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M o d u la r U P S s y s t e m
1 0 k V A t o 1 0 0 k V A , 3 x4 0 0 V
Technical Guide
Copyright 2008 by Gamatronic Electronic Industries Ltd. All rights reserved worldwide.
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is the only warranty offered by Gamatronic Electronic Industries Ltd. in relation thereto.
This document may contain flaws, omissions or typesetting errors; no warranty is granted nor liability assumed in
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subject to change without prior notice.
TABLE OF CONTENTS
1. SYSTEM STRUCTURE ........................................................................................................1
4. SYSTEM INSTALLATION..................................................................................................44
4.1. Inspections to be Performed Prior to Installation ..............................................46
4.2. Installation Procedure and System Start-up .......................................................47
4.3. Initial Start-up Sequence .......................................................................................48
4.4. Checks to be Performed Following Initial Startup ............................................. 50
4.5. Special considerations for 1-phase output .........................................................51
4.5.1. Dip-switch settings on the modules ...................................................51
4.5.2. Wiring of input and output terminals ..................................................51
4.5.3. System start-up .....................................................................................52
4.6. dip switch SETTINGS of THE UPS modules .......................................................53
6. BATTERIES........................................................................................................................ 62
8. TROUBLESHOOTING .......................................................................................................69
LIST OF FIGURES
Figure 1-1: Block diagram.......................................................................................................1
Figure 1-2: Sub-assemblies ....................................................................................................2
Figure 1-3: 10kVA configuration............................................................................................. 2
Figure 1-4: 50kVA configuration............................................................................................. 3
Figure 1-5: 100kVA configuration .......................................................................................... 3
Figure 2-1: Single UPS Module- Front/Rear View .................................................................4
Figure 2-2: Block diagram of a single UPS Module.............................................................. 5
Figure 2-3: Power section of the PFC in a single UPS module ........................................... 6
Figure 2-4: Input currents of the PFC (without filters) ......................................................... 6
Figure 2-5: PFC control scheme............................................................................................. 7
Figure 2-6: DC/AC inverter principal topology...................................................................... 8
Figure 2-7: System controller - Front panel ........................................................................10
Figure 2-8: System controller - Block diagram ...................................................................11
Figure 2-9: ST/SW front panel view......................................................................................13
Figure 2-10: ST/SW block diagram.......................................................................................13
Figure 2-11: 3-Phase ST/SW block diagram........................................................................14
Figure 3-1: Power+ system - Modular structure .................................................................15
Figure 3-2: Schematic of a 3:1 Phase 30kVA POWER+ System .......................................16
Figure 3-3: Schematic of a 3-Phase 30kVA POWER+ System ..........................................17
Figure 3-4: POWER+ System - Rear View ...........................................................................18
Figure 3-5: Control PCB and flat cable ................................................................................19
Figure 3-6: Wrong way to connect UPS with grounded-neutral-generator ..................... 21
Figure 3-7: Acceptable connection for grounded generator and 4-pole switch .............22
Figure 3-8: Preferred generator (neutralized) and connection (3-pole) ...........................23
Figure 3-9: UPS module Rear view ...................................................................................24
Figure 3-10: UPS module connectors - Pin assignments..................................................24
Figure 3-11: DC distribution panel (50KVA model) ............................................................27
Figure 3-12: DC distribution. panel (100kVA model)..........................................................27
Figure 3-13: DC fuses on front side of DC dist. panel (50KVA model)............................. 28
Figure 3-14: DC fuses on front of DC dist. panel (100KVA model)................................... 28
Figure 3-15: UPS modules - AC input fuses (100KVA model)............................................ 29
Figure 3-16: AC input fuse assignments (50KVA model) ..................................................29
Figure 3-17: AC distribution..................................................................................................30
Figure 3-18: AC distribution panel (100KVA model) ..........................................................30
Figure 3-19: AC distribution panel (50KVA model) ............................................................30
Figure 3-20: Input & output main terminals ........................................................................31
Figure 3-21: Static switch terminals Rear view................................................................32
Figure 3-22: System controller outside the shelf - Rear view ...........................................33
Figure 3-23: The PC917 Control PCB on a shelf general view .......................................34
LIST OF TABLES
Table 2-1 Single UPS Module Specifications ........................................................................9
Table 2-2: System controller specifications........................................................................12
Table 3-1: UPS module pin assignment and function........................................................25
Table 3-2: DIP switch setup in a 100kVA system (X = don't care). ...................................36
Table 4-1: Power Configuration DIP Switch Settings ........................................................52
Table 5-1: Controller main menu options .............................................................................54
Table 5-2: System controller alarms .....................................................................................61
Table 8-1: UPS Module Indicators ........................................................................................70
Table 8-2: Troubleshooting table .........................................................................................71
Table 9-1: General information screen ................................................................................76
Table 9-2: Main Menu functions ...........................................................................................77
Table 10-1: Setup Menu options...........................................................................................78
Table 10-2: Setting alarm thresholds ...................................................................................78
Table 12-1: Calibrating battery current measurements .....................................................89
Table 13-1: Time displays......................................................................................................91
Table 13-2: Main dip switch statuses...................................................................................91
Table 13-3: Panel and slave dip switch statuses................................................................92
Table 13-4: Controller external and internal power statuses ............................................92
vi Power+ Technical Guide, Release 1.5
Gamatronic Electronic Industries Ltd.
WARNING: RISK OF
SEVERE DAMAGE TO THE UPS!!!
1. SYSTEM STRUCTURE
The Power+ is a parallel redundant UPS. A block diagram is shown in Figure 1-1 below.
System
Controller
Bypass Power
Output
Static Switch
Isolation
Mains Power
UPS Transformer
10KVA
(optional)
UPS
10KVA
UPS
10KVA
UPS
10KVA
Centralized
System Controller
System
Controller
4 x 10kVA UPS
Modules
DC Distribution
Static Switch
(ST.SW) Module
AC Distribution
(Behind ST.SW.)
