is within the designated S.W.L. of any handling equipment. See the UPS specification for weight details.
Do not move battery cabinets with the batteries fitted.

The UPS module should be located in a cool, dry, clean-air environment with adequate ventilation to keep the ambient temperature within the specified operating
range. Where ventilation is poor and the ambient temperature high, a system of
extractor fans should be installed to aid cooling-air flow; and a suitable air filtration system used where the UPS is to operate in a dirty environment.

Cables: All control cables should be screened and run in metal conduits (or
ducts) separate from the power cables; all conduits and ducts should be electrically bonded to the metalwork of the cabinets to which they are connected.
Cooling air flow: All the models in the 7200 range are force-cooled by internal
fans. Cooling air enters the cabinet through ventilation grills located at the bottom
of the front doors and is exhausted through the fan grills located on the rear panel;
you must therefore allow for a minimum gap of 250mm behind the unit to allow
adequate air flow (See Figure 2-1).

Clearances: Clearance around the front of the equipment should be sufficient to


enable free passage of personnel with the doors fully opened.
1.1.2

Raised Floor Installation


If the equipment is to be located on a raised floor it should be mounted on a pedestal suitably designed to accept the equipment point loading. The installation diagrams accompanying the system identify the location through which the cabinet
can be secured to the floor.

1.1.3

Battery Location
Temperature is a major factor in determining the battery life and capacity. Battery
manufacturers quote figures for an operating temperature of 20C. Operating
above this temperature will reduce the battery life, yet operating below will
reduce the battery capacity. In a normal installation the battery temperature
should be maintained between 15C and 25C.
Batteries should be mounted in an environment where the temperature is consistent and even over the whole battery. Keep batteries away from main heat sources
or draughty air flows etc.
Pedestals are required for the battery cabinets if they are to be installed on raised
floors, in the same way as for the UPS cabinets.

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SECTION 2 - Installation & Commissioning


CHAPTER 1 - Installation Procedure

Figure 2-1: Installation Diagram


FRONT VIEW
250

SIDE VIEW
800

1400

FRONT

55

710
Adjustable fixing
feet

Castors for
ease of movement

REAR VIEW

BASE

200 85 10 200 125


710

800
92.5

40

125

605

REAR VIEW

Entry panel for all power cables

Entry panel for all control cables

Air inlet ventilation grills

Minimum clearance from wall 250mm

Cabinet extractor fans - additional fans are fitted


when the input harmonic filter is included
Weights
30kVA = 480kg.

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40kVA = 540kg.

60kVA = 620kg.

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1.2

7200 Series UPS Service Manual

Preliminary Checks
Before you install the UPS hardware you should carry out the following preliminary checks:
1. Verify that the UPS room satisfies the environmental conditions stipulated in
the equipment specification, paying particular attention to the ambient temperature and air exchange system.
2. After removing any packaging debris, visually examine the UPS and battery
equipment for transit damage, both internally and externally. Report any such
damage to the shipper immediately.
3. Verify that the shipment is complete - e.g. that the battery contains the correct
number of cells etc. Report any discrepancy immediately.
4. When you are satisfied that the equipment is complete and in good condition
move it to its proposed final position.
Figure 2-2: Cable Entry Locations

Auxiliary terminal block


(X3)
Main chassis
earth busbar

Power cable
entry panel

Adjustable fixing feet

2-4

Castors

Control cables
entry position

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SECTION 2 - Installation & Commissioning


CHAPTER 1 - Installation Procedure

Connecting the UPS power cables


Before cabling-up the UPS, ensure that you are aware of the location and operation of the external isolators that connect the UPS input/bypass supply at the
mains distribution panel.
Check that these supplies are electrically isolated, and post any necessary warning signs to prevent their inadvertent operation.

WARNING

1.3.1

Cable entry
Cables enter the UPS modules via entry panels in the base of the cabinet. As
shown in Figure 2-2, separate entry points are provided for the power cables
(which include the input, output and battery cables) and control cables (which includes battery control, remote stop and remote communication wiring).

1.3.2

Cable rating
The input/output cables can be sized to suit the modules' rating according to Table
2-1 below.
Table 2-1:
BUSBAR
CONNECTION
STUD SIZE

NOMINAL CURRENT: Amps


Recommended Cable Size (mm2)
UPS
RATING
(kVA)

Input Mains
with full battery
recharge
380V

30

40

60

400V

415V

Bypass/Output
at full load

380V

400V

415V

Battery at
min.
battery
voltage

64

59

56

46

44

42

82

(16)

(16)

(16)

(10)

(10)

(10)

(25)

85

78

73

61

58

56

110

(25)

(25)

(25)

(16)

(16)

(16)

(35)

128

117

109

91

87

84

163

(35)

(35)

(35)

(25)

(25)

(25)

(50)

Input/
Output
Cable
Terminat
ions
U-V-W-N

Battery
Terminat
ions
+ve &
-ve

M6 Bolt

M8 Bolt

M6 Bolt

M8 Bolt

M6 Bolt

M8 Bolt

(nn) mm2 is the recommended minimum size according to BS7671 Table 4D1A
(IEE regs. 16th Edition).
The following recommendations are guidelines only and superseded by local
regulations and codes of practice where applicable:
1. The neutral conductor should be sized for 1.5 times the output/bypass phase
current.
2. The earth conductor should be sized at 2 times the output/bypass conductor
(this is dependent on the fault rating, cable lengths, type of protection etc.).
3. BS7671 Table 4D1A applies to single core PVC-insulated, non armoured
cable in an ambient temperature of 30C, according to fixing method 1 samples shown in Figure 2-3.

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CHAPTER 1 - Installation Procedure

7200 Series UPS Service Manual

Figure 2-3: Cable fixing samples from method 1


Sheathed cables
clipped direct to or
lying on a non-metallic
surface

1.3.3

Cable connections
The input (bypass) mains cables, UPS output cables and main battery cables are
connected to busbars fitted to the power isolator switches (lug terminations required). The battery circuit breaker control cables and the external emergency
stop cables (optional) are connected using female spade connectors to an auxiliary
terminal block identified as X3 - (See Figure 2-5).

1.3.4

Safety earth
The safety earth busbar is located near the input and output power supply connections as shown in Figure 2-5. The site safety earth cable must be connected to the
earth busbar and bonded to each cabinet in the system and all cabinets and cable
trunking should be earthed in accordance with local regulations.

WARNING

1.3.5

Failure to follow adequate earthing procedures can result in electric shock hazard
to personnel, or the risk of fire, should an earth fault occur.

Cabling procedure
Once the equipment has been finally positioned and secured, connect the power
cables as described in the following procedure.
Study the connection diagram in Figure 2-5.
Input mains supply cables

1. Verify that the UPS equipment is totally isolated from its external power
source and all the UPS power isolators are open.
2. Connect the a.c. input supply cables between the mains distribution panel and
the UPS rectifier input supply busbars (top of Q1) and tighten the connections
to 5,4 Nm ensure correct phase rotation.
Bypass mains supply cables

3. If the installation does not include the provision of a separate bypass supply
then:
a) Ensure that the split bypass links are fitted between the input mains busbars (top of Q1) and the bypass supply busbars (junction of Q2/Q3) see
Figure 2-5.
b) Ensure that the input supply neutral is connected to N3.
c) Jump to step 5.
4. If the installation does include the provision of a separate bypass supply then:
a) Connect the bypass supply cables between the bypass mains distribution

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CHAPTER 1 - Installation Procedure

panel and the bypass supply busbars (junction of Q2/Q3) see Figure 2-5.
ensure correct phase rotation.
b) Ensure that the bypass supply neutral is connected to N3
c) Tighten the connections to 5,4 Nm.
d) Remove the split bypass links are (if fitted) between the input mains busbars (top of Q1) and the bypass supply busbars (junction of Q2/Q3) see
Figure 2-5.
Figure 2-4: UPS External Cables

A
B
C

D
E
F
G
H

Rectifier a.c. input supply

Battery control/temp. compensation

Bypass a.c. input supply

Communications to PC or modem

UPS a.c. output

Communications to AS400/external alarms

Battery power

Remote emergency power off (EPO)

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7200 Series UPS Service Manual

Figure 2-5: Power and control cable connections

F13

K1

Reset
button
Auxiliary terminal block (X3)
Terminals are male type spade connectors

R S T N
Input connections for
split bypass system
(from mains a.c. supply)
R S T N

9 10 11 12

Batt CB trip

Output
Connections
(to Load)

Batt CB aux. contact

R S T N

Common

These links
must be
removed for
split bypass
systems

Batt.
Temp

Safety
Earth

E.P.O.

Bypass input supply neutral (split bypass system)


OR
Input supply neutral (non-split bypass)
UPS Rectifier (input mains)
connections
(from mains a.c. supply)

2-8

F12

F11

F13

R S S T

All power connections require lug type terminations.


Connections torque loading is 5,4Nm

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SECTION 2 - Installation & Commissioning


CHAPTER 1 - Installation Procedure

5. Connect the UPS output cables between the output busbars (junction Q3
&Q4) and the load distribution panel, and tighten the connections to 5,4 Nm.
6. Connect the battery power cables between the UPS battery terminals and the
associated battery circuit breaker - see Figure 2-5 and Figure 2-7 - observe
the correct battery cable polarity. As a safety precaution remove the battery
fuse in the module until the arrival of the commissioning engineer.

WARNING

Do not close the battery circuit breaker before the equipment is commissioned.

7. Connect the safety earth and any necessary bonding earth cables to the copper
earth busbar located below the battery power connections.
Note: The earthing and neutral bonding arrangement must be in accordance
with local and national codes of practice.
8. Connect the battery circuit breaker control and temperature compensation
cables between the UPS auxiliary terminal block X3 and battery circuit
breaker controller board as shown in Figure 2-5 and Figure 2-7. These cable
must be shielded.
Caution

If battery temperature compensation is not to be used, it must be de-activated by


the commissioning engineer.

9. If the remote emergency power off (EPO) facility is to be used then remove
the link between terminals 10 and 11 of the auxiliary terminal block X3 and
connect the normally closed remote stop switch between these two terminals using shielded cable.

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1.4

7200 Series UPS Service Manual

Battery Installation

SAFETY
WARNINGS

Only qualified personnel should install or service batteries.


Batteries present a risk of electric shock or burn from high short circuit currents.
Eye protection should be worn to prevent injury from accidental electrical arcs.
Remove rings, watches and all metal objects.
Only use tools with insulated handles.
Wear rubber gloves.If a battery leaks electrolyte, or is otherwise physically damaged, it should be placed in a container resistant to sulphuric acid and disposed
of in accordance with local regulations.
If electrolyte comes into contact with the skin the affected area should be washed
immediately.
Batteries must be disposed of according to local environmental laws.

Due to the IGBT inverter design, the required DC busbar voltage level is dependent on the system output a.c. voltage; the required number of battery blocks therefore differ according to the system voltage, as shown below:380V a.c. system requires a 432V DC busbar = 192 battery cells.
400V a.c. system requires a 446V DC busbar = 198 battery cells.
415V a.c. system requires a 459V DC busbar = 204 battery cells.
The batteries associated with the UPS equipment are usually contained in a purpose-built battery cabinet which sits alongside the main UPS equipment. Sealed,
maintenance-free batteries are normally used in this type of installation.
There are three types of battery cabinet offered with the Series 7200 UPS which
are graded according to their recommended ampere hour capacity. Type B is rated
at 38 Ah; Type C is rated at 50 Ah and Type D is rated at 85 Ah. The cabinets are
of the same height as the UPS and can be sited on either side of the UPS cabinet.
A full description of these cabinets is given in the Options Section of this manual.
Where battery racks are used, they should be sited and assembled in accordance
with the battery manufacturer's recommendations. In general, batteries require a
well ventilated, clean and dry environment at reasonable temperatures to obtain
efficient battery operation.
Battery manufacturers literature provides detailed safety measures to be observed when employing large battery banks: these should be studied, and the proposed battery installation checked, to verify compliance with the appropriate
recommendations.
In general a minimum space of 10 mm must be left on all vertical sides of the battery block. A minimum clearance of 20 mm should be allowed between the cell
surface and any walls. A clearance of 150 mm should be allowed between the top
of the cells and the underside of the shelf above (this is necessary to for monitoring and servicing the cells). All metal racks and cabinets must be earthed. All live
cell connections must be shrouded.
The batteries are connected to the UPS through a circuit breaker which is manually closed and electronically tripped via the UPS control circuitry. If the batteries
are cabinet-mounted this circuit breaker is fitted within the cabinet; however, if
the batteries are rack-mounted or otherwise located remote from the main UPS
cabinet then the battery circuit breaker must be mounted as near as possible to the
batteries themselves, and the power and control cables connected to the UPS
using the most direct route possible. Liebert offer a purpose-designed remote bat-

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CHAPTER 1 - Installation Procedure

tery circuit breaker box, containing the circuit breaker and its necessary control
board, as a standard option kit. The battery cabinet or circuit breaker box should
be bonded to the UPS cabinet to maintain EMC compliance.
1.4.1

Battery circuit breaker boxes


A battery circuit breaker box houses the battery circuit breaker and its controller
board and is used to connect the battery to the UPS in installations where the batteries are not contained in the standard battery cabinet.
Two boxes are available which are similar in design and content, and described
below:
100 Amp C/B Part No. 4641027 B for use with 30 - 40 kVA models.
160 Amp C/B Part No. 4641028 C for use with 60kVA model.
Usually the box' is fitted as close as possible to the batteries. Battery circuit
breaker boxes must be earthed. The connections are similar to the connections
made to the battery cabinet.
Figure 2-6 shows details of the power and control cable connections between the
circuit breaker box or battery cabinet and the UPS itself. Two methods of connecting the three pole battery circuit breaker are illustrated. Method A shows the spare
pole being used to divide the battery bank in half, thereby reducing the battery
total voltage to half when the circuit breaker is open during servicing etc. Method
B connects the spare pole in series with the positive connection, thereby providing
two sets of contacts in the positive line as an added safety precaution.
When installing the battery cabinet remove the battery fuse in the UPS before
making the battery circuit breaker power connections.
Figure 2-6: Battery CB layout of switching poles

UPS

Half Potential Switching Method

UPS

Double Positive Pole Method

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7200 Series UPS Service Manual

Figure 2-7: Battery Control and Power connections


LM355A Sensor
0835047F

TO BATTERIES

UPS CABINET
123456

12

D2
V<
11

X3

14

D1

X3 X4
X2
X5
X10
X6
X8
X9
Battery CB
Controller

BATTERY
CIRCUIT
BREAKER

12 345

HALF POTENTIAL SWITCHING METHOD

TO BATTERIES
LM355A Sensor
0835047F

UPS CABINET
123456

12

D2
V<

X3
11

14

BATTERY
CIRCUIT
BREAKER

D1

X3 X4
X5
X2
X6
X10
X8
X9
Battery CB
Controller
12 345

DOUBLE POSITIVE POLE METHOD

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Section 2:

Chapter 2 - Commissioning Procedure

2.1

Introduction
The information contained in this calibration procedure is intended for use only
by engineers employed by the Liebert service organisation or who have attended
a training course concerning the Series 7200 equipment. While every precaution
has been taken to ensure the accuracy of this information, Liebert assume no responsibility and disclaim all liability for damages resulting from the use of this
information or any errors or omissions contained within.
This procedure aims at satisfying two functions: first it should enable a producttrained engineer to commission the equipment safely and correctly; second, it
should provide a recovery procedure to supplement the procedures contained in
the troubleshooting section of this manual i.e. if the troubleshooting procedures
fail to identify/rectify a problem then this procedure provides the means of completely recalibrating the UPS equipment.