2. FUNCTIONAL OVERVIEW
A general module view is shown in Figure 2-1. The module classic on-line double-
conversion type block diagram is illustrated in Figure 2-2.
This design has proved to be very stable. No transfer time is required for the UPS to switch
from normal to backup mode; the load is supplied constantly by stable and clean power. A
Power Factor Correction (PFC) 1 is responsible for the low Total Harmonic Distortion (THD)
and unity Power Factor (PF) at the input.
This stage can maintain current sharing between the three input phases as well as among
other parallel units, because of the current sharing signal that it produces.
1
PFC is a feature included that reduces the amount of generated reactive power. Reactive power
operates at right angles to true power and energizes the magnetic field. Reactive power has no real
value for an electronic device, but electric companies charge for both true and reactive power
resulting in unnecessary charges.
In power factor correction, the power factor (represented as "k") is the ratio of true power (kwatts)
divided by reactive power (kvar). The power factor value is between 0.0 and 1.00. If the power factor
is above 0.8, the device is using power efficiently. A standard power supply has a power factor of
0.70-0.75, and a power supply with PFC has a power factor of 0.95-0.99.
The PFC power section block diagram is shown in Figure 2-3. Input currents of the PFC
(without filters) is shown in Figure 2-4; the control scheme is illustrated in Figure 2-5.
+
Ir
-
Control
+
Is
-
Control
+
It
R S T
-
Control
N
Figure 2-3: Power section of the PFC in a single UPS module
Ipeak Ir Is
(CCM)
t
-Ipeak It
Figure 2-4: Input currents of the PFC (without filters)
As shown in Figure 2-3, the PFC section operates in Continuous Current Mode (CCM)
conduction, which has many advantages. Input currents are shaped in such a way that they
follow the input voltages with precision.
This makes the system appear to be nothing more than a resistive load with respect to the
line voltage. In other words, the system corrects the input current waveform of the connected
load, and acts as an active power filter.
The PFC section also draws symmetrical currents from each phase, and maintains good
current sharing among identical UPS modules in parallel.
Each phase input is sensed for voltage and current, required to force the input current drawn
from the phase input to follow its voltage and emulate a resistor. Two feedback loops are
required for the proper operation, an inner current loop for maintaining a correct wave shape
and an outer voltage loop to ensure a correct DC output level.
The voltage sample (k*Vin) is multiplied by the error voltage from a common voltage
feedback amplifier (Integrator). The result is than compared to the actual sampled phase
current which forces the current amplifier current to follow the phase input voltage. The
output of the integrator is connected to a current sharing bus causing all other modules to be
connected to this bus via the same resistor. This ensures that all the multipliers of each UPS
module receive the same input and all that modules are equally loaded.
Current
MULT Amplifier
Comparator
K1*V1 +
-
+ PWM
POWER Vout (DC)
-
BLOCK
Triangle
PH1
NEUTRAL
Current
MULT Amplifier
Comparator
K1*V2 +
-
+ PWM
POWER
-
BLOCK
Triangle
PH2
NEUTRAL
Current
MULT Amplifier
Comparator
K1*V3 +
-
+ PWM
POWER
-
BLOCK
Triangle
PH3 Verror
DC
NEUTRAL share K2*Vout
bus -
Integarator Vref
This stage is fed by the DC symmetrical voltage produced by the PFC stage which then it
inverts to create clean sinusoidal output(s).
POWER+ employs 3-L (3-level) topology which achieves very high efficiency (over 96%)
which in turn enhances the overall AC-AC efficiency of the entire system.
As shown in Figure 2-6 the inverter voltage is produced using three levels of DC voltage
(unlike standard two-level system).
The POWER+ inverter uses Insulated Gate Bipolar Transistors (IGBT) as efficient high
frequency switches.
Apart from the AC/DC PFC and DC/AC inverter each UPS module also contains a digital
controller, responsible for all the control mechanism and all communications with other
modules of the system.
Each UPS module also provides the system controller with a report related to its condition
and operation status. All the data available from all modules is displayed on an LCD display.
The UPS module is cooled using forced convection. The fan varies with the load level,
making for improved reliability, reduced noise, and less dust is introduced.
L
Vr
L
Vs
L
Vt
C
- + - + - + C
C
N
Control
Some other useful features include temperature compensation of the battery voltage.
The POWER+ can work without the system controller but with reduced functionality.
Figure 2-8 shows the system controller block diagram. The core of the controller is a
powerful embedded micro-controller, surrounded by many peripherals (analog, digital,
communication).
Generally the ST/SW connects the output of the paralleled UPS modules to the main output
of the system. However, if the modules fail to provide an adequate voltage for a determined
time, i.e. detection time, the ST/SW module instantly switches to the alternative power
source, that is the AC input, as illustrated in Figure 2-10. The unit employs an efficient AC
switch for this purpose using a combination of fast semiconductors and an
electromechanical relay.
The module monitors all the inputs in real time to determine the method of operation. The
ST/SW modules front panel is shown in Figure 2-9.
Outputs
INV BP
INV BP
INV BP
3. SYSTEM INTERCONNECTION
The POWER+ system comprises UPS Modules, a System Controller, Static Switch and
distribution elements such as AC, DC and fuses. These components are assembled as
shown in Figure 3-1.
A major advantage of the POWER+ is its upgradability simply by adding UPS modules and
shelves as required.
The system controller occupies the same space as the UPS module and although not
critical, is most often mounted at the top shelf for convenience. This permits easier viewing
of the display. The static switch module however, is always mounted at the bottom of the
system (see Figure 3-1).
Note: For use with single-phase input, all 3 phases of each AC input are connected together
internally inside the cabinet. REFER TO SINGLE-PHASE OUTPUT INSTRUCTIONS.
Cables for the POWER+ are all connected at the rear of the system.
Cables are routed between the UPS modules system controller and static switch down to
the AC and DC distribution sections that are mounted at the bottom of the rack. Figure 3-1
shows the rear view of the POWER+ system. (Note that 3 UPS modules are in use in this
illustration). UPS modules are numbered from bottom to top; i.e. the lowest UPS module is
"UPS #1"; the UPS above it is "UPS #2" and so on.
UPS modules are inter-connected by a flat cable which is used for the transmission of digital
and analog data.
This data is essential for maintaining synchronization and current sharing between modules.
This flat cable is connected to a small PCB in the UPS shelf and is connected to the control
DIN48 connector described on page 24.
NOTE:
PROPER CONNECTION OF THE FLAT CABLE
IS OF CRITICAL IMPORTANCE.
INCORRECT OR WEAK CONNECTION
WILL PREVENT THE SYSTEM FROM OPERATING.
Each shelf has a digital address that is preset at the factory and determined by the DIP
switch mounted on the small control board as shown in Figure 3-5.
Caution: If at any time the neutral line becomes disconnected, there will be no input or
output reference voltage, because the input neutral line and the output neutral line are
physically linked together. That may result in system defining its own reference voltage,
which will be set by the load distribution between the three phases. This can result in
serious damage to the UPS.
To avoid these problems, we strongly recommend that, if you use a four-pole mains-to-
generator switching system, you install an isolation transformer that will constantly provide
the UPS with a neutral line.
Figure 3-6 on page 21 illustrates the wrong way to connect the UPS with a grounded-neutral
generator.
Figure 3-7 on page 22 illustrates an acceptable connection solution if you already have a
grounded-neutral generator.
Figure 3-8 on page 23 shows the preferred generator (neutralized, not grounded) and the
preferred connection (three-pole).
Figure 3-7: Acceptable connection for grounded generator and 4-pole switch
Figure 3
WARNING
ALL THE CONNECTOR PINS CARRY HAZARDOUS VOLTAGES
ALWAYS AVOID ACCESS TO THESE PINS!
The connectors pin assignments are illustrated in Figure 3-10 and described in Table 3-1
below.
a b c
1
2
3
4
5
6
30 26 22 18 14 10 6 7
b8
8
9
10
32 28 24 20 16 12 8 4 11
12
"DIN 15" CONNECTOR 13
14
15
16
WARNING
THE DATA PROVIDED BELOW IS FOR INFORMATION ONLY.
DO NOT ATTEMPT TO MAKE ANY CONNECTIONS.
Output Connector
4 = OUT3 (T) 6 = OUT3 (T) 8 = OUT2 (S) 10 = OUT2 (S) 12 = OUT1 (R)
14 = OUT1 (R) 16 = N.C. 18 = N.C. 20 = N.C. 22 = Neutral
24 = Neutral 26 = Neutral 28 = N.C. 30 = N.C. 32 = N.C.
Control Connector
"a" Column "b" Column "c" Column
Device Address = Identifies the location of a UPS module within the system
WARNING
BATTERY CABINETS MAY BE CONNECTED AND
MAINTAINED BY A QUALIFIED TECHNICIAN ONLY!!!
NOTE:
The Neutral line is common to the input and
output as well as to the battery "0V" point!
The DC distribution panel is located at the bottom of the system on the rear, below the first
UPS module (UPS #1).
This panel receives the DC wires from the systems UPS modules and from the controller, as
well as from internal or external battery cabinets.
External battery connections are performed at the right side of this panel.
The DC distribution panel on your system will have one of two possible layouts, depending
on whether your system has a maximum capacity of 50KV or 100KV. maximum capacity, as
shown in Figure 3-11.
The Anderson connector plugs on the DC distribution panel are color coded: RED=positive,
BLACK=negative, BLUE=neutral.
3.2.1. DC FUSES
All DC fuses are located on the opposite side (the front side) of the DC distribution panel.
There are two fuses for each power module and for the controller one for the positive line
and one for the negative line. Figure 3-13 and Figure 3-14 show the assignments.
WARNING
ALWAYS REPLACE FUSES WITH THE SAME TYPE AND RATINGS !!!
The AC input to the modules are protected by the AC fuses as described above.
NOTE:
The Neutral line is common to the input and
output as well as to the battery "0V" point!
This module communicates with the rest of the system via the communication port located at
the right side of the unit.
Additional terminals are provided as shown for Emergency Power-Off (EPO) and for Load
On Bypass indication.
Although the UPS modules reads their digital address number from the Control PCB
(discussed later) the controller does not!
Connections to the System Controller are from the rear, as shown in Figure 3-22.
NOTE:
Several Controller options are available
(e.g TCP/IP, cellular and more).
Refer to your dealer for further details.
No two shelves can have the same address. The address is related to the physical location
of a specific shelf, and is preset at the factory by the Module Location DIP switch
mounted on the control PCB. (See Figure 3-23). When adding a new module to an existing
system, the address of the newly added shelf must be set correctly.
The control PCB contains an additional DIP switch the Master/Slave DIP switch that
is used to indicate which of the UPS modules is the Master, and which UPS modules are
the Slaves. Only one UPS module is designated as Master; all of the other UPS modules
are Slaves.
Figure 3-24 shows the DIP switches on the PC719 card, which is located on the back of
each shelf housing a UPS or the controller module.
1= "on", 2= "on", 3= "on", 4="on, indicating UPS #1. See Table 3-2 below and FIGURE
3-26.
Lowest Module Select (LMS) jumper: The first module (UPS #1) must be assigned as
such by a jumper on the MOLEX-2 connector.
Other versions of the Control PCB may have a 2 level DIP switch instead of this connector,
in which case both switches must be ON.
3.9.1. BATTERIES
Q. What will happen if the battery capacity was not setup correctly?
A. Right values of Ah battery capacity should be entered; otherwise the reliability of the smart battery
test will be lower.
Q. Why should I use the battery current limit? If I activate it, what
parameters do I use?
A. Correct parameters for battery current limit are specified by a battery manufacturer, in a datasheet.
It improves the battery lifetime and protects from overcharging. Caution: Incorrect setting might cause
unexpected system operation.