WARNING
NOTICES
Please read.

The UPS equipment contains POTENTIALLY LETHAL VOLTAGES at all times


once power has been applied from the MAINS DISTRIBUTION PANEL.
Therefore, before applying mains power to the UPS ensure that the UPS output
cables are safely isolated or, If they have already been connected to the load
equipment, ensure the load equipment is ready to receive power.
DO NOT close the battery circuit breaker before instructed to do so. Closing the
battery circuit breaker before the DC busbar is live could damage the UPS.
DO NOT apply BOOST CHARGE to sealed batteries.
Before commencing this procedure confirm the location and operation of the external power isolators used to switch the UPS input mains supply. If these isolators cannot be LOCKED OUT, then post notices warning against their closure.
These precautions should be taken as necessary at any time during the commissioning procedure.

The 7200 Series UPS leaves the manufacturer fully tested and adjusted to operate
at 400Vac, 50Hz, but it can be converted to operate at 380V or 415V, at either 50
or 60Hz. Such a conversion is effected by selecting the appropriate tap voltages
on the control power supply transformers and operating parameters via the Operator Control Panel menuing system details are provided at the appropriate stages
of this procedure. An additional procedure is included at the end of the chapter
(See paragraph 2.10) which provides instructions for changing the working voltage/frequency parameters on an already-commissioned module. In both cases,
where reference is made to the nominal voltage, this should be taken as the required equipment working voltage e.g. 380/400/415 volts.
A set of Commissioning Records are included at the end of this section which can
be used to record the parameters set during commissioning and handed to the customer if required. The pages are published in a single-sided format to facilitate
photocopying for in-field use.

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CHAPTER 2 - Commissioning Procedure
Important Note:

1+1

2.2

7200 Series UPS Service Manual

When commissioning a 1+1 system we recommend that the system is split into
two single modules; and each module then commissioned independent of the
other. Once both modules are fully working as single modules they can be
reconfigured for 1+1 operation and the remaining parallel control functions
checked and calibrated as instructed.
This commissioning procedure is therefore based on a single-module installation, and any actions which specifically apply to 1+1 systems are identified by
a 1+1 graphic in the margin as shown here.
Note: if you are converting an early (pre Jan 97) single module to operate in a
1+1 system then ensure the appropriate control boards are fitted prior to commencing the commissioning (See Chapter 3). (Later models are shipped with the
appropriate boards already fitted).

Procedure overview
This procedure has several defineable stages:
1. Pre-commissioning checks verify that:
the main equipment has been correctly installed
the circuit board configuration links have been selected correctly
the battery installation is satisfactory
the control power transformers are wired for the required working voltage
2. Start-up and software commissioning:
low voltage supply checks
Operator Control Panel language selection
UPS Setup parameters selection (from Operator Control Panel)
UPS Maintenance parameters selection (from Operator Control Panel)
UPS Function parameters selection (from Operator Control Panel)
3. UPS Power checks:
UPS Power measurements
inverter checks
bypass checks
rectifier and battery autonomy checks
programming automatic battery check parameters
emergency power off (emergency stop) checks
battery boost set-up (if applicable)
on generator checks (if applicable)

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CHAPTER 2 - Commissioning Procedure

Figure 2-8: Major component location

14

8
1
9
2

4530025T

10

11

12

4
4550007H

13
X1

4520075B
X2
X3

5
15
6
Table 2-2:
1. Battery Cable Connections

9. AC - AC Power Supply PCB 4503030M

2. UPS Output Cable Connections

10. Rectifier Logic PCB 4520074A

3. Static Bypass Input Cable Connections

11. Inverter Logic PCB 4530025T

4. Rectifier Input Cable Connections

12. UPS Logic PCB 4550007H

5. Main Chassis Safety Earth Connection

13. Remote Alarm Interface 4590056Q

6. Auxiliary Terminal Block X3

14. UPS Serial Number Tag

7. Control Power Transformers T2 & T3

15. 1+1 Parallel Option 4645004A


(consisting of Parallel Logic Board
4520075B & ribbon cables)

8. DC - DC Power Supply 4503028K

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2-15

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

2.3

7200 Series UPS Service Manual

Pre-commissioning Checks

WARNING
2.3.1

Ensure these checks are carried out before applying power to the unit.

Power cable installation


1. Verify that the input, output and battery cables are suitably rated, in accordance with local regulations see notes on cable rating in paragraph 1.3.2.
2. Check that the power cables entering the UPS have been correctly routed and
the appropriate gland has been fitted to the power cable entry panel.
3. Check that the power cables are correctly terminated and securely fitted to the
stepped input and output busbar studs as shown in Figure 2-9.
4. Check that the bypass links have been removed if the unit is to be operated in
the Split Bypass configuration. If a separate supply is connected to the
bypass terminals without the split bypass links removed it could cause
damage to the supply distribution system.

Important Note:

1+1

5. In a 1+1 system ensure that the paralleled module output cables are connected with the correct phasing (i.e. U2-U2; V2-V2; W2-W2; N2-N2).
Figure 2-9: Power cable connections

Bypass Links
These links must be removed
for split-bypass operation

Output Cables connected to load

Input cables for split-bypass system


Connected to Q2/Q3 busbar connection U3, V3, W3 & N3
From Bypass Supply distribution panel

Battery
Cables

Bypass Supply Neutral connection (split-bypass system)


OR
Input Supply Neutral connection (non-split-bypass system)
UPS rectifier input connection from input mains supply:
For non-split-bypass system:
a) Connect to Q1 busbar connections U1,V1,W1.
b) Connect input neutral to Q2/Q3 busbar connection N3.
Note: an input neutral connection to N3 is not required in a split-bypass system
as the bypass neutral will be used to reference the inverter output.

2-16

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7200 Series UPS Service Manual

2.3.2

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

Control cable installation


1. Verify that the battery control cables are correctly terminated and connected
to the auxiliary terminal block (X3) shown in Figure 2-10 in accordance with
Table 2-3.
Note: terminal block X3 requires 4mm (yellow) female spade terminations.
Figure 2-10: Auxiliary terminal block X3

Battery
Temperature

Batt CB trip
Batt CB Aux contact
Common

E.P.O.

Table 2-3: Auxiliary terminal block connections


UPS Auxiliary
Terminal block
X3
Termination
X3 - 2
X3 - 3

Function

Battery temperature
sense signal

Battery Control Board


(4520067T) termination
X1 - 5
X1 - 4

X3 - 4

Battery circuit breaker


control common

X1 - 3

X3 - 5

Battery circuit breaker


status signal

X1 - 2

X3 - 6

Battery circuit breaker


trip signal

X1 - 1

X3 - 10

Remote Emergency Stop


normally closed

Terminals normally linked


if not used

X3 - 11

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2-17

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure
Important Note:

1+1

7200 Series UPS Service Manual

2. In a 1+1 system:
a) Ensure that the Parallel Logic Board Part N 4520075B is firmly fitted in
the correct location as shown in Figure 2-8.
b) Ensure that the 60 way ribbon cable is connected from X1 on the Parallel
Logic Board, to X7 on the UPS Logic Board.
c) Ensure that the two 34-way ribbon cables providing inter module control
are fitted between the Parallel Logic Board connector X2 of one module
and X3 in the second module (See Figure 2-11). Note that it is crucial that
these cables are cross-coupled between X2/X3 as shown. Failure to
observe this rule will result in the modules being permanently shut down.
Figure 2-11: Module parallel logic PCB interconnection
Module 1
4520075B

2-18

Module 2
4520075B

X2

X2

X3

X3

s2-c2a.fm5 - Issue 3 Dated 09/11/98

7200 Series UPS Service Manual

2.3.3

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

Battery Power Cable Installation


1. Verify that the battery has been correctly installed and all cables are connected to the batteries and battery circuit breaker as shown in the installation
instructions (see paragraph 1.4 on page 2-10). Typical connection configurations are shown in Figure 2-12.
2. Verify that the battery power cables are correctly terminated and securely fitted to the DC busbar studs as shown in Figure 2-9.
Figure 2-12: Battery control and power connections
Temperature Sensor

To Batteries

X3

Battery Circuit
Breaker

Half Potential Switching Method of Connection


Battery C.B.
Controller PCB Part
N 4520067T
To Batteries

Double Positive Pole Method of Connection

Temperature
Sensor

X3

Battery Circuit
Breaker

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2-19

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

2.3.4

7200 Series UPS Service Manual

Printed circuit board configuration jumper selection


Ensure that the printed circuit board jumpers are selected appropriately according
to the following tables:
Table 2-4: Rectifier Logic Board 4520074A. 30 to 60kVA
JUMPER

POSITION

FUNCTION

1-2

Disable battery temperature/voltage compensation


(Standard)

2-3

Enable battery temperature/voltage compensation

1-2

Increased DC regulation speed for units below 60kVA

2-3

Decreased DC regulation speed for units above 80kVA

1-2

Fast walk-in : 1 Second

2-3

Slow walk-in : 5 Seconds

0-1

open

0-2

open

0-1

closed

0-2

open

0-1

open

0-2

closed

0-1

closed

0-2

closed

X5

X6

X7

Rectifier in Auto mode (Standard)

Rectifier in Float mode

Rectifier in Boost mode

Set Rectifier to
Manual Mode
from the Display Panel

Rectifier in Test mode

X9
closed

Reduced input current limit forced on

open

(Standard)

closed

Rectifier forced on - Ignore UPS Logic

open

UPS Logic control enabled (Standard)

open

Disable driver IC - D6

closed

Enable driver IC - D6 (Standard)

0-3

0-4

0-5
1-2

Enable rectifier temperature monitor

2-3

Disable rectifier temperature monitor (Standard)

X10

2-20

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7200 Series UPS Service Manual

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

Table 2-5: Inverter Logic Board 4530025T. 30 - 60kVA


JUMPER

POSITION

X12

open

0-1

closed

Disable Inverter over-temperature sensors (Standard)

0-2

open

Enable ribbon cable detector (Standard)

0-2

closed

Disable ribbon cable detector

closed

Voltage select
override

0-4

X16

Test Inverter over-temperature sensors (Enables open cct. sensors)

0-1

0-3

X15

FUNCTION

Manual inverter
volts Adj R243

0-5

Frequency select override

0-6

Force the Inverter ON => ignore all blocks

0-7

Ignore Inverter On Load signal

0-1

2400 Hz switching frequency (Standard)

0-2

4800 Hz switching frequency

0-1
0-2

9600 Hz switching frequency

0-5

1200 Hz switching frequency

0-1
0-2

6 pulse Inverter current feedback (Standard)

0-3

12 pulse Inverter current feedback

Testing only
Open = standard

Table 2-6: UPS Logic Board 4550007H. 30 - 60kVA


Note: when commissioning a 1+1 system these jumpers will required temporary
reconfiguration (See paragraph 2.3.5.1)
JUMPER

X12

POSITION

FUNCTION

open

Pre- Release Rev.:5.0G Software

1-2

Link if Rev.:5.0G or later and HVI PCB Part N 5490054O is


fitted.

3-4

Link if Rev.:5.0G 0r later and HVI PCB Part N 5490058S is


fitted.

1-2

EPROM Enable

2-3

RAM Enable (Standard)

1-2

Not Required

3-4

Not Required

5-6

Not Required

7-8

Not Required

X13

X14

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Testing only
normally
open

2-21

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

JUMPER

7200 Series UPS Service Manual

POSITION

FUNCTION

1-2

PLL option with

CAP IN

2-3

PLL option with

FIN AUX

open

CAN Bus to display disabled

1-2

CAN Bus to display enabled (Standard)

1-2

ALE enable data save

2-3

Power supply fail enable data save (Standard)

1-2

EPROM II enable (not required)

2-3

RAM II enable (not required)

1-2

+5V PCB enables microprocessor ref.


For VA calculations (Standard)

2-3

V ref. enables microprocessor ref.