Q. When the Ah value for the batteries is entered, and there are two or
three battery cabinets selected, will the unit add the entered values or
divide them between the cabinets?
A. If the number of battery cabinets is set to more than one, then you will have to select the battery Ah
rating for each battery cabinet independently, as it can be different. Eventually the unit will add these
values and obtain the global Ah value.
3.9.2. GENERAL
Q. How can this system work as a single and triple phase (selectable) on
the input?
A. This unit features advanced rectifier technology which allows you to connect triple phase voltage to
the inputs or just a single phase linked together on R (L1), S (L2) and T (L3) inputs. The unit will
accept both connection types on the input, no additional settings are needed.
Q. How can this system work as a single and triple phase (selectable) on
the output?
A. The special inverter function allows single phase output operation. To switch the system to single
phase operation, each UPS module should be removed while the system is off and its dip switch
number 3 (they are located in a small window on the left side of each module) should be moved to the
OFF position (ON for 3 phase output operation). Then the output phases R (L1), S (L2) and T (L3)
should be linked altogether to a single phase wire output (used with the output neutral), as the phase
angle will be switched to 00 and each module will have its inverters operating in parallel.
Q. How will the ST/SW module react to a change from triple to single
phase and vice versa on the output?
A. The bypass input of the unit should fit the output voltage. If the output voltage is triple phase, then
the bypass input should be triple phase as well. If the output is single phase, and the output phases
are linked altogether, then the same thing should be done with the bypass input of the unit one
phase connected and the R (L1), S (L2) and the T (L3) inputs of the bypass linked altogether. The
ST/SW module will detect it and function as a triple or single phase unit automatically.
Q. Does this unit have dry contact outputs, and for what alarms?
A. These systems have 6 dry contacts on the controllers rear panel. Two of them are in a DB9
connector (pins 3, 4 alarm no. 1 and pins 5, 4 alarm no. 2). The other four are located in a marked
wide green connector with screw wire attachments. There are N.O., N.C. and the COMMON
connections for each dry contact. All dry contacts are programmable through the controller, selectable
from the global list of 32 alarms. Any number of alarms can be set for any dry contact. All the contacts
are rated at 24V 1A.
3.9.3. MENUS
Q. Why should I use the individual UPS module turn on/off feature?
A. The individual UPS turn on/off feature is disabled.
Q. Why are there two settings for a number of UPS modules in the system?
A. A total number of modules represent the units with which the controller will communicate and
monitor. The redundancy number of modules shows how many units are functioning as a backup,
without being calculated in a global load level of the system. For example, if you have a 30KVA unit
with a setting for 1 redundant module, when the output load will reach 20KVA the unit will show a full
load condition. It will still not switch to bypass, but will alarm you with overload if the output load will
rise above 20KVA. For the user this means that the unit does not have the redundancy anymore
under this load. If the redundant modules value is set to 0, then a 40KVA unit will function as a
standard unit of 40KVA output load maximum. It you set this parameter to 3, the same unit will have a
load bar-graph of a 10k system and will alert the customer with overload when there is more then 10k
of load on the output.
Q. What is the DC-I offset removal and the DC-I calibration menu entries?
A. The DC-I offset removal and the DC-I calibration should be performed only if the battery current
measurement is not correct. It is being used on new controllers only upon current sensors connection.
You might have do use these features if adding current sensors on a later stage. To perform it the unit
should work without a load and with batteries disconnected. Then the offset removal should be
preformed (only if the measurement current is not zero) and then the unit should be connected to
some load and batteries and operated in input power failure mode. Then the actual current is being
measured and corrected live in the controller using the calibration menu entry.
3.9.4. INSTALLATION
Q. When the EPO is deactivated, the unit still wont return to normal
operation. Why is that?
A. When the EPO function was activated, the unit stopped functioning and provided voltage to battery
breaker trip coil (option of the battery cabinet) to switch the batteries off as well. To restore normal
operation of the UPS system, it should be completely restarted.
Q. Upon the installation, the unit wont switch to inverter and the Sync
LED on ST/SW module is in red. Everything else is ok. Why is that?
A. Usually this means that the phase sequence on the ST/SW input (the bypass) is not correct. These
units get synchronized on the bypass and therefore check the phase sequence there. Swapping
phase S (L2) and T (L3) on the bypass input should correct the situation.
Q. When I press the Inv/Byp button on the ST/SW module, it doesnt switch
to/from bypass. How do I do the manual transfer?
A. The Inv/Byp button is a press and hold button for protection. It should be held for a number of
seconds until the alarm LED lights in green, and then released. There is the same button on the
controller; there it should be pressed twice to initiate a manual transfer.
Q. Is there a neutral connection on the input and the output of the unit?
A. Power Plus units operate with neutral on input and on the output. To achieve three-phase
operation without neutral delta to star (or the opposite for output) transformers can be used.
Q. Does the unit have dry contact for the Load on bypass signal?
A. Yes, it is located on the ST/SW module. Unscrew two mounting screws on the front panel of the
ST/SW module and slightly pull it out. The dry contact connection is on its top, 230v rated, usually for
use with electricity switchboards with make-before-break load transfer function for protection.
3.9.5. MECHANICS
Q. An alarm LED is in red on the front panel. How can I quickly understand
what is wrong?
A. On the left side of the controller there is an alarm off button. When you press it, you will see the
list of all the alarms for the system and their state. They can be browsed using the up and down
arrows. The active alarms will have an asterisk (*) sign near them.
Q. When I look at the list of the alarms, I can see some alarms which are
always on. Why is that?
A. There is a number of alarms that might be on. One of them is the STRTUP alarm, which stands
for the startup time stamp. This alarm only means that the unit is on, and it will not raise an alarm
signal. Other alarms can be the user alarm 1-4, which are the input dry contacts. If they are not in
use, you can disable them through the controller menus.