For VA calculations

1-2

Not Required

2-3

RAM enable (Standard)

1-2

EPROM enable (Standard)

2-3

Not Required

1-2

Not Required

2-3

EPROM enable (Standard)

3-4

Not Required

4-5

Not Required

1-2

RAM enable (Standard)

2-3

EPROM enable (not required)

3-4

RAM enable (Standard)

4-5

EPROM enable (not required)

1-2

Manual reset of output buffers

2-3

Microprocessor reset of output buffers (Standard)

1-2

Inverter operation in Manual mode


(Bypass preferred) = Closed
Inverter operation in Auto mode
(Inverter Preferred) = Open (Standard)

3-4

Inverter Bad voltage for 10 seconds


Off latch enabled = Closed (Standard)
Off latch disabled = Open

5-6

Not Required

7-8

Security Password Over-ride.


Closed = Over-ride security Password
Open = Enable security Password (standard)

X15
(Standard)

X16

X17

X19

X20

X21

X22

X23

X24

X25

X26

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7200 Series UPS Service Manual

JUMPER

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

POSITION
open

FUNCTION
Power up reset enabled (Standard)

X28
closed

Power up reset disabled

open

2.5V power supply monitor enabled (Standard)

1-2

2.5V power supply monitor disabled

open

Internal battery disabled

1-2

Internal battery installed and charger enabled (Standard)

open

RS485 port disabled

1-2

RS485 port enabled (Standard)

1-2

Calendar IC supply from VRAM (Standard)

2-3

Calendar IC supply from internal battery

1-2

G.V.C.O. to inverter logic (parallel module operation)

2-3

Micro V.C.O. to inverter logic (single module operation)

1-2

Separate battery per module (1 for each rectifier)

2-3

Common battery (parallel rectifiers)

1-2

Separate battery per module (1 for each rectifier)

2-3

Common battery (parallel rectifiers)

X29

X31

X32

X33

X34

X35

X36

Table 2-7: Operator Control Board 4550005F 30-60 kVA


JUMPER

POSITION
open

FUNCTION
+5v enable main CPU (Standard)

X11
closed

ALE enable main CPU

1-2

Main CPU enable EPROM

2-3

+5v enable EPROM (Standard)

1-2

Main CPU enable RAM

2-3

+5v enable RAM (Standard)

1-2

Not Required

2-3

Not Required

1-2

Main CPU enable EPROM (Standard)

2-3

Not Required

X12

X13

X14

Testing Only
Open = Standard

X15

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SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

JUMPER

7200 Series UPS Service Manual

POSITION

FUNCTION

1-2

Not Required

2-3

Main CPU enable EPROM (Standard)

3-4

Not Required

4-5

Not Required

1-2

Write to RAM enable (Standard)

2-3

Not Required

3-4

Main CPU enable RAM (Standard)

4-5

Not Required

1-2

Not Required

2-3

Main CPU enable RAM (Standard)

1-2

Not Required

2-3

Not Required

1-2

Read/Write RS232 enable (Standard)

2-3

Read/Write RS485enable

1-2

Enable port x4 for RS485

2-3

Enable port x4 for RS232 (Standard)

1-2

Enable port x4 for RS485

2-3

Enable port x4 for RS232 (Standard)

1-2

Inhibit buzzer

2-3

Enable buzzer (Standard)

1-2

Enable CAN bus to UPS logic (Standard)

2-3

Disable CAN bus to UPS logic

1-2

Enable RS485 bus to port x4 (Standard)

2-3

Disable RS485 bus to port x4

open

+5v power supply reset enabled (Standard)

x16

x17

X18

x19

RAM extension
Normally open

x20

x21

x22

x23

x24

x25

x26
closed

2-24

+5v power supply reset disabled

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7200 Series UPS Service Manual

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

Table 2-8: Static Switch Driver Board 4542043Z 30-60 kVA


JUMPER

POSITION

X11

FUNCTION

0-1

open

Enable load on inverter command


(Standard)

0-1

closed

Disable load on inverter command

0-2

open

Enable load on bypass command


(Standard)

0-2

closed

Disable load on bypass command

0-3

open

0-3

closed

0-4

N/A

Not used

0-5

open

Test static switch temperature monitor

0-5

closed

Disables bypass fire command


Enable bypass fire command (Standard)

Inhibit static switch temperature monitor


(Standard)

Table 2-9: High Voltage Interface Board 4590058S & (old 4590054O) 3060kVA
JUMPER

POSITION

0-1

X31

0-2

X31 : X32 : X33 : X34 : X35 : X37 :


X38 : X39 : X40

0-3

0-1

X31 : X32 : X33 : X34

0-2

X35 : X36 : X37 : X38 : X39 : X40

0-3

0-1

0-2

X31: X32 : X33 : X34 : X35 : X36 :


X37 : X38 : X39 : X40

s2-c2a.fm5 - Issue 3 Dated 09/11/98

FUNCTION

30 kVA CT burden selection

40 kVA CT burden selection

60 kVA CT burden selection

0-3

2-25

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure
Applicable only to:

7200 Series UPS Service Manual

Table 2-10: Parallel Logic Board 4520075B

1+1
JUMPER

POSITION

FUNCTION
open

Priority selector disabled

closed

Priority selector enabled (standard 1+1)

open

Priority selector for 2 modules (multi


module use only)
open = standard for 1+1

open
closed

Link combination sets logic for number


of units operating
For 1+1 operation links 0 - 1, 0 - 2, 0 - 3
are closed.

open

1 + 1 redundant module (standard)

closed

1 + 1 non-redundant module

open

Common battery for all UPS modules

closed

Separate battery for each module (std)

open

Priority selector enabled (std)

closed

Priority selector disabled

open

No MSSC installed (1 + 1) (std)

closed

MSSC installed

0-1
X4

X5

0-2
to
0-8
0-1
to
0-5

0-1

0-2

0-3

X6

0-4
0-5

N/A

0-6

N/A
open

No contactor in MSSC (std)

closed

Contactor in MSSC

open

Normal operation

closed

Test mode active

0-7

0-8
1-2

60 Hz operation

2-3

50 Hz operation (std)

X7
open

G.V.C.O. slew rate = 0.1 Hz/Sec (std)

closed

G.V.C.O. slew rate = 0.2 Hz/Sec

X11
1-2

Parallel cable screen earthed

2-3

Parallel cable screen not earthed (std)

X13

2.3.5

Pre-power checks
1. Ensure that all the UPS isolators, including the battery circuit breaker, are
open i.e. OFF or in position 0.
2. Carry out a thorough visual examination of the equipment. Check the security
of all cable terminations and ensure that all electrical connectors, plugs and
sockets are correctly located and firmly fitted.
3. Ensure that the correct primary voltage tap selections are made on the Power
Supply transformers T2 and T3, as shown below.

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7200 Series UPS Service Manual

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

Table 2-11: Power supply transformers T2 and T3 voltage selection.


380V Operation

400V Operation

415V Operation

A3 - B

A2 - B

A1 - B

4. Ensure that on the UPS Logic Board (4550007H):


a) S1 is selected OFF (Static Bypass disabled).
b) S2 is selected OFF (Inverter disabled).
c) S3 is selected OFF (Rectifier disabled).
2.3.5.1

1+1 system module split

Only applicable to:

1+1

As mentioned at the beginning of this chapter, it is recommended that when dealing with a 1+1 parallel-operating system each module is checked individually
for correct single module function before any attempt is made at parallel operation. To satisfy this requirement the system must therefore be temporarily re-configured to allow single-module operation by completing the following steps:
1. Override the parallel control functions by disconnecting the ribbon cable
between the Parallel Logic Board (4520075B) connector X7 and connector
X1 of the UPS Logic Board (4550007H).
2. Reconfigure the UPS Logic Board (4550007H) jumpers for single module
operation as shown in the table below note that a complete link table for
this board is shown in Table 2-6.
Table 2-12: Temporary UPS Logic Board configuration changes.

X26

X34
X35
X36

1-2

*Inverter operation in Auto mode (Open = Standard)

3-4

Inverter Bad voltage for 10 seconds


*Off latch enabled = Closed (Standard)
Off latch disabled = Open

5-6

Not Required

7-8

Security Password Override.


*Closed = Override security Password
Open = Enable security Password (standard)

1-2

G.V.C.O. to inverter logic (parallel module operation)

2-3

*Micro V.C.O. to inverter logic (single module operation)

1-2

*Separate battery per module (1 for each rectifier)

2-3

Common battery (parallel rectifiers)

1-2

*Separate battery per module (1 for each rectifier)

2-3

Common battery (parallel rectifiers)

X34 must be in position 2-3 for single module operation.


X26 must be in position 7-8 to override the password security control.

WARNING

These jumpers must be returned to the 1+1 configuration before the system is
operated in parallel (as instructed later in the commissioning procedure).

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SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

2.3.6

7200 Series UPS Service Manual

Initial utility power connection

WARNINGS

Check that the Maintenance Bypass isolator Q3 is open before applying external
power. If Q3 is to be closed, inform the user that power will be connected to the
load when the input utility isolator is made.
When commissioning a 1+1 system module do not close any power isolators in
the second module while the module being commissioned is turned on.

1. Apply mains voltage to the input terminals U1, V1and W1.


a) Measure the line-to-line voltage of all three phases and ensure that the values are within 10% of nominal rating.
b) Ensure correct clockwise phase rotation U, V, W using an oscilloscope or
rotation meter.

WARNING

If a separate supply is connected to the bypass terminals without the split bypass links removed it could cause damage to the supply distribution system.

2. If a split bypass is fitted, first ensure that the Split Bypass links have been
removed (See Figure 2-9) then energise the (bypass) mains voltage to the
bypass terminals U3, V3, W3 and N.
a) Measure the line-to-line and line-to-neutral voltages of all three phases
and ensure that values are within 10% of nominal rating.
b) Ensure correct clockwise phase rotation U, V, W using an oscilloscope or
phase rotation meter.

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7200 Series UPS Service Manual

SECTION 2 - Installation & Commissioning


CHAPTER 2 - Commissioning Procedure
Section 2:

2.4

Start-Up and software commissioning


During this part of the commissioning procedure, the bypass supply is connected
to the unit in order to power-up the control power supplies. With control power
available, the control circuit boards are live and the programmable UPS operating
parameters can be entered into control systems non-volatile RAM (NVRAM) via
the Operator Control Panel, before energising the UPS power sections.

2.4.1

Operator Control Panel display screen


The LCD screen can display four rows of up to twenty characters, and normally
indicates the UPS operating status, warnings and alarms. However, it can also be
selected to show messages associated with the UPS configuration setup menuing
system which allows operational data to be entered, or control parameters to be
set these menus are shown in Figure 2-14 to Figure 2-27.
Figure 2-13: LCD control screen & selection buttons

ENTER

ESCAPE

When selecting an option, pressing the ENTER button steps forward to the
next LCD Display screen in the menu map.
When entering data or selecting a parameter, pressing the ENTER button
saves the chosen parameter in non-volatile memory.

Pressing ESCAPE will cancel the most recent action i.e. when entering
data or selecting parameters, pressing ESC steps back the LCD display to
the previous screen and exits the current screen without saving the new
settings.
To return to the default screen ESC must be pressed repeatedly.

The MENU buttons allow the window cursor to be moved up and down to
select a desired menu option.
UP
The UP button moves the cursor up through the options displayed in the
window; the highlighted option can then be selected by pressing ENTER.
When selecting a parameter value it also moves a rectangular entry cursor
horizontally to the next digit on the right.
DOWN
The DOWN button moves the cursor down through the options displayed in
the window, the highlighted option can then be selected by pressing
ENTER.
When changing a parameter value the DOWN button will rotate through an
available value table for the specific parameter digit.

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SECTION 2 - Installation & Commissioning


CHAPTER 2 - Commissioning Procedure

Important Note:

2.4.2

7200 Series UPS Service Manual

This procedure refers to Version 4.0 software installed in all units manufactured
after 2nd May 1997. Units manufactured before this date may have Version 2.0,
or earlier, software installed and will exhibit slightly different menu screens and
parameter locations.

Applying power to the UPS

WARNING

Do not close the Output Isolator Q4 during the setting-up procedure as this will
connect power to the load.

1. Close the Bypass Isolator Q2.


a) The power supply and electronics will energise.
b) The Operator Control Panel display will power up.
c) The rectifier and inverter power sections will remain off.
2. On the Operator Control Panel, verify that the bypass LED and amber battery
isolator LED are illuminated.
3. Verify that the LCD control screen initialising window activates and then
changes to the Default screen.
Note: the screen shown below is referred to as the default screen in the
remainder of this procedure.
OUTPUT BREAKER OPEN

INT USCITA APPERTO

RECTIFIER BREAKER OPEN

INT RADDRIZZ APERTO

BYPASS INHIBIT
24-09-95

14:33:00

DEFAULT SCREEN

BATTERIA PINE SCAR


24-09-95

14:33:00

The module status alarms are initially displayed on the default screen in the
default language, e.g. Italian.
Note: The first three lines of the default screen will indicate any current UPS
alarm conditions, but these can be ignored at this stage.
2.4.3

Password protection and operation


A password is required to change parameters other than those listed below:

Time and Calendar


ON/OFF UPS CONTROL (rectifier, inverter and bypass)
Battery test (star, time/date stamp, repetition rate)
Modem configuration and operation

You can completely override the password system during initial start-up and commissioning by connecting a link to jumper X26 pins 7-8 on the UPS Logic Board.
This link, which must be removed when commissioning is completed, can be
fitted while the UPS is in its Normal Operation mode without affecting the system
integrity.
Note: any parameter not re-programmed during the commissioning procedure
will maintain its factory default setting.

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7200 Series UPS Service Manual

2.4.4

SECTION 2 - Installation & Commissioning


CHAPTER 2 - Commissioning Procedure

Language Selection
If required, select the appropriate language using the following procedure:
Figure 2-14: Language selection menu map
MAIN MENU SCREEN

FUNCTION MENU SCREEN

PANEL SETUP MENU SCREEN

1. Ensure a jumper link is fitted to X26 pins 7-8 on the UPS Logic Board (overrides the password protection facility as described previously).
2. Press the ENTER button to access the main menu screen.
3. Press the DOWN menu button to scroll the cursor to FUNCTION.
MISURE

MEASUREMENT
FUNCTION

MAINTENANCE

MAIN MENU
SCREEN

SETUP

FUNZIONI
MANUTENZIONE
IMPOSTAZIONE

4. Press the ENTER button to access the password entry screen.


WRITE
MOVE

SAVE
EXIT

ESC

INPUT PASSWORD

IMPOSTA
PASSWORD
SCREEN

MEMOR.

SPOSTA

USCITA

ESC

DIGITARE PASSWORD

00000000

00000000

5. A password must be entered to gain further access to the function menu. The
initial default password of 00000000 need not be changed at this point in time
instructions for changing the password are given later. (See paragraph
2.4.7.4) .
6. Press the ENTER button to move from the password entry screen to the function menu screen.
TEST BATTERIA

BATTERY TEST
GENERATOR
PANEL SETUP
NEXT PAGE

FUNCTION MENU
SCREEN

GRUPPO ELETTR.
DATI PANNELIO
PAGINE SUCCESSIVE

7. Press the DOWN menu button to select PANEL SETUP.


8. Press ENTER to display the panel setup menu screen.

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SECTION 2 - Installation & Commissioning


CHAPTER 2 - Commissioning Procedure

7200 Series UPS Service Manual

9. On the panel setup menu move the cursor to select LANGUAGE.


LANGUAGE
TYPE 0000
GROUP 1
PASSWORD

ENG
MASTER

LINGUA
TIPO 0001

PANEL SETUP
MENU SCREEN

UPS 1

GROPPO 1

00000000

PASSWORD

ITA
MASTER
UPS 1
00000000

10.Press ENTER to display the language selection screen.


ROTATE

SAVE
EXIT

LANGUAGE

ENG

ESC

LANGUAGE
SELECTION
SCREEN

MEMOR.
USCITA
LINGUA

ESC

ITA

11.Use the UP menu button to rotate through the available options and select
the required default language e.g. ITA, ENG, FRA, DEU, SPA
12.Press ENTER to accept and store the language selection, then step back to the
default screen by repeatedly pressing ESC, as required; the current alarms
should now be displayed in the selected language.
IMPORTANT

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Ensure the data entered during the following procedures are recorded in the
appropriate commissioning documentation.

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2.4.5

SECTION 2 - Installation & Commissioning


CHAPTER 2 - Commissioning Procedure

Selecting the UPS SETUP parameters


The following procedure set-up the basic UPS operating parameters e.g. kVA,
working voltage/frequency and battery parameters.
Menu selection is carried out in the same manner as previously described in the
language selection procedure i.e. by first selecting a menu option using the UP
and DOWN menu buttons and then accepting the selection by pressing the ENTER
button. In the remaining procedures these two actions are jointly summarized as
select and enter.
Figure 2-15: UPS system SETUP menu map (Issue 5.0 software)
MAIN MENU SCREEN

UPS MENU
SCREEN

SETUP MENU
SCREEN

VOLTAGE
MENU
SCREEN

FREQUENCY
MENU
SCREEN
BATTERY
MENU
SCREEN

Continued in
Figure 2-16

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1. From the default screen press ENTER to access the main menu screen.
2. Select and enter SETUP the password screen will now be shown.
3. If the password has been left at the initial default setting, pressing ENTER
will now step forward to the setup menu screen, as shown in Figure 2-15. If
the password has been set, then enter the correct password to continue.
2.4.5.1

Setting the basic UPS configuration

1. Select and enter UPS this will access the UPS menu screen.
2. Select and enter POWER.
3. Enter the UPS modules kVA rating using the data entry screen shown below.
WRITE
MOVE
POWER

SAVE
EXIT

ESC

0060 kVA

a) Pressing the DOWN menu button will move the cursor to select each digit
in turn: the value of the selected digit can then be incremented by pressing
the UP menu button.
b) When the indicated kVA rating is correct, press ENTER to save the selection, then press ESC once to move back to the UPS menu screen.
4. Select and enter TYPE.
a) Press the UP menu button repeatedly until the TYPE is shown as 3PH.
b) Press ENTER to save the selection, then press
the UPS menu screen.

ESC

once to move back to

5. Select and enter CONFIG.

1+1

a) Using the data entry method described above enter the word SINGLE.
(Note: in a 1+1 installation this will be changed to PAR 1+1 later).
b) Press ENTER to save the selection, then press
UPS menu screen.

ESC

to move back to the

6. Verify that the UPS menu screen data shows the correct:
UPS kVA rating (shown as 60kVA in the example screen in Figure 2-15)
UPS type (3 phase)
UPS configuration (single)
Repeat this procedure if any data is incorrect.
7. Press ESC again to move back to the setup menu screen.
2.4.5.2

Setting the UPS working voltage parameters

1. Select and enter VOLTAGE this will access the voltage menu screen.
2. Select and enter RATED VOLTS..
a) Press the UP menu button repeatedly until the appropriate input/output
working voltage is indicated.
b) Press ENTER to save the selection and then press ESC once to move back
to the voltage menu screen.

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3. Select and enter LOWER.


a) Using the data entry method described above, enter the required input and
output voltage undervoltage thresholds.
Note: Standard settings are for -10% (input) and -10% (output).
b) Press ENTER to save the selection, then press
the voltage menu screen.

ESC

once to move back to

4. Select and enter UPPER.


a) Using the data entry method described above, enter the required input and
output overvoltage thresholds.
Note: Standard settings are for +10% (input) and +10% (output).
b) Press ENTER to save the selection, then press
the voltage menu screen.

ESC

once to move back to

5. Verify that the data shown on the voltage menu screen is correct and repeat
this procedure if necessary.
6. Press ESC again to move back to the setup menu screen.
2.4.5.3

Setting the UPS frequency parameters

1. Select and enter FREQUENCY this will access the frequency menu screen.
2. Select and enter NOMINAL.
a) Press the UP menu button repeatedly until the desired nominal frequency
is indicated.
b) Press ENTER to save the selection, then press ESC once to move back to
the frequency menu screen.
3. Select and enter SYNC WINDOW.
a) Enter the required sync window limit.
Note: Standard setting is 2.0%.
b) Press ENTER to save the selection, then press ESC once to move back to
the frequency menu screen.
4. Select and enter SLEWRATE.
a) Enter the required slew rate from the following selections.
0.1 Hz/sec
0.5 Hz/sec
1.0 Hz/sec
Note: Standard setting is 0.10 Hz/s.
b) Press ENTER to save the selection, then press
the frequency menu screen.

ESC

once to move back to

5. Verify that the data shown on the frequency menu screen is correct and repeat
this procedure if necessary.
6. Press ESC again to move back to the setup menu screen.

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2.4.5.4

7200 Series UPS Service Manual

Setting the Battery parameters

Continued from
Figure 2-15

Figure 2-16: SETUP menu map continued for battery parameter (Issue 5
software)
UPS
0060 kVA
VOLTAGE
400 V
FREQUENCY 50 Hz
BATT.CELLS
198

SETUP MENU SCREEN


BATTERY MENU SCREEN

BATT.CELLS
198
CAPACITY
052 Ah
VOLTAGE/CELL

WRITE
MOVE
BATT.CELLS

BATT.CELLS
198
CAPACITY
052 Ah
VOLTAGE/CELL

WRITE
MOVE
CAPACITY

BATT.CELLS
198
CAPACITY
052 Ah
VOLTAGE/CELL

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

WRITE
MOVE
END DIS.

SAVE
EXIT
1.67 v/e

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

WRITE
MOVE
BAT.LOW

SAVE
EXIT
1.82 v/e

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

WRITE
MOVE
MAX.

BATTERY VOLTAGE
MENU SCREEN

SAVE
EXIT
198

SAVE
EXIT
052 Ah

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

SAVE
EXIT
2.45 v/e

Continued in
Figure 2-17

1. From the setup menu select and enter BATT.CELLS this will access the battery menu screen (illustrated in Figure 2-16).

Setting the number of cells:


2. From the battery menu screen, select and enter BATT.CELLS.
3. Following the data entry method described earlier, using the UP, DOWN
menu buttons, enter the number of cells contained in the battery string.
4. Press ENTER to save the data to memory, then press ESC once to return to
the battery menu screen.

Setting the Battery Capacity:


5. From the battery menu screen, select and enter CAPACITY.
6. Using the UP, DOWN menu buttons, enter the total battery A/Hr capacity (at
the 10Hr rate C10).

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7. Press ENTER to save the data to memory, then press ESC once to return to
the battery menu screen.

Setting the battery voltage characteristics:


8. From the battery menu screen, select and enter VOLTAGE this will take you
to the battery voltage menu, which is concerned with selecting the battery
charging characteristics.
Battery undervoltage trip setting

9. From the battery voltage menu, select and enter END DIS..
a) Using the UP, DOWN menu buttons, enter the specified end-of-discharge voltage standard setting is 1.67V/cell.
Note: this is the end-of-discharge voltage and is the voltage at which the
battery breaker is tripped.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery voltage menu screen.
Battery low voltage warning setting

10.From the battery voltage menu, select and enter BAT LOW.
a) Using the UP, DOWN menu buttons, enter the specified low battery voltage standard setting is 1.82V/cell.
Note: this is the voltage at which low-battery warning annunciates.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery voltage menu screen.
Battery overvoltage trip setting

11.From the battery voltage menu, select and enter MAX.


a) Using the UP, DOWN menu buttons, enter the specified max battery
voltage standard setting is 2.45V/cell. This sets the slow overvoltage
level which is effective only when the batteries are in the float charge
mode, and is the voltage at which, after 3 minutes, the battery breaker is
tripped, and the rectifier and inverter turned OFF.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery voltage menu screen.
Battery boost charge values

WARNING

DO NOT apply BOOST CHARGE to sealed batteries

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7200 Series UPS Service Manual

Figure 2-17: Battery boost charge parameters


Continued from
Figure 2-16

BATTERY VOLTAGE MENU SCREEN


BATTERY BOOST MENU SCREEN

BATTERY BOOST SETUP


MENU SCREEN

12.From the battery voltage menu, select and enter BOOST CHARGE this will
take you to the boost charge menu screen.
13.From the boost charge menu, select and enter SETUP this will take you to
the battery boost setup menu screen.
14.From the battery boost setup menu, select and enter DURATION.
a) Using the UP, DOWN menu buttons, enter the required boost operation
time (in minutes) factory setting is 600 mins.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery boost setup menu screen.
15.From the battery boost setup menu, select and enter THRESHOLD.
a) Using the UP, DOWN menu buttons, enter the required current changeover threshold factory setting is 20% of the battery current limit.
Note: this is the level that the battery current must reach before boost
charge is enabled upon mains return.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery boost setup menu screen.
16.It is advisable to set the NOW and AUTOMATIC parameters to NO at this
stage in the commissioning, and reset to YES (if required) once the rectifier
has been fully commissioned.

Verification:
17.Press ENTER to save the data to memory, then press ESC once to return to
the battery voltage menu screen.
18.Verify that the data shown on the battery voltage menu screen is correct and
repeat this procedure if necessary.
19.The setup menu parameters have now all been entered and stored in the control systems non-volatile memory. Press ENTER repeatedly to return to the
default menu

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2.4.6

SECTION 2 - Installation & Commissioning


CHAPTER 2 - Commissioning Procedure

Selecting the UPS MAINTENANCE parameters


Figure 2-18: MAINTENANCE menu map

MAIN MENU SCREEN

DEFAULT SCREEN

MAINTENANCE MENU
SCREEN

The UPS serial number, service information, and current time and date are all entered via the maintenance menu map shown in Figure 2-18.
2.4.6.1

Accessing the maintenance menu

1. From the default screen press ENTER to access the main menu screen.
2. Select and enter MAINTENANCE the password screen will now be shown.
3. If the password has been left at the initial default setting, pressing ENTER
will now step forward to the maintenance menu screen, shown in Figure 2-18.
If the password has been set, then enter the correct password to continue.
2.4.6.2

Entering the Serial Number

1. From the maintenance menu screen, select and enter S.N.


Note: The UPS serial number can be found stamped on a circular metal plate
attached to the top of the unit, behind the left hand door.
2. Using the UP and DOWN menu buttons, enter the UPS serial number.
3. Press ENTER to save the settings, then press ESC once to return to the maintenance menu screen.

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2.4.6.3

7200 Series UPS Service Manual

Entering the current Date and Time

1. From the maintenance menu screen, select and enter the line showing the
time and date. (This may initially indicate all zeroes).
2. Using the UP and DOWN menu buttons, enter the current time and date
information.
3. Press ENTER to save the settings, then press ESC once to return to the maintenance menu screen.
2.4.6.4

Entering the Service details

1. From the maintenance menu screen, select and enter LAST SER. to register the
date of the current service or commissioning.
2. Using the UP and DOWN menu buttons, enter the current time and date
information.
3. Press ENTER to save the settings, then press ESC once to return to the maintenance menu screen.
4. Select and enter NEXT SER. to record the date of the anticipated next service.
5. Using the UP and DOWN menu buttons, enter the current time and date
information.
6. Press ENTER to save the settings, then press ESC once to return to the maintenance menu screen.
7. Verify that the data shown on the maintenance menu screen is correct and
repeat this procedure if necessary. Then press ESC repeatedly to step back to
the default menu screen.
8. The maintenance menu parameters have now all been entered and stored in
the control systems non-volatile memory.