Q. What will happen if the equalizing mode was activated in the unit?
A. The equalizing mode should always be set to DISABLED, this feature is not available. If you had it
on in your system, please note that it could simulate a failure condition and a shutdown to the
computers. On all the units today this feature is absent. Please contact your Gamatronic
representative to upgrade your controller software version.
Q. The unit always shows battery test fault alarm. The batteries are OK.
What is wrong?
A. On some older systems the controller might show false battery alarms. This was corrected, so in
case that you have this problem and positively sure that the batteries are alright, please contact your
Gamatronic representative to upgrade your controller software version. After you perform this action,
the unit will still show battery test fault. Please perform manual battery test to restore normal
operation.
4. SYSTEM INSTALLATION
RISK OF ELECTRICAL SHOCK OR INJURY!
INSTALLATION MAY BE PERFORMED BY
QUALIFIED TECHNICIAN ONLY!
WARNING
Figure 4-1 illustrates the cabling of the POWER+ system to the mains electricity cabinet.
Figure 4-2 below shows required switch and wire ratings for 10-100kVA installation.
For battery connections, see Figure 6-3 on page 64.
10 16 2.5 32
20 32 6 63
30 50 10 100
40 63 16 120
50 80 25 140
60 100 35 175
70 100 35 200
80 125 50 225
90 140 50 250
Remove rear covers and connect AC input and output power cables to terminals according to markings as shown
1. in this User Guide and according to connection schematic.
Verify correct phase sequence between board and UPS
Connect ground lines to busses according to markings as shown in the connection schematics (Figure 3-2 on
2.
page 16, Figure 3-3 on page 17, Figure 4-1 on page 44). Verify secure connections.
Connect the DC power cables of the battery cabinets to the UPS terminals according to markings as shown in
Figure 4-1 on page 44 and Figure 6-3 on page 64. Connect neutral and ground lines to busses as above.
3. Verify correct polarity of the connections (+ / N / -) Between the Battery Cabinets C.B.s / Terminals and the UPS
terminals. Auxiliary contacts of Battery C.B.s are connected to UPS Controller inputs Bat CB and Com as
marked, and as shown in Figure 7-2 on page 66.
An external dual-pole / N.C. EPO switch may be connected according to connection schematic.
4.
EPO wiring and switch rating must be rated for at least 5A / 230VAC.
Before connecting power to each system verify again that all connections are secure and are according to
5.
instructions and schematics.
6. Follow the instructions in section 4.3, Initial Start-up Sequence, on page 48.
Power up
Start-up 1
Power up
Start-up 2
Power up
Start-up 3
Power up
Start-up 4
3. Ensure that you have a normal reading on the System Controller display. The bar
graph on the left side displays loads of all 3 phases as shown in Figure 4-7.
Power up
Default
window
Phase to Phase:
AC input voltage during operation under load. Not less than 2% below no-load values measured in item 5 below.
1. Take measurements on the input terminals of
the system Phase to Neutral:
Not less than 2% below no-load values measured in item 5 below.
With no load on the system, measure current
2. Irst should be <15A
circulation between the units.
With no load on the system, measure the DC Total DC voltage between + and terminals should be
3.
voltage of the system. between 850V and 880V.
Voltage between neutral and ground during
4. operation under load 02VAC
On the input terminals of the system
220V +/- 2%
5. System output voltage
or other according to system specifications
Verify that the system is not overloaded in relation to system
6. Total system load / output current
specifications
Verify that the UPS is operating normally in accordance with this
7. Correct and orderly operation
User Guide and that no alarms or fault indications are evident
NOTE: It is the responsibility of the customer to notify Gamatronic Electronic Industries Ltd. and receive
approval for any deviations from these requirements.
R-
S
Phase to Phase:
S-
Not less than 2% below no-load values measured in T
AC input voltage during operation under load. item 5 below.
8. Take measurements on the input terminals of T-
the system R
Phase to Neutral: R
Not less than 2% below no-load values measured in S
item 5 below. T
With no load on the system, measure current
9. Irst should be <15A
circulation between the units.
R
With no load on the system, measure the DC Total DC voltage between + and terminals
10. S
voltage of the system. should be between 850V and 880V.
T
Voltage between neutral and ground during
11. operation under load 02VAC
On the input terminals of the system
220V +/- 2%
12. System output voltage
or other according to system specifications
Verify that the system is not overloaded in relation to
13. Total system load / output current
system specifications
Verify that the UPS is operating normally in accordance
14. Correct and orderly operation with this User Guide and that no alarms or fault
indications are evident
NOTE: It is the responsibility of the customer to notify Gamatronic Electronic Industries Ltd. and receive
approval for any deviations from these requirements.
Figure 4-8: Example of dip switch setting for 3/3 phase, 50 Hz UPS
NOTE: All settings must kept the same on each of the modules in a single system.
The location of the dip switches on a UPS module is shown in the picture below.
The SYSTEM option on the Main Menu (option 1) shows the DC voltages and current
(positive, negative and summary):
1. From the DC voltages screen, scroll down to view the three-phase input and
output total voltage and current:
2. From the DC voltages screen, press the key to view the current output power
factors 2.
2
1KVA is 1000 VA. Apparent power is measured in VA which is a reactive (i.e. a mix of both
capacitive and inductive) loads RMS voltage multiplied the RMS current. True power is VA multiplied
by the power factor, and the power factor is the cosine of the phase angle between voltage and
current. A reactive load that draws an apparent power of 1000VA and has a 0.5 power factor is
consuming 500 watts of power. If a device were purely inductive, it would have a power factor 0. See
also footnote 1, on page 4.
56 Power+ Technical Guide
Gamatronic Electronic Industries Ltd.
1. From the Main Menu, select option 2 UPS MODULE. The message shown in
Figure 5-8) appears.
2. Use the and keys to scroll between UPS modules. The display shows the
voltage and current measurements for each module (see Figure 5-9 on page 58).
3. Scroll and keys to view additional information for the specific module chosen
(see Figure 5-10 on page 58).
Figure 5-9 and Figure 5-10 show parameters for the first module of a UPS system with four
modules. (UPS: #01/04).