2.4.7

Selecting the UPS FUNCTION parameters


The function menu screens, shown in Figure 2-19 and Figure 2-20, enable certain
parameters to be set and also gives access to various software-initiated functional
checks.
The procedures contained in this section are concerned with parameter setting; the
functional checks facilities are used later in the commissioning procedure,
during the power checks.

2.4.7.1

Accessing the function menu

1. From the default screen press ENTER to access the main menu screen.
2. Select and enter FUNCTION the password screen will now be shown if the
password has been left at the initial default setting, pressing ENTER will now
step forward to the main menu screen. If the password has been set, then
enter the correct password to continue.
3. From the main menu, select and enter FUNCTION to access the function menu
screen.

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Figure 2-19: FUNCTION selection menu map(Issue 5 software

BATTERY TEST MENU SCREEN

FUNCTION MENU
SCREEN

BATTERY TEST SETUP


MENU SCREEN

GENERATOR
MENU
SCREEN

PANEL
SETUP
MENU
SCREEN

Continued in Figure 2-20

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4. From the default screen press ENTER to display the option selection screen.
5. Select and enter FUNCTION.
6. The password screen will now be shown.
7. If the password has not yet been set, pressing ENTER will step forward to the
maintenance selection screen shown in Figure 2-19.
2.4.7.2

Setting the Battery Test parameters

1. From the function menu screen, select and enter BATTERY TEST to access the
battery test menu.
2. Three selections are available: NOW, AUTOMATIC and SETUP.

NOW Selection: When NOW is set to YES, it initiates an immediate battery


test by switching off the UPS rectifier section. This is not required at this time but
is used later in the commissioning during the power checks.
3. From the battery test menu, select and enter NOW.
4. Press ENTER to step to the selection screen and, using the UP menu button,
select NO (N).
5. Press ENTER to save the settings, then press ESC to return to the battery test
menu screen.

AUTOMATIC Selection: AUTOMATIC initiates a battery test cycle at a predefined set time and date (as entered in the setup selection menu below).
6. From the battery test menu, select and enter AUTOMATIC.
7. If an automatic battery test function is required, press ENTER to step to the
selection screen and, using the UP menu button, select YES (Y).
8. Press ENTER to save the settings, then press ESC to return to the battery test
menu screen.

SETUP Selection: SETUP allows the parameters to be set for the automatic
testing cycle (see above).
9. From the battery test menu, select and enter SETUP to access the battery test
setup menu screen.
10.From the battery test setup menu select and enter DURATION.
11.Using the UP and DOWN menu buttons, enter the test DURATION time in
minutes. (This would normally be set to 5 minutes).
12.Press ENTER to save the settings, then press ESC to return to the battery test
setup menu screen.
13.From the battery test setup menu select and enter THRESHOLD.
14.Using the UP and DOWN menu buttons, enter the minimum battery test voltage THRESHOLD level. (This would normally be set to 1.9V/Cell).
15.Press ENTER to save the settings, then press ESC to return to the battery test
setup menu screen.
16.From the battery test setup menu select and enter PERIOD.

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17.Using the UP and DOWN menu buttons, enter the PERIOD (in days) at
which the test is to occur in days.(This would normally be set to 90 days).
18.Press ENTER to save the settings, then press ESC to return to the battery test
setup menu screen.
Note: Once the first Automatic Battery test has been actioned, the time and
date will up-date according to the selected period. This will change on the
display to indicate when the next battery test will be carried out.

Verification:
19.Verify that the data shown on the battery test setup menu screen is correct and
repeat this procedure if necessary.
20.Step back to the battery test menu screen by pressing ESC.
21.Verify that the data shown on the battery test menu screen is correct and
repeat this procedure if necessary.
22.Step back to the function menu screen by pressing ESC.
2.4.7.3

Setting the Generator parameters

1. From the function menu screen, select and enter GENERATOR to access the
generator menu screen.
2. Three selections are available: INV: SYNC INHIBIT, RECT: I INHIBIT and
BAT: I INHIBIT.
Note: These features require external control input via the Remote Alarms
Board in order to become active.

INV: SYNC INHIBIT Selection: This disables synchronisation between the


UPS and generator when the generator is on-line. When selected, it helps to overcome Sync Error problems occurring when running on a generator whose frequency is unstable.
3. From the generator menu screen, select and enter INV: SYNC INHIBIT.
4. Using the UP menu button, set the attribute to YES Y or NO N as required.
5. Press ENTER to save the settings, then press ESC to return to the generator
menu screen.

BAT: I INHIBIT Selection: This restricts the maximum charge current to the
batteries when the generator is on-line and is used if the generator power output
is limited.
6. From the generator menu screen, select and enter BAT: I INHIBIT.
7. Using the UP menu button, set the attribute to YES Y or NO N as required.
8. Press ENTER to save the settings, then press ESC to return to the generator
menu screen.

RECT: I INHIBIT Selection: This reduces the maximum UPS input current
by 30% of the standard factory-set current limit when the generator is on-line.
This facility is used if the generator power output is limited.
9. From the generator menu screen, select and enter RECT: I INHIBIT.
10.Using the UP menu button, set the attribute to YES Y or NO N as required.

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11.Press ENTER to save the settings, then press ESC to return to the generator
menu screen.

Verification:
12.Verify that the data shown on the generator menu screen is correct and repeat
this procedure if necessary.
13.Step back to the function menu screen by pressing ESC.

2.4.7.4

Setting the Panel Setup selections

1. From the function menu screen, select and enter PANEL SETUP to access the
panel setup menu screen.
2. Four selections are available: LANGUAGE, TYPE (STATE), GROUP and
PASSWORD.

TYPE & STATE Selection: These parameters register the equipment type
number and Master/Slave paralleling configuration.
3. From the panel setup menu screen, select and enter TYPE _(STATE).
Note: The first selection, LANGUAGE, was completed earlier in this procedure
(See paragraph 2.4.4) .
4. Using the UP and DOWN menu buttons:
a) Enter the TYPE of UPS system in this case enter 7200.
b) Enter the UPS system STATE in the case of a single module system
enter the word MASTER.
5. Press ENTER to save the settings, then press ESC to return to the panel setup
menu screen.

GROUP & UPS Selection: This selection sets the communications address
for the UPS Module.
6. From the panel setup menu screen, select and enter GROUP _ UPS.
7. Using the UP and DOWN menu buttons:
a) Enter the UPS address in the case of a single module system enter 1
unless instructed otherwise.
b) Enter the NODE address in the case of a single module system enter
1 unless instructed otherwise.
8. Press ENTER to save the settings, then press ESC to return to the panel setup
menu screen.

PASSWORD Selection: This selection sets the password which will give restricted entry to certain screens once set i.e. access to a password protected
screen is possible but no data can be entered or changed. Until now, the default
password (00000000) has been used.
9. From the panel setup menu screen, select and enter PASSWORD.

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Figure 2-20: FUNCTION selection menu map NEXT PAGE selections


Continued from
Figure 2-19

FUNCTION MENU SCREEN

MODEM MENU
SCREEN

NEXT PAGE MENU


SCREEN

ON/OFF
MENU
SCREEN

When selected to YES and saved, all UPS


parameters are reset to zero. The parameter values will then require
re-entering into the software

Important

Once the eight digit password has been selected and saved into the NVRAM further changes to the UPS parameters will be inhibited unless the correct password
is entered. ENSURE THE NEW PASSWORD IS SAFELY RECORDED IN THE
RELEVANT COMMISSIONING OR SERVICE DOCUMENTATION.

10.Using the UP and DOWN menu buttons enter an 8-digit password.


11.Press ENTER to save the settings, then press ESC to return to the panel setup
menu screen.

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Verification:
12.Verify that the data shown on the panel setup menu screen is correct and
repeat this procedure if necessary.
13.Step back to the function menu screen by pressing ESC.
2.4.7.5

Setting the NEXT PAGE selections

1. From the function menu screen select and enter NEXT PAGE this accesses
the next page menu screen (See Figure 2-20).
2. Three selections are available: PC-CONN, ON/OFF UPS, RELOAD UPS DATA.

PC-CONN Setting: This establishes the UPS software settings to interface


via a modem to a remote location.
1. From the next page menu screen select and enter MODEM
access the modem menu screen.

CONNECTION

to

2. From the modem menu screen, select and enter PC-CONN..


3. Select either LOCAL or REMOTE modem connection as appropriate.
4. Press ENTER to save the settings, then press ESC to return to the modem
menu screen.
5. From the modem menu screen, select and enter RESET.
6. Select either NO or YES as appropriate.
Note: Selecting YES will enable any alarm to be reset from a connected PC.
7. Press ENTER to save the settings, then press ESC to return to the modem
menu screen.
8. Verify that the data shown on the modem menu screen is correct and repeat
this procedure if necessary.
9. Step back to the next page menu screen by pressing ESC.

ON/OFF UPS CONTROL Setting: The on/off menu screen allows the
UPS inverter, static bypass line, and rectifier sections to be switched on or off
from the control panel and will be covered in the power checks.

RELOAD UPS DATA Setting : Setting this option to YES resets the
micro-processor NVRAM to the default parameters and should be carried out
only if a complete reprogramming sequence is required.

WARNING

DO NOT enter a RELOAD UPS DATA selection while the UPS is on load, as it
will disable the inverter, rectifier and bypass sections, and remove load power.

10.From the next page menu screen select and enter RELOAD UPS DATA. and if
you wish to reset the stored data to the default parameters select YES.
11.Using the setup menu screen locate and enter the POWER screen and Re-enter
the units KVA rating.
12.Turn the UPS off for 5 seconds then turn it back on
13.Step back to the default screen by repeatedly pressing ESC. The UPS function menu parameters have now all been stored in NVRAM

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Section 2: 1

2.5

Power checks
Once the UPS parameters have been entered into the software, full power can be
applied to the unit and the following power checks carried out.

WARNING

2.5.1

Ensure that the load is isolated or safe to receive power, before continuing with
the following procedure

Applying power to the UPS


1. Check that the Bypass Isolator Q2 is still closed close Q2 if it is open.
a) Verify that the LCD shows the default screen.
b) Verify that the Amber Load on Bypass LED is flashing.
2. Close the UPS Input Isolator Q1.
a) Verify that after approximately 30 seconds the Green Load on Inverter
LED illuminates and the Load on Bypass LED extinguishes.
b) The LCD default screen indication should be:
BATTERY BREAKER OPEN
OUTPUT SWITCH OPEN
DEFAULT SCREEN
24-09-95

14:33:00

3. Close the Output Isolator Q4.


4. Close the Battery Circuit Breaker (located in the battery cabinet or adjacent to
any external battery racks).
a) The LCD default screen indication should be:
NORMAL OPERATION
DEFAULT SCREEN
24-09-95

2.5.2

14:33:00

Monitoring & recording the UPS operating parameters


5. Using the menu screen navigation techniques described earlier in this section,
access the main menu screen and then access the measurement menu screen
a menu map is shown in Figure 2-21.
6. From the measurement menu screen select and enter INPUT then note and
record indicated input voltage in the appropriate commissioning documentation.
7. From the measurement menu screen select and enter BATTERY then note and
record in the appropriate commissioning documentation the battery voltage,
current, and percentage charge.
8. From the measurement menu screen select and enter TEMPERATURE then note
and record the indicated temperatures in the appropriate commissioning documentation:

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Figure 2-21: Menu tree for the MEASUREMENT parameters (Issue 5 software)

INITIALISATION
SCREEN
MAIN MENU SCREEN
DEFAULT MENU SCREENS

MEASUREMENT MENU
SCREEN

9. From the measurement menu screen select and enter OUTPUT then further
select and record in the appropriate commissioning documentation:
output voltage
output current
output power
output frequency.

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CHAPTER 2 - Commissioning Procedure

Figure 2-22: Menu tree for the FUNCTON- NEXT PAGE test selections
Continued from
Figure 2-19

FUNCTION MENU SCREEN

MODEM MENU
SCREEN

NEXT PAGE MENU


SCREEN

ON/OFF
MENU
SCREEN

10.Navigate back to the default screen by repeatedly pressing the ESC button.
2.5.3

2.5.3.1

Power module ON/OFF functional checks


The UPS power sections can be independently switched off and on from the Operator Control Panel, as checked below, which enables each section to be tested
individually.
Accessing the ON/OFF menu screen

The following functional checks are carried out from the ON/OFF menu screen.
To gain access to this screen:

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1. Using the menu navigation methods described previously, step from the
default screen via the main menu screen (FUNCTION), password screen, function menu screen (NEXT PAGE) and next page menu screen (ON/OFF UPS CONTROL) to the ON/OFF menu screen.
Refer to the menu maps in Figure 2-18, Figure 2-19 and Figure 2-22 for
assistance if necessary.
2.5.3.2

Inverter test

1. Gain access to the ON/OFF menu screen (See paragraph 2.5.3.1).


2. From the ON/OFF menu screen, select and enter INVERTER.
3. Using the UP menu button, select INVERTER OFF, then press ENTER to save
the selection.
4. On the UPS mimic, verify that the inverter has turned off and the load has
transferred to the static bypass supply.
a) The green Load on Inverter LED is extinguished and the amber Load
on Bypass LED is flashing.
5. Step back to the default screen, by continually pressing the ESC button, and
verify that:
a) The INV: OFF VIA DISPLAY and LOAD ON BYPASS alarms are present.
6. Repeat steps 1 and 2 to return to the ON/OFF menu inverter selection screen.
then select INVERTER ON and press ENTER to save the selection.
7. On the UPS mimic, verify that the inverter has turned on and the load has
transferred back to the inverter from the static bypass supply.
a) The green load-on-inverter LED is illuminated and the amber load-onbypass LED is extinguished.
8. Step back to the default screen, by continually pressing the ESC button, and
verify that:
a) The NORMAL OPERATION status indication is present.
2.5.3.3

Bypass test

1. Gain access to the ON/OFF menu screen (See paragraph 2.5.3.1).


2. From the ON/OFF menu screen, select and enter LINE.
3. Using the UP menu button, select BYPASS OFF, then press ENTER to save
the selection.
4. Step back to the default screen, by continually pressing the ESC button, and
verify that the BYP: OFF VIA DISPLAY (bypass remotely inhibited), is displayed.
5. Repeat steps 1 and 2 to return to the ON/OFF menu line selection screen. then
select BYPASS ON and press ENTER to save the selection.
6. Step back to the default screen, by continually pressing the ESC button, and
verify that the NORMAL OPERATION status indication is present.
2.5.3.4

Rectifier and battery autonomy test

1. Gain access to the ON/OFF menu screen (See paragraph 2.5.3.1).

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2. From the ON/OFF menu screen, select and enter RECTIFIER.


3. Using the UP menu button, select RECTIFIER OFF, then press ENTER to save
the selection.
4. Verify that the rectifier has turned off and the inverter is still operating from
battery power.
5. Step back to the default screen, by continually pressing the ESC button, and
verify that:
a) The RECT: OFF VIA DISPLAY and ON BATTERY alarms are present.
b) The green battery bargraph LEDs indicate the remaining battery time.
Note: If the UPS is allowed to run in this condition the battery bargraph
LEDs will progressively turn off indicating the remaining autonomy time.
6. Step forward to the measurements menu screen (See paragraph 2.5.2), then
enter and select BATTERY, and note and record the indicated remaining
autonomy time. Each illuminate bar-graph segment is equivalent to 2 minutes
remaining. All 5 will be illuminated for greater than 10 minutes.
7. Step back to the default screen, by continually pressing the ESC button.
8. Repeat steps 1 and 2 to return to the ON/OFF menu rectifier selection screen.
then select RECTIFER ON and press ENTER to save the selection.
9. Verify that the rectifier turns on.
10.Step back to the default screen, by continually pressing the ESC button, and
verify that the NORMAL OPERATION status indication is present.
11.Step forward to the measurements menu screen (See paragraph 2.5.2), then
enter and select BATTERY, and note and record the indicated capacity charge.
12.Step back to the default screen, by continually pressing the ESC button.
2.5.4

Battery test
A software-controlled battery test facility can be initiated from the Operator Control Panel on an immediate or periodic basis. This test turns off the rectifier
and runs the inverter (and load) from the battery for a predetermined period. If the
battery voltage falls below a preset minimum level prior to the termination of the
test period a BATTERY FAIL alarm is annunciated and the rectifier is immediately
turned on to prevent the load transferring to bypass and recharge the battery.
The instructions given below initiates an immediate battery test.
For the following test to be meaningful as part of the UPS commissioning procedure, the batteries should be fully charged prior to the test being carried out. The
UPS rectifier section must therefore be allowed to operate with the battery connected for several hours to provide the battery with an adequate initial charge.

Caution

Do not continue with this procedure if the battery has not yet been charged

1. Using the menu navigation methods described previously, step from the
default screen via the main menu screen (FUNCTION), password screen, function menu screen (BATTERY TEST) to the battery test menu screen.
Refer to the menu map in Figure 2-23 for assistance if necessary.
2. From the battery test menu screen, select and enter SETUP.

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Figure 2-23: Menu tree for the FUNCTON- BATTERY TEST selections (Issue 5 software)

BATTERY TEST MENU SCREEN

FUNCTION MENU
SCREEN

BATTERY TEST SETUP


MENU SCREEN

Date & Time of


NEXT periodic test

3. Verify that the parameters entered in the battery test setup menu are appropriate. If not then enter the correct setup parameters (See paragraph 2.4.7.2).
4. Press ESC to return to the battery test menu screen.
5. From the battery test menu screen, select and enter NOW.
6. Using the UP menu button, select Yes (Y), then press ENTER to initiate an
immediate battery test.
7. Verify that the rectifier enters the test mode by confirming that LED H1
(Amber) is illuminated on the Rectifier Logic Board. (The inverter will continue its operation and discharge the battery.)
8. Step back to the default screen, by continually pressing the ESC button and
verify that the ON BATTERY and RECT: SOFTWARE BLOCK alarms are displayed.
The green LED battery bargraph will indicate the remaining battery time.
Note: If the UPS is allowed to run in this condition the battery bargraph
LEDs will progressively turn off indicating the remaining autonomy time.
9. The battery will be tested for the selected DURATION time after which the
UPS will revert to normal operation.
the rectifier will return to the Float mode.
LED H3 (green) will be illuminated on the Rectifier Logic Board.
Note: If the battery fails the test (i.e. falls below the THRESHOLD value before
the DURATION time expires), the rectifier will immediately return to the float

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mode and the BATTERY FAIL alarm will be displayed on the default screen.
This alarm can be reset by pressing the RESET Button (S1) on the UPS Logic
Board.
2.5.5

Emergency remote power off check


1. Ensure that NORMAL OPERATION is displayed on the default screen.
2. Remove the link between terminals 10 & 11 on the Auxiliary Terminal Block
(X3) (See Figure 2-10). Or open the remote EPO button if installed.
3. Verify that the UPS power sections shut down and CUT-OFF: EMERGENCY is
displayed on the default screen.
4. Refit the link between terminals 10 & 11 on the Auxiliary Terminal Block
(X3) (See Figure 2-10). Or close the remote EPO button if installed.
5. Press the Reset Button (S1) on the UPS Logic Board.
6. Verify that the UPS returns to normal operation NORMAL OPERATION displayed on the default screen.
Figure 2-24: Menu tree for the SETUP- BATTERY selection
Continued from
Figure 2-16

BATTERY VOLTAGE MENU SCREEN


BATTERY BOOST MENU SCREEN

BATTERY BOOST SETUP


MENU SCREEN

2.5.6

Battery boost test (if applicable)


A software-controlled battery boost facility can be initiated from the Operator
Control Panel on an immediate or periodic basis. This increases the rectifier
output (dc bus) to the selected boost voltage level for a predetermined period.
The instructions given below initiates an immediate battery boost charge.

WARNING

DO NOT APPLY BOOST CHARGE TO SEALED BATTERIES

1. Using the menu navigation methods described previously, step from the
default screen via the main menu screen (SETUP), password screen, setup
menu screen (BATTERY) to the battery menu screen.
Refer to Figure 2-15 and Figure 2-16 for assistance if necessary.

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2. From the battery menu screen select and enter VOLTAGE to access the battery
voltage menu screen.
3. From the battery voltage menu screen select and enter BOOST CHARGE to
access the battery boost menu screen.
Note: The boost parameters (accessed via SETUP) were entered earlier in this
procedure (see page 2-37). These may reviewed here if required.
4. From battery boost menu screen, select and enter NOW.
5. Using the UP menu button, select Yes (Y), then press ENTER to save the
selection, followed by ESC to return to the battery boost menu screen.
6. The rectifier should now be in its boost charge mode.
a) Verify that the boost charge indicator LED H2 (green) is illuminated on
the Rectifier Logic Board.
b) Step back to the main menu screen and then access the measurement menu
screen (See Figure 2-21). Verify that the battery voltage has increased to
the appropriate boost charge level.
7. The rectifier will revert to its float charge mode (LED H3 illuminated and
LED H2 extinguished on the Rectifier Logic Board) in the event of:
a) The selected DURATION time being reached.
b) The battery charge current falling below the boost THRESHOLD current
prior to the completion of the boost DURATION time.
c) Manual intervention turning OFF the boost charge facility.
Note: this is achieved by changing the NOW parameter to No (N) in the
battery boost menu screen (see steps 6 & 7 above).
8. Step back to the default screen, by continually pressing the ESC button.
2.5.7

On-Generator test (if applicable)


The following test checks the operation of the generator parameters set-up earlier
(See paragraph 2.4.7.3) in the generator menu screen (See Figure 2-19).
The test is unnecessary if the generator parameters have not been selected i.e.
the function parameters for the GENERATOR options must be selected to Yes (Y).
Any combination of the three functions can be selected.
1. To initiate this test, the generator must apply a voltage in the range
12-24Volts (ac or dc) between pins 5 and 6 of the Alarm Interface Board terminal block X5 when the generator is operating.
2. Start the generator.
3. On the default screen, check for the following alarms:
a) INV: UNSYNCHRONIZED
The UPS will not synchronise to the unstable generator supply
b) CHARGER INHIBITED
The battery current is inhibited due to the generator power being limited.
c) REDUCED CURRENT LIMIT
The rectifier current is inhibited due to the generator power being limited.
4. Stop the generator

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5. Verify that NORMAL OPERATION is displayed on the default screen.

2.6

Commissioning conclusion (single module)


1. The (single) UPS module has now been commissioned and can be put into
normal service. Be sure that the commissioning records are completed and
filed appropriately.
2. If the password protection system is to be enabled ensure that the link is
removed from jumper X26 pins 7-8 on the UPS Logic Board.
Note: If the password protection system is enabled only those parameters
listed below are changeable without first entering the selected password:
Time and Calendar
ON/OFF UPS CONTROL (rectifier, inverter and bypass)
Battery test (star, time/date stamp, repetition rate)
Modem configuration and operation
3. For 1+1 systems, the commissioning procedure must be repeated for each
module. When both modules have been satisfactorily commissioned, continue with the commissioning procedure for the 1+1 system outlined below.

1+1
2.7

Parallel System Start Up (1+1 System)

Applies only to

1+1

2.7.1

The procedures contained in paragraph 2.7 and paragraph 2.8 are used to commission two 1+1-configured modules as a parallel-operating system. It is crucial
that both modules have passed the single module commissioning checks before
any attempt at paralleling is carried out.

Initialisation
1. Ensure that both modules are fully powered down.
2. On each module in turn:
a) Fit the 60 way flat ribbon cable between the Parallel Logic Board
(4520075B) connector X1 and UPS Logic Board (4550007H) connector
X7 this cable was removed earlier in the commissioning procedure to
allow the modules to operate in their single module mode.
b) Reconfigure the UPS Logic Board (4550007H) jumpers for parallel operation (See Table 2-13) these were changed earlier in the commissioning
procedure to allow the modules to operate in their single module mode.
c) Check that the Parallel Logic Board (4520075B) jumpers have been
selected in accordance with Table 2-10.

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Table 2-13: UPS Logic Board jumper configuration


1-2

Inverter operation in Manual mode (Bypass preferred) = Closed


Inverter operation in Auto mode (Inverter Preferred) = (Standard)

3-4

Inverter Bad voltage for 10 seconds


Off latch enabled = Closed (Standard)
Off latch disabled = Open

5-6

Not Required

7-8

Security Password Over-ride.


Closed = Over-ride security Password
Open = Enable security Password (standard)

1-2

*G.V.C.O. to inverter logic = parallel module

2-3

Micro V.C.O. to inverter logic = single module

X26

X34
X35
X36

1-2

Separate battery per module (1 for each rectifier)

2-3

Common battery (parallel rectifiers)

1-2

Separate battery per module (1 for each rectifier)

2-3

Common battery (parallel rectifiers)

Note: *X34 must be in position 1-2 for 1+1 operation.


X26 must be in position 7-8 to override the password security control.
2.7.2

Parallel logic PCB calibration


Complete paragraph 2.7.2 for each module in turn, ensuring that only the module
under calibration is energised.
1. Ensure that switches Q1, Q2, Q3 on the UPS Logic Board are selected OFF
i.e. to disable the rectifier, inverter, and bypass operation.
2. Ensure that all power isolators are OPEN, take particular care that the bypass
isolator Q2 is OPEN.
3. Close the rectifier power isolator Q1 to energise the control electronics.

Governing Voltage Controlled Oscillator (GVCO) calibration:


4. Connect a DVM to X8 pin 1 and check that the level is high (+5V) to ensure
that the G.V.C.O. is free running (0V is available at TP10).
5. Adjust R18 to obtain a 50Hz square wave at X8 pin 2. Note: for 60Hz operation connect jumper X7 to 1-2 and adjust R18 for 60.00Hz @ X8 pin 2.

Reverse/Forward current detector calibration: .


6. Connect a DVM to the lower end of R68.
7. Adjust R19 to obtain the appropriate voltage for the expected nominal output
current as shown in Table 2-14.
Table 2-14:
UPS Rated Voltage

R68 Lower End Value

220/380V

5.90V

230/400V

6.20V

240/415V

6.45V

Software re-configuration:

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8. Using the software driver menu display screens enter the SETUP menu (See
Figure 2-15).
9. Select and enter the CONFIG screen.
10.Using the ROTATE button select PAR 1+1 and press SAVE to store the parameters into memory.
11.Using the ESCAPE button return to the DEFAULT alarms screen.
12.Ensure the procedures detailed in paragraph 2.7.2 are carried out individually
on both modules.

2.8
2.8.1

Testing the Complete Parallel System


Module starting
1. Ensure that the bypass input isolator Q2 remains OFF on both modules.
2. Ensure that the switches Q1, Q2 & Q3 on the UPS Logic Board are OFF.
3. Close the rectifier input isolator Q1 on each module.
4. Start the rectifier in each module by closing the UPS Logic Board switch Q3
and check for the correct battery float voltage on each modules MEASUREMENT screen.
5. Close the appropriate battery isolators for the system configuration.
6. Start a selected inverter by closing switch Q2 on the module UPS Logic
Board and then close the module output isolator Q4 the inverter should run
up and its output contactor K1 close.
Check for correct output voltages on the MEASUREMENT screen.
7. Start the inverter in the second module by closing switch Q2 on the UPS
Logic Board the second modules inverter should run up and its output contactor K1 close.
Check for correct output voltages on the MEASUREMENT screen.
8. Using the current MEASUREMENT screens or current clamp CTs on the output
critical busbar interconnecting cables, check for circulating currents between
the paralleled inverters.
d) The measured circulating current should be less than 10% of the modules
kVA rating e.g. 6 amps for a 60kVA unit.
e) Adjust the inverter displacement using R247 on the Inverter Logic
Board (4530025T) on one module to minimise the circulating current.
9. Close the bypass input isolators Q2 on each module.
10.Enable the static bypass on each module by closing the switch Q1 on each
UPS Logic Board.
The inverters should now synchronise to the bypass supply.
11.Allow the system to stabilise.
Check for NORMAL OPERATION indicated on the DEFAULT screen of each
module.