1. From the Main Screen, press Ent to display the Main Menu
2. Select "7>SETUP" (Figure 5-1).
3. Enter the password and press Ent (default password is 8 x <).
4. Select "8>Service" (Figure 5-11).
5. Select "5>Configure" (Figure 5-12).
6. Select "2> # of UPSs" (Figure 5-13).
7. Set the number of UPS modules by using the and keys (Figure 5-14).
8. Press Enter to complete the setup.
The controller applies and saves the new number of modules.
1. Select "4>HISTORY" (Figure 5-1). The last 255 events reserved in the LOG are
displayed, as shown in Figure 5-15.
2. Navigate the LOG by scrolling using the and keys.
6. BATTERIES
For systems from 10kVA through 30kVA, the batteries may be internal; otherwise, the
batteries are housed in external cabinets. See Figure 6-3 on page 64 for details on battery
cabinet wiring and connections.
Each battery pack is 6U high and weighs about 135kg on average, depending on the
manufacturer and model. It comprises. 4 drawers, each containing 16 batteries, to help
facilitate removal and replacement. See Figure 6-2 on page 63.
System controller
DC distribution
Static switch
Battery drawers
These batteries are connected to the system by heavy duty cables, care must be taken to
ensure correct polarity. Overall voltage may be as high as 870vDC + to -, i.e. +435vDC and
435vDC with respect to ground/earth. Precautionary measures must be taken whenever
connecting the battery or servicing the battery cabinets.
WARNING: After connecting the batteries to the UPS, do not turn on the battery circuit breaker until
the UPSs AC INPUT circuit breaker is turned on.
Cables from battery banks are connected to the Anderson connectors on the DC distribution
shelf as indicated in Figure 3-11 on page 27 and Figure 3-12 on page 27.
When you are installing the battery for the first time, or if you have changed either
NAME IN
INPUTS DRY CONTACT DESCRIPTION
ALARM DISPLAY
COM Shared contact ---
To install the temperature sensor, connect the sensor according to Figure 7-3 and Figure
7-1.
To see the temperature reading, a configuration change must be made to the controller.
Enter the following commands on the system controller panel:
To see the temperature reading, enter the following commands on the system controller
panel:
8. TROUBLESHOOTING
Reading the UPS module's front panel may provide the user with indication of malfunctions.
As shown in Figure 8-1 there are three LEDs on the front panel of each UPS module: Alarm,
Output and Line. The internal buzzer in the UPS module sounds when there is no
communication with the system controller.
These 3 LEDs and the buzzer indicate the status of the UPS module (see Table 8-1 below).
The alarm LED is red, line and output LEDs are green.
Normal condition is indicated by the green line LED and output LED on, with no beeps from
the buzzer.
Wake-up On On On
Start Off Off Off About 1 minute
Normal On On Off
Operation
Abnormal Off On On
Input voltage
Circulation On Off On
Current
PROBLEM SOLUTION
1 After the startup the unit wont 1. Check the phase sequence of the bypass
switch to inverter. input. Swap phases S (L2) and T (L3) on this
input for proper phase rotation.
2. Make sure that the bypass input voltage and
frequency is within the tolerance.
3 The unit shows output load while 1. Check and compare each modules output
there is no load connected. voltage on each phase. One of the modules
might be configured to a voltage different from
others, thus causing circulation currents on the
output.
2. Compare I-BUS and I-ACT for each module in
the UPS module menu on the controller. If
these values are not similar for one of the
modules, check it individually.
5 Red alarm LED is lit on the 1. To see the list of active alarms with short
controller. descriptions, press the ALARM OFF button
(the middle one on the right hand side of the
controller). Navigate with arrow keys.
2. To see the list of active alarms with full
description, press and hold ESC key to get in
to the menu and choose Alarms Status.
Navigate with arrow keys.
6 LINE LED blinks in green on a A phase is missing on the main input. If the problem
module, while output is green and exists on one module only, check the input fuses
alarm is not lit. (located on the rear side of base unit, above the AC
terminals). There is one fuse for each phase of
each module.
7 DC voltage gets low, sometimes 1. The unit might be in the middle of the battery
until the unit switches off and test. Check it through the controller. If it is,
goes on bypass. either let it finish or stop it manually.
2. Check the current limit and battery temperature
compensation settings in the controller. They
can cause severe drop in DC voltage if not
configured properly.
3. Try to remove the system controller and check
if the DC voltage restores to normal. If it does,
check controller settings. This will not stop P+
operation or cause interference with the load.
4. If battery temperature compensation and/or
battery current limit are enabled, make sure
that the unit has the required optional sensors
installed. If not, disable the corresponding
feature.
8 The modules are working 1. Check AC fuses (located on the rear side of
normally, but the system base unit, above the AC terminals) and DC
controller is off. fuses (located behind a blank cover above the
ST/SW module).
2. Replace PC093 power supply PCB inside the
system controller.
3. Replace the system controller.
9 The system is running normally, Check the number of modules value in the
but shows UPS-CM alarm. controller. If the system is set up for more modules
then actually exist, it will fail to communicate with
non-existing modules.
10 No values are received from the In the COMM. menu there are three communication
unit through the communication options. In units with PC375 communication boards
port or through the WING. (before 2006) the first option should be selected,
TCP/IP Comm. Board. On units with PC575 boards,
which appeared from the beginning of 2006, the
second option should be selected PC575. WING
will work with both options, and the third option,
WING communication, should not be used. It is
designed for special units without communication
cards only.
9.1. INTRODUCTION
The SCC POWER+ controller enables you to control and monitor all the individual
components of the POWER+ system. Flexibility in setting the various configurations allows
you to adjust the system to suit specific individual needs.