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2.8.2

7200 Series UPS Service Manual

Inverter bypass re-transfer checks


The UPS system can be configured to operate in two ways, i.e.:
Redundant module

Where the proposed rated load level is less than or equal to the nominal kVA of
one module. Either module operating is therefore capable of sustaining the load.
Non-redundant module

Where the proposed rated load level is greater than the nominal kVA of one
module but less than the sum of both. Both modules are therefore required to sustain the load.
2.8.2.1

Redundant configuration system power checks

This paragraph applies to a Redundant module system only. If the system under
test is configured as Non-redundant then jump to paragraph 2.8.2.2.
The static bypass thyristor switches contained within each module will operate together, always opening and closing in unison. However it is possible to have one
in a BLOCKED state by selecting switch Q1 of the relevant UPS Logic Board to
OFF simulating a bypass disabled condition.
1. Ensure that jumper X6 0-1 is open on the Parallel Logic Board (4520075B)
for redundant operation.
2. Start both modules and ensure they operate as expected, with the inverters
paralleled and NORMAL OPERATION displayed on both modules DEFAULT
screen.
3. Stop one modules inverter by selecting OFF Q2 on its UPS Logic Board.
a) The inverter should stop and the modules output contactor K1 open
thereby disconnecting the module from the critical bus.
b) The remaining module should continue to operate and support the critical
bus supply.
4. Stop the second modules inverter by selecting OFF Q2 on its UPS Logic
Board.
a) The second modules inverter should stop and its output contactor K1
open, thereby disconnecting the second module from the critical bus.
b) Critical bus power should now transfer to the bypass supply, without a
break i.e. both modules bypass static switches should close.
5. Check for the appropriate default alarms on each module mimic display.
6. Start the inverter on one module by selecting ON Q2 on the relevant modules
UPS Logic Board.
a) The inverter should run up and achieve synchronisation.
b) The critical bus should transfer to the inverter i.e. the output contactor
(K1) should close in the running module only, and the static switches
should open in both modules.
7. Start the remaining modules inverter by selecting ON Q2 on its UPS Logic
Board.
a) The inverter will run up and achieve synchronisation.

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b) Check that the LED H3 illuminates on the Parallel Logic Board during
slave mode operation.
c) The second modules output contactor (K1) should close connecting the
inverter to the critical bus.
d) Check that the LED H3 extinguishes on the Parallel Logic Board, indicating master mode operation.
2.8.2.2

Non-redundant configuration system power checks

This paragraph applies to Non-redundant configured systems only. If the system


under test is configured as a Redundant system then jump to paragraph 2.9.
The static bypass thyristor switches contained within each module will operate together, always opening and closing in unison. However it is possible to have one
in a BLOCKED mode by selecting OFF switch Q1 of the relevant UPS Logic
Board, simulating a bypass disabled condition.
1. Ensure that link X6 0-1 is closed on the Parallel Logic Board (4520075B) for
Non-redundant operation.
2. Start both modules and ensure they operate as expected, with the inverters
paralleled and NORMAL OPERATION displayed on both modules DEFAULT
screen.
3. Stop one module inverter by selecting OFF switch Q2 on the UPS Logic
Board.
a) The inverter should stop and the module output contactor K1 open
thereby disconnecting the module from the critical bus.
b) The output contactor (K1) should also open in the remaining module.
c) If available both modules static switches should close to connect the critical bus to the bypass supply.
d) Check on the appropriate module mimic displays for verification.
4. Turn OFF the remaining inverter by selecting OFF switch Q2 on its UPS
Logic Board.
a) The second modules inverter should stop the load is already on bypass.
5. Start the inverter on one module by selecting ON switch Q2 on the relevant
modules UPS Logic Board.
a) The inverter should run up but its output contactor (K1) should remain
open.
b) The load will remain connected to the bypass waiting for the start of the
second module.
6. Start the second modules inverter by selecting ON switch Q2 on its UPS
Logic Board.
a) The inverter will run up in slave mode i.e. led H3 on the Parallel Logic
Board will illuminate until the module achieves synchronisation and parallels with the existing inverter.
b) Both modules should now transfer the critical bus supply to inverter by
closing the output contactor (K1) and turning off the static switch in both
modules simultaneously.

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7. Check on the appropriate module mimic displays for verification.


8. Allow the system to stabilise.
Check for NORMAL OPERATION indicated on the mimic DEFAULT screen for
each module.

2.9

Commissioning conclusion (1+1 system)


1. The (1+1) parallel UPS system has now been commissioned and can be put
into normal service. Be sure that the commissioning records are completed
and filed appropriately.
2. If the password protection system is to be enabled (both modules) ensure that
the link is removed from jumper X26 pins 7-8 on the UPS Logic Board.
Note: If the password protection system is enabled only those parameters
listed below are changeable without first entering the selected password:
Time and Calendar
ON/OFF UPS CONTROL (rectifier, inverter and bypass)
Battery test (star, time/date stamp, repetition rate)
Modem configuration and operation

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Section 2:

2.10

Voltage and Frequency Conversion


The 7200 Series UPS leaves the manufacturer fully tested and adjusted to operate
at 400Vac / 50Hz with a 198 cell battery; however, but can be converted to 380V
or 415V, at either 50 or 60Hz. Such a conversion is effected by:
changing the control power supply transformers primary tap voltages.
entering the revised working parameters into the control systems memory
via the Operator Control Panel SETUP menus.
amending the number of batteries, if required.
The modules working voltage and frequency is set as a matter of course within
the commissioning procedure: the purpose of the following paragraphs is to provide a consolidated procedure for changing these parameters post commissioning
i.e. to change the voltage/frequency of an already working module.
Note: Where reference is made to the nominal voltage, this should be taken as
the required equipment working voltage e.g. 380/400/415 volts.

2.10.1

Rating considerations and battery sizing


If the module is to operate at 415V input/output its power capacity will increase
by approximately 10%. i.e. A 60kVA unit will be increased to 66kVA.
The number of battery elements required to enable the unit to meet its design
specifications is shown in the table below.
Note: If additional elements are required they should be of the same type and capacity as those already in use.
Table 2-15: Number of battery elements

2.10.2

Nominal Operating Output Voltage

Specified N of Battery Elements

380V AC

192 Cells

400V AC

198 Cells

415 V AC

204 Cells

Hardware conversion
1. Ensure that the module is completely powered down i.e. all the UPS isolators, including the battery circuit breaker, are open (OFF or in position 0)
if necessary transfer the load to the Maintenance Bypass supply.
2. Select the correct primary voltage tap on the Power Supply transformers T2
and T3, according to Table 2-16 below.
Table 2-16: Power supply transformers T2 and T3 voltage selection.
380V Operation

400V Operation

415V Operation

A3 - B

A2 - B

A1 - B

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2.10.3

7200 Series UPS Service Manual

Software conversion Entering new voltage / frequency / battery data


Figure 2-25: SETUP menu map (Issue 5.0 software)
MAIN MENU SCREEN

UPS MENU
SCREEN

SETUP MENU
SCREEN

VOLTAGE
MENU
SCREEN

FREQUENCY
MENU
SCREEN
BATTERY
MENU
SCREEN

Continued in
Figure 2-26

1. Inhibit the UPS power sections by selecting switches Q1, Q2, Q3 on the UPS
Logic Board to OFF.
2. Close the Bypass Isolator Q2.
a) The power supply and electronics will energise.
b) The Operator Control Panel display will power up.
c) The rectifier and inverter power sections will remain off.
3. From the default screen press ENTER to access the main menu screen.

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4. Ensure that a link is fitted to jumper X26 pins 7-8 on the UPS Logic Board to
override the password protection system.
5. Select and enter SETUP the password screen will now be shown.
2.10.3.1

Setting the UPS working voltage parameters

1. From the setup screen, select and enter VOLTAGE this will access the voltage menu screen.
2. Select and enter RATED VOLTS..
a) Press the UP menu button repeatedly until the desired input/output working voltage is indicated.
b) Press ENTER to save the selection and then press ESC once to move back
to the voltage menu screen.
3. Select and enter LOWER.
a) Using the data entry method described above, enter the required input and
output voltage undervoltage thresholds.
Note: Standard settings are for -10% (input) and -10% (output).
b) Press ENTER to save the selection then press
the voltage menu screen.

ESC

once to move back to

4. Select and enter UPPER.


a) Using the data entry method described above, enter the required input and
output overvoltage thresholds.
Note: Standard settings are for +10% (input) and +10% (output).
b) Press ENTER to save the selection then press
the voltage menu screen.

ESC

once to move back to

5. Verify that the data shown on the voltage menu screen is correct and repeat
this procedure if necessary.
6. Press ESC again to move back to the setup menu screen.
2.10.3.2

Setting the UPS frequency parameters

Note: go directly to paragraph 2.10.3.3 if the frequency is not to be changed.


1. Select and enter FREQUENCY this will access the frequency menu screen.
2. Select and enter NOMINAL.
a) Press the UP menu button repeatedly until the desired nominal frequency
is indicated.
b) Press ENTER to save the selection then press ESC once to move back to
the frequency menu screen.
3. Select and enter SYNC WINDOW.
a) Enter the required sync window limit.
Note: Standard setting is 2.0% i.e. the inverter will sync to the bypass if
it is 1Hz of 50Hz nominal.
b) Press ENTER to save the selection then press ESC once to move back to
the frequency menu screen.

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CHAPTER 2 - Commissioning Procedure

7200 Series UPS Service Manual

4. Select and enter SLEWRATE.


a) Enter the required slew rate (range 0.1 - 1.0 Hz/s).
Note: Standard setting is 0.10 Hz/s i.e. the speed the inverter will track
a change in bypass frequency.
b) Press ENTER to save the selection then press
the frequency menu screen.

ESC

once to move back to

5. Verify that the data shown on the frequency menu screen is correct and repeat
this procedure if necessary.
6. Press ESC again to move back to the setup menu screen.
2.10.3.3

Setting the Battery parameters

Figure 2-26: SETUP BATTERY MENU


Continued from
Figure 2-25

UPS
0060 kVA
VOLTAGE
400 V
FREQUENCY 50 Hz
BATT.CELLS
198

SETUP MENU SCREEN


BATTERY MENU SCREEN

BATT.CELLS
198
CAPACITY
052 Ah
VOLTAGE/CELL

WRITE
MOVE
BATT.CELLS

BATT.CELLS
198
CAPACITY
052 Ah
VOLTAGE/CELL

WRITE
MOVE
CAPACITY

BATT.CELLS
198
CAPACITY
052 Ah
VOLTAGE/CELL

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

WRITE
MOVE
END DIS.

SAVE
EXIT
1.67 v/e

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

WRITE
MOVE
BAT.LOW

SAVE
EXIT
1.82 v/e

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

WRITE
MOVE
MAX.

BATTERY VOLTAGE
MENU SCREEN

SAVE
EXIT
198

SAVE
EXIT
052 Ah

END DIS. 1.67 v/e


BAT.LOW
1.82 v/e
MAX.
2.45 v/e
BOOST CHARGE

SAVE
EXIT
2.45 v/e

Continued in
Figure 2-27

1. From the setup menu select and enter BATT.CELLS this will access the battery menu screen (illustrated in Figure 2-26).

Setting the number of cells:


2. From the battery menu screen, select and enter BATT.CELLS.
3. Following the data entry method described earlier, using the UP, DOWN
menu buttons, enter the number of cells contained in the battery string.

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SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

4. Press ENTER to save the data to memory, then press ESC once to return to
the battery menu screen.

Setting the Battery Capacity:


5. From the battery menu screen, select and enter CAPACITY.
6. Using the UP, DOWN menu buttons, enter the total battery A/Hr capacity.
(at the 10Hr rate C10).
7. Press ENTER to save the data to memory, then press ESC once to return to
the battery menu screen.

Setting the battery voltage characteristics:


From the battery menu screen, select and enter VOLTAGE this will take you to
the battery voltage menu, which is concerned with selecting the battery charging
characteristics.
Battery undervoltage trip setting

8. From the battery voltage menu, select and enter END DIS..
a) Using the UP, DOWN menu buttons, enter the specified end-of-discharge voltage standard setting is 1.67V/cell.
Note: this is the end-of-discharge voltage and is the voltage at which the
battery breaker is tripped.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery voltage menu screen.
Battery low voltage warning setting

9. From the battery voltage menu, select and enter BAT LOW.
a) Using the UP, DOWN menu buttons, enter the specified low battery voltage standard setting is 1.82V/cell.
Note: this is the voltage at which low-battery warning annunciates.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery voltage menu screen.
Battery overvoltage trip setting

10. From the battery voltage menu, select and enter MAX.
a) Using the UP, DOWN menu buttons, enter the specified max battery
voltage standard setting is 2.45V/cell. This sets the slow overvoltage
level which is effective only when the batteries are in the float charge
mode, and is the voltage at which, after 3 minutes, the battery breaker is
tripped, and the rectifier and inverter turned OFF.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery voltage menu screen.