The system is equipped with clear, simple, user-friendly menus and submenus for easy
monitoring, parameter definition and control of the system. The SCC provides
communication with a wide range of management equipment, such as computers and
mobile phones.
y 40 4 LCD panel
y 6 Navigation Keys
y 3 Quick Command Buttons
y 8 Indication LEDs
y 2 Communication LEDs
These programs allow canceling and performance of low-level operations in the system at
the same time. These operations are complex and can modify the system configuration,
affecting its operation. The service utilities should only be used by authorized personnel.
y Change configuration
y Manually turn off and on UPS
y Test dry contact outputs
y Switch to alternative version of the software
y Change communication settings
y Restart the controller
y Restart the network adapter
On completion of the self-check test the initializing screen appears and remains on display
until the controllers restarting process is completed. The softwares version is shown on the
second row. The time remaining in the restart process appears on the fourth row of the
screen. The main screen appears once the initializing screen closed.
The main screen provides the basic and essential information about the real-time status of
the power system. The LED indicator lights located to the right of the screen, warn if there is
a problem. The main menu remains displayed until one of the keys is pressed. The controller
automatically returns to this main menu screen whenever a key is not pressed for five
minutes.
y The Fast Information Menu through which you can access the 7 Fast Information
screens
y The Main Menu from which you can access:
y Monitor Screens that let you monitor the system and components
y Calibration Screens that let you calibrate the system and components
y Control Screens that let you control the system and components
There is also a counter that shows the number of times the controller failed to connect with
the server. The maximum value that the counter can display is 225. Under normal operating
conditions the value should be 0.
There is also a count of the number of times there was no SNMP link. This value resets the
Network card.
Dry Contact Fast Information Screen
This screen provides real-time data on the status of the input and output dry contacts.
1 ALARM SET Opens menu with options for setting the threshold levels that
trigger alarms
2 UPS Sets the UPS Parameters
3 BATTERY Sets the Battery current parameters
4 CHARGE Sets the Charge mode parameters
5 TIME Sets the systems clock which sets a time stamp on log entries
6 SITE Sets the power system's ID number
7 PASSWORD Sets Level 1 Password
8 SERVICE Opens menu of service utility programs
9 SILICON Opens menu with options for restoring factory-defined default
values to parameters
Press the number that appears beside a menu option to open a screen in which you can set
the alarm thresholds for that option.
0 AC VOLT Sets the permitted AC voltage range (minimum and maximum input
voltage) and the AC voltage hysteresis
1 OUTPUT VOLT Sets the permitted DC voltage range (minimum and maximum
output voltage)
6 BATTERY Sets the permitted battery voltage range (minimum and maximum
output voltage) (indicates possible battery fault)
7 TEMPERATURE Sets the permitted battery temperature range (minimum and
maximum temperature)
8 VIBRATION Sets the number of times an alarm must occur within a specified
period of time to be considered a vibrating alarm
9 INTEGRATION Sets the number of times the controller must receive an
alarm from the system before it logs the alarm
Ent, Setup,
Ent, Service ,
Ent, Configure
Ent , Ent
Ent, Setup,
Ent, Battery,
Esc.
ACCESS
Press ESCAPE key and hold it for 3S. Using ARROW UP/DOWN key, select GENERAL (8)
and press ENTER. Screen 1 is presented.
SCREEN 1
a) ACV: nominal value of the input/output AC voltage (220 for 2x32 batteries ; 110 for 2x16
batteries)
b) ALM: input AC voltage alarm HIGH/LOW
c) TEMP.ALARM: high temperature limit for external thermosensor
d) MODULES: QUANTITY/REDUNDANCY 07/02 in the screen means that 7 modules are
presented in the system, 2 modules are reserve (full load is 10KVA*(7-2)=50KVA/40KW)
e) C.LIM.=off (VALUE)- battery current limit function is de-activated (off) or max. battery current
value in Amps. In C.LIM is activated, the system must be equipped with optional battery
current sensor.
f) T.C.=2.0mV negative temperature coefficient of the battery DC voltage in mV per C per
battery cell. Nominal temperature is 25C. For DC nominal voltage 432V , temperature 35C,
32 batteries of 6 cells, T.C.=2mV, the voltage is 432- 2*6*32*(35-25)~=428V. NOTE. For
most applications T.C. must be 0 (off).
g) DCV: DC nominal voltage for both positive and negative battery sets. For 32 batteries in the
set DCV=432V, for 16 batteries 216V.
h) DCV ALM: DC voltage alarms HIGH/LOW/SHUTDOWN. SHUTDOWN alarm is DC voltage
value when the unit is stopped due to battery discharge.
i) BATT.TEST: PERIOD IN WEEKS/MAX.DURATION IN HOURS/ALARM
VOLTAGE/CHARGER DERATED VOLTAGE. In the screen: the test is performed
automatically once per 4 weeks, max. test duration is 5 Hours, if battery voltage drops below
360V alarm Battery Low is given, the chargers of the modules continue to supply voltage
352V to prevent shutdown if battery is faulty.
j) CAP: CAPACITY in Amp-Hours. Is used to calculate estimated back up time of the system
and battery test duration.
SCREEN 2
To access SCREEN 2 press the key ARROW RIGHT when SCREEN 1 is selected.
a) #OF PHASE: FORCE 3 for 3 phase output, FORCE 1 for single phase output or AUTO when
the mode is defined by DIP SWITCH of the modules.
b) REV: revision of system controllers (SC) software
c) LVD BY AC FAIL: DIS (disabled) or EN (enabled). This function, if enabled, performs system
shutdown after 3 Hours of AC failure to prevent deep battery discharge by low current. In
most application the function must be DIS.
d) MAINT: YEAR.MONTH.DAY: date of last maintenance
e) TEMP. SENSOR: DIS or EN . External thermosensor is disabled/ enabled. In most
applications must be DIS.
f) SITE: the site identification number. Is used in network applications.
g) CURR.SENSOR: DIS or EN. Optional battery current sensor is disabled/ enabled. In most
applications must be DIS.
SCREEN 3
To access SCREEN 3 press the key ARROW RIGHT when SCREEN 2 is selected.
a) Not HARD Silicon. Must be HARD only initially, during first activation of non-configured
controller. After production should be Not HARD Silicon.
b) Silicon Mode. Regular mode allowing setups change. The setups are saved in EEPROM
chip.
c) CAPACITY HI (LO). High/low battery capacity mode when battery capacity is more/less than
100AH to achieve optimal resolution of battery current displayed value.
d) No/Yes Rmt Pan. Outputs of SC are not configured/ configured for optional remote panel
connection.
e) AC: 220V. Nominal AC input voltage: 220V for 2x32 batteries, 110V for 2x16 batteries in
series.
WARNING: Do not touch or short-circuit metal pins on rear plugs of the module, as they might still be
energized. Let the module discharge for at least 15 minutes prior to any operation or disassembly.
NOTE: Other UPS modules operation will not be affected by this removal, unless the load will
become too high for them with less power in total. For instance, if the load is 25Kva and one module
out of three was removed, the system might switch to bypass due to overload of the remaining UPS
modules.
WARNING: Make sure that the module has the same configuration as other modules in the system.
This includes the dip switch settings (on the module itself) for frequency and number of output
phases, as well as the internal output voltage configuration, like 240v or 230v, which can be changed
through the system controller only. If the UPS module configuration will diverse from other modules
configuration, this and/or other modules might be damaged.
NOTE: If the Power+ system was energized during modules connection, the module will switch on
automatically within one minute. This will not affect other modules or the load.
NOTE: Controller removal will not affect modules operation and the load. Every module has its own
internal control and will keep up with proper operation, like current sharing and battery charging.
Some functions will not be available while the system controller is removed: battery test, battery
conditioning systems etc.
WARNING: If the controller is not properly configured for the given Power+ system, it might produce
false alarms and incorrect DC voltage handling.
NOTE: If the system was energized, the controller will start automatically within one minute.
WARNING: This operation is not possible to perform live, without load and Power+ system
disconnection. The system should be switched off completely. Ensure that there are no AC voltages
on the terminals. If another ST/SW module will not be mounted immediately, all disconnected wires
should be isolated to prevent accidental damage and protect from electrocution.
Jumper J2 on card PC714 determines access to setup mode, and therefore controls access
to service mode. When the jumper is removed, access to setup mode is denied, and access
to service mode is impossible. When jumper J2 is in place, access to setup and service
modes is permitted.
Main menu > Setup > Password > Service menu > SC2012.
The options on the SC2012 menu are the controllers low level utilities. These options are described
in Figure 12-1.
Main menu > Setup > Password > Service menu > Configure > Calibration
y Power Meter
y System operating times
y System configuration
y Status of input dry contact
y Status of the UPSs
y Status of the batteries
y System temperature
y Communication status
1) Press Enter to display the main menu. (See Figure 5-1, page 54.)
2) Press Enter to view the battery voltages. (See Figure 5-3, page 55.)
Total Time Total elapsed time the system has been running
Boots Number of times the system has been rebooted
Current Sess. Total time the system has run since the last restart
(19:33:58) When the system was last restarted
Previous Controller Duration of the previous session
Session
HH:MM:SS YYYY.MM.DD When the last session began and ended, format :
hours,minutes, seconds year, month, day
Main Menu > System > press down arrow five times
Battery Temperature Temperature reading from a sensor located near the batteries.
y Screens displaying information about the dialog between the controller card and the
P.D. card. The function of the P.D. card is to measure voltages (AC, DC) and currents
(AC, DC), check the dry contactors input value, and control the LVDs. There are
seven screens displaying data about the controller-P.D. dialog.
y Screens displaying information about the dialog between the controller and the
rectifiers. There is a screen for each rectifier in the system
y Screens displaying information about the dialog between the controller and the
converters. There is a screen for each converter in the system
y Screens displaying information about the performance record sent by the controller to
all the converters and the rectifiers at once. The rectifiers and converters carry out the
commands in the record according to the priority the record provides.
In these screens:
T Indicates that the data in that row is transmitted by the controller
y UPSs
y Batteries
y General information
y Information on the battery test progress and the status of the last battery test
Information Description
Max/Estim. Time Left Maximum or estimated time remaining until the end of
the current battery test
Battery Test in Progress Time elapsed since the start of the battery test
Batt. Volt Battery voltage during the battery test
Batt. Current Discharge current during the battery test
Last Test Status of the last battery test
Days Left Time remaining until the next periodic or automatic test
y A series of screens containing the names of the alarms and their status (i.e. whether
each alarm is enabled or disabled and whether the alarm is active or inactive.
y The status of the output dry contacts.
y A series of screens detailing the relationship between the alarms to the serial number
in the alarm list.
y 6 screens (corresponding to the number of dry contacts) detailing the dependency of
each dry contact to the alarms.
y Six screens showing the relationship of the LED lights which can be user-programmed
to the alarms.
y 4 screens corresponding to the alarm severity definitions which may be programmed
by you
y Use the Up and Down arrows to scroll through all the screens in a series.
1. To return the UPS system to normal operation after use of the Emergency Power Off
(EPO) switch, you must do the following:
2. Turn OFF the AC Input circuit breaker.
3. Turn OFF the Battery circuit breaker.
4. Return the EPO switch to its normal position.
5. Turn ON the AC Input circuit breaker.
6. Turn ON the battery circuit breaker.
7. Wait about 2 minutes until the UPS initialization procedure has completed.
UPS MODULE
2
10KVA 10110033H-PP 2U 9.5Kg
HOUSING
4 DC/AC DISTRIBUTION
and BASE 50KVA 101B050-PP 11U 40Kg
5 DC/AC DISTRIBUTION
and BASE 100KVA 101B100-PP 11U 40Kg
6 14kg
Static switch 50KVA 1090503H-PP 6U
7 16kg
Static Switch 100KVA 1091003H-PP 6U
BATTERY PACK
64 5AH
(up to 3 packs per
8 system; minimum 1 pack 6U 130kg
per 10KVA. 29B004064-PP ea. ea.