Battery boost charge setting:


WARNING

DO NOT apply BOOST CHARGE to sealed batteries

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7200 Series UPS Service Manual

Figure 2-27: Battery boost charge parameters


Continued from
Figure 2-26

BATTERY VOLTAGE MENU SCREEN


BATTERY BOOST MENU SCREEN

11. From the battery voltage menu, select and enter BOOST CHARGE this will
take you to the boost charge menu screen.
12. From the boost charge menu, select and enter SETUP this will take you to
the battery boost setup menu screen.
13. From the battery boost setup menu, select and enter DURATION.
a) Using the UP, DOWN menu buttons, enter the required boost operation
time (in minutes) factory setting is 600 mins.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery boost setup menu screen.
14. From the battery boost setup menu, select and enter THRESHOLD.
a) Using the UP, DOWN menu buttons, enter the required current changeover threshold factory setting is 20% of the battery current limit.
Note: this is the level that the battery current must reach before boost
charge is enabled upon mains return.
b) Press ENTER to save the data to memory, then press ESC once to return
to the battery boost setup menu screen.
15. It is advisable to set the NOW and AUTOMATIC parameters to NO at this
stage in the commissioning, and reset to YES (if required) once the rectifier
has been fully commissioned.

Verification:
16. Press ENTER to save the data to memory, then press ESC once to return to
the battery voltage menu screen.
17. Verify that the data shown on the battery voltage menu screen is correct and
repeat this procedure if necessary.

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7200 Series UPS Service Manual

SECTION 2 - Installation and Commissioning


CHAPTER 2 - Commissioning Procedure

Figure 2-28: Battery CHARGE MODE Selection (Issue 5.0 software)


Continued from
Figure 2-19

FUNCTION
MENU SCREEN

NEXT PAGE MENU


SCREEN

ON/OFF
MENU
SCREEN

CHARGE MODE
SELECTION SCREEN

2.10.4
2.10.4.1

Calibration conversions
Recalibrating the battery charging voltages

This part of the procedure calibrates the battery charging voltages using the appropriate potentiometers on the Rectifier Logic Board and requires the rectifier to
be fully powered-up.
1. Connect a DC voltmeter across the battery cable connections (adjacent to the
battery fuse).

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CHAPTER 2 - Commissioning Procedure

7200 Series UPS Service Manual

2. Close the UPS input mains isolator (Q1).


3. Turn switch Q3 on the UPS Logic Board to ON the rectifier should now
start and ramp up to float voltage, as indicated on the voltmeter.

Float charge voltage calibration:


4. On the Rectifier Logic Board:
a) Ensure led H3 (green) is illuminated.
b) Adjust R21 to obtain the required float charge voltage, indicated on the
DC voltmeter.

Manual charge voltage calibration:


5. Using standard screen navigation techniques, gain access to the charge mode
selection screen via the FUNCTION NEXT PAGE ON/OFF UPS CONTROL menu path (See Figure 2-28).
6. Scroll through the menu options and select manual charge mode (MAN).
7. On the Rectifier Logic Board:
a) Ensure led H4 (yellow) illuminates (H3 extinguished).
b) Adjust R22 to obtain a charge voltage, indicated on the DC voltmeter,
appropriate to forming open vented cells (if applicable). If sealed cells
are used then set this voltage to equal the float voltage set previously.

Boost charge voltage calibration:


8. Leave the charge mode selected to manual (MAN), as instructed above.
9. On the Rectifier Logic Board:
a) Link-out pins 0-2 on jumper X9 to force the charger to the Boost mode.
b) Ensure led H2 (green) illuminates (H4 should extinguish).
c) Adjust R20 to obtain the required boost charge voltage, indicated on the
DC voltmeter.
Note: If sealed cells are used then set this voltage to equal the float voltage
set previously.

Calibration completion:
10. Open the UPS input mains isolator Q1 and bypass isolator S2.
11. On the UPS Logic Board set S1, S2, S3 to ON to re-enable the UPS power
sections.
12. On the Rectifier Logic Board remove the link from pins 0-2 on jumper X9.
13. Disconnect and remove the DC Voltmeter.
2.10.4.2

Completion of UPS SETUP configuration

The setup menu parameters have now all been entered and stored in the control
systems non-volatile memory.
1. Start the UPS following the normal start-up instructions and verify that it
now operates at the desired voltage and frequency.
2. If required, remove the link from jumper X26 pins 7-8 on the UPS Logic
Board to re-enable the password security system.

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Section 2:

Chapter 3 - Converting single (pre Jan 1997) units


to 1+1 capability

3.1

Introduction
Series 7200 single module units manufactured prior to January 1997 will require
upgrading before they can operate in a 1+1 system configuration. This chapter
outlines the procedure to be followed before the units are commissioned.
Before the 1+1 paralleling option can be fitted the upgrade procedure requires mechanical changes to be made by fitting Modification Kit Part N 4641030E, which
then changes the unit part number as shown below.
Table 2-17:

3.1.1

Model
Rating kVA

Pre January 1997


unit Part N

Modification Kit
Required

Converted Unit
Part N

30

5410303P

4641030E

5410305R

40

5410304Q

4641030E

5410307T

60

5410308U

4641030E

5410310W

Important Considerations

Caution

This modification must be carried out only by a fully trained and authorised Liebert
engineer.

Allow approximately two hours for the modification of each module.


The mechanical relocation of existing PCBs and control transformers must be
carried out prior to fitting the 1+1 parallel option kit Part N 4645004A.
Step by step instructions are included with the conversion kit Part N 4641030E
but are not in the scope of this manual. However the basic mechanical differences
and repositioning of components is shown in Figure 2-29.

3.2

Conversion Procedure
1. Fit the conversion kit Part N 4641030E, follow the instructions supplied
with each kit.
2. Upgrade the PCBs, refer to below.
Remove PCB
Pre Jan. 97

Fit New PCB


Post Jan. 97

Inverter Logic

4530024S

4530025T

UPS Logic

4550004E

4550007H

Static Switch

4542041X

4542043Z

PCB Description

Units manufactured after January 1997 will have the new PCBs factory fitted.

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SECTION 2 - Installation & Commissioning


CHAPTER 3 - Commissioning Procedure

7200 Series UPS Service Manual

4530025T

Figure 2-29: Pre/Post modification mechanical layouts

4550007H

Pre January 1997 unit


before conversion

Pre January 1997 unit after conversion.


Factory supplied units post Jan 97

3. Check the software version on the UPS Logic Board (D35/D36) and Operator Logic PCB (D8). This must be Version 3.0 or later. If the software version
is incorrect, replace these devices according to the table below
Table 2-18: .
EEPROM

Old Part Number

New Part Number

D35

0837044A Rev x.xx

0837044A Rev D.00

D46

0837045B Rev x.xx

0837045B Rev D.00

D8

0837046C Rev x.xx

0837046C Rev D.00

On completion of the mechanical conversion, PCB replacement and software


upgrade, the converted unit should be commissioned as detailed in Chapter 2.

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s2-c2d2.fm5 - Issue 3 Dated 09/11/98

Commissioning Report Sheet

Section 2 : Commissioning Parameter Settings

Sample Commissioning Recordsheets System Details


Customer Site Details

Module Type/Rating
Module Part/Serial Number

SET UP MENU Parameters


Menu
Selection
UPS

Parameter

Max

UPS TYPE

3 Phase

Single

230

220

240

INPUT UNDERVOLTAGE

10%

1%

99%

INPUT OVERVOLTAGE

+10%

+1%

+99%

NOMINAL INPUT VOLTAGE

230

220

240

OUTPUT UNDERVOLTAGE

10%

1%

99%

OUTPUT OVERVOLTAGE

+10%

+1%

+99%

NOMINAL FREQUENCY

50 Hz

50Hz

60Hz

2%

0.5%

9%

0.1 Hz/Sec

0.1

1.0

SYNC WINDOW
SLEW RATE (SPEED)
BATTERY

Min.

60kVA

NOMINAL OUTPUT VOLTAGE

FREQUENCY

Range

KVA VALUE
CONFIGURATION

VOLTAGE

Standard
Factory
Setting

NUMBER OF CELLS

198

190

210

85 AHr

000

499

END OF DISCHARGE VOLTS

1.67 Volts/cell

1.60

1.69

LOW BATTERY VOLTAGE

1.82 Volts/cell

1.70

1.89

MAX. BATTERY OVER VOLTAGE

CAPACITY

2.40 Volts/cell

2.30

2.70

BOOST CHARGE ENABLE

NO

BOOST CHARGE AUTO

NO

BOOST CHARGE DURATION

0000 min.

0000

9999

BOOST CHARGE THRESHOLD

00 Amps

00

99

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Selected Setting

Commissioning Report Sheet

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Commissioning Report Sheet

MAINTENANCE MENU Parameters


Menu
Selection

Parameter

Standard
Factory
setting

Range
Min

Max

PASSWORD

PASSWORD

0000 0000

S.N.

SERIAL NUMBER

0000 0000

12.00.00

CURRENT TIME AND DATE

12.00.00
01.01.96

LAST SER.

LAST SERVICE TIME AND DATE

01.01.96

NEXT SER.

NEXT SERVICE TIME AND DATE

01.01.96

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Selected Setting

Commissioning Report Sheet

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Commissioning Report Sheet

FUNCTION MENU Parameters


Menu
Selection

Parameter

0000 0000

0000
0000

9999
9999

NOW

NO

AUTOMATIC

NO

00 Min

00

99

1.70 V/e

1.70

1.90

DURATION
THRESHOLD
PERIOD

000 dd

000

999

01.01.96

INV: SYNC INHIBIT

NO

BAT: I INHIBIT

NO

RECT: I INHIBIT

NO

Requires
an alarm
interface
PCB
fitted

START AT

LANGUAGE

PANEL
SETUP

Selected Setting

Max

SETUP

GENERATOR

Range
Min

Input Password To Gain Access To Function Selection Screen


BATTERY
TEST

Standard
Factory
setting

ITALIAN

TYPE
GROUP

UPS : NODE :

PASSWORD

Eng : Fr : Esp :
Deu.

MASTER. 0060

1:1

0000 0000

0000
0000

9999
9999

LOCAL

MODEM
CONNECTION

PC CONN
RESET

NO

ON/OFF UPS
BLOCK

INVERTER

ON

BYPASS

ON

RECTIFIER

ON

RECTIFIER

FLO

FLO

MAN

RELOAD DATA

NO

RELOAD UPS
DATA

S2-c2e.fm5 - Issue 3 Dated 09/11/98

DO NOT perform this test as part of the


normal commissioning procedure unless
the UPS parameters have to be reset to
factory default values.

Commissioning Report Sheet

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Commissioning Report Sheet

MEASURMENT MENU Parameters


Selection
Screen
OUTPUT

Standard
Factory
setting

Parameter
VOLTAGE

AB

400 Volt

BC

400 Volt

CA

400 Volt

AN

230 Volt

BN

230 Volt

CN

230 Volt

0 Amp

0 Amp

0 Amp

0 Amp

0 kW

0 kW

CURRENT

POWER

FREQUENCY

INPUT

BATTERY

TEMPERATURE

0 kW

0 kVA

0 kVA

0 kVA

Bypass Line

50 Hz

Inverter

50 Hz

AB

230 Volt

BC

230 Volt

CA

230 Volt

VOLTAGE

VOLTAGE

460 Volt

CURRENT

0 Amp

CHARGE CAPACITY

100%

Tt (Transformer)

Ta (Input air)

To (Output air)

Tb (Batt cabinet)

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Enter
On Site Readings

Commissioning Report Sheet

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Commissioning Report Sheet

Hardware Parameters
Rectifier Logic Board
Parameter

Potentiometer

Test Point

Factory
setting

R17

X8 pin 7

Proportional kVA

Rectifier Current Limit


Battery Current Limit

R18

X8 pin 8

Proportional kVA

Battery Temperature Compensation

R121

X8 pin 5

2.98Vdc

DC Float Voltage

R21

DC Bus

449Vdc

DC Manual Voltage

R22

DC Bus

449Vdc

DC Boost Voltage

R20

DC Bus

449Vdc

DC Test Voltage

R19

DC Bus

390Vdc

Site Setting

Inverter Logic Board


Potentiometer

Test Point

Factory
setting

150% Current limit

R248

X10 pin 4

0.6Vdc

Inverter Tri-wave PWM


reference

R241

Scope to LHS of R27

4Vp-p
(+2V to -2V)

Output Voltage R-N

R246

Inv output terminal R-N

230Vac

Output Voltage S-N

R244

Inv output terminal S-N

230Vac

Output Voltage T-N

R245

Inv output terminal T-N

230Vac

Output Voltage R-S

R242
Adjust all 3
phases together

Inv output terminal R-S

400Vac

Inv output terminal S-T

400Vac

Inv output terminal R-T

400Vac

Output Frequency R-T

Inv output terminal R-T

50Hz

Inverter/Bypass phase
shift

R247

Scope Bypass R-phase


and Inv R-phase.

0 Shift

Parameter

Output Voltage S-T


Output Voltage R-T

Site Setting

UPS Logic Board


Potentiometer

Test Point

Factory
setting

5V Voltage reference

R209

X20 pin 1

5.00Vdc

2.5V Voltage reference

R212

V45 anode

2.50Vdc

Parameter

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Site Setting

Commissioning Report Sheet

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Commissioning Report Sheet

Operator Logic Board


Parameter

Potentiometer

Test Point

Factory
setting

R21

LCD Display

N/A

LCD Display Contrast

Battery information
Parameter

On-Site notes

Battery Type
Number of Cells
Float Voltage

Ampere/Hr capacity
Battery Current Limit
Battery Breaker Size

ENGINEERS NAME:
SIGNATURE:
DATE:

WITNESSED BY:
SIGNATURE
DATE:

S2-c2e.fm5 - Issue 3 Dated 09/11/98

Site Setting

Commissioning Report Sheet

S2-c2e.fm5 - Issue 3 Dated 09/11/98