Installation and Maintenance Manual S400D-230/110V UPS

Installation and Maintenance Manual S400D-230/110V UPS

Installation and Maintenance Manual S400D-230/110V UPS

Installation and Maintenance Manual S400D-230/110V UPS 1

Installation and Maintenance Manual S400D-230/110V UPS

Installation and Maintenance Manual S400D-230/110V UPS 2 Dear Customer, Please accept our thanks for giving us the privilege to serve you by choosing a Liebert make ‘UPS’. If this is your first Liebert UPS, we hope it is the beginning of a long relationship Which delivers value to your organisation. If you already own and use a Liebert Product, we are doubly honored by your decision of continuing this relationship. It is our constant endeavor to partner you for the growth and success of your Business.

This philosophy is reflected in our Mission statement “To deliver value through Air & Power Quality solutions to achieve customer delight”. Please do give us feedback to help us realize our Mission.

Emerson Network Power (India) Private Limited

Installation and Maintenance Manual S400D-230/110V UPS

Installation and Maintenance Manual S400D-230/110V UPS 3 IMPORTANT This manual contains information concerning the installation, operation and Maintenance of the S400D Uninterruptible Power System (UPS) for the single Module and one plus one Systems. All relevant parts of the manual should be read prior to commencing installation. The UPS must be commissioned by an engineer approved by the manufacturer (or his agent) before being put into service. Failure to observe this condition will invalidate any implied warranty.

The S400D UPS has been designed for Commercial / Industrial use only. The S400D has not been designed for direct use in any life support application. If you encounter any problem with the procedures contained in this manual you should seek immediate assistance from Emerson Network Power (India) Pvt. Ltd. Sales Office from whom the equipment was purchased. Alternatively contact the Emerson Network Power (India) Pvt. Ltd Customer Service & Support department at the address shown below: EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED Plot No. C-20, Road No. 19 Wagle Industrial Estate Thane – 400 604, INDIA Phone: (00 91 22) 33154400 Fax: (00 91 22) 25828358 25800829 Emerson Network Power (India) Private Limited pursues a policy of continual product development and reserves the right to change the equipment without notice.

@ Copyright 1999 by Emerson Network Power Unauthorized reproduction prohibited All rights reserved

Installation and Maintenance Manual S400D-230/110V UPS

Installation and Maintenance Manual S400D-230/110V UPS 4 ***SOUTH ZONE*** Banglore No. 412, Jindal Center, Opp Sukhsagar Hotel, 3rd Flr, 100 Fleet Road, Koramangalam, Bangalore - 560 095. Tel: 91-080-33154000 Fax: 91-080-41135570 Chennai Oms Court, No.1, Nathamuni Street, T.Nagar, Chennai - 600 017. Tel: 91-044-33154000 to 4039 Fax: 91-44-33154035 Cochin No. 40 / 9338, (New No. 59 / 4517), 4th Floor, Chakos Towers, Padma Pullepady Road, Cochin - 682035 Tel: 91-484-3325400/405 Fax: 91-484-2341 986 Hyderabad 405/406 First Floor,No.

62, Navketan Complex, S D Road , Hyderabad - 500003 Tel: 91-40-33154000 Fax: 91-40-2780 6777 Coimbatore 343/ B-17, SVP Complex, 2nd floor, Avaram Palayam Road, Sidha Pudur, Coimbatore- 641044 Tel: 0422 33254000 Fax: 0422-4389625/3325403 Mangalore Raj Business Centre , 3rd Floor, Balmatta Road, Mangalore - 575001 Tel: 9901055188 Fax: Vishakhapatanam No.7,Vishakha Executiva Centre, 47-11-1/5,1st Floor Eshwar Arcade, Dwarkanagar,1st Lane,Vishakhapatnam - 530 016.

Tel: 9908400029 Fax: Trivandrum 2nd Floor , Megabyte , Business Centre , Capital Tower, Statue Junction , Trivandram-695001 Tel: 0471-6450388 Fax: TELEPHONE: (00 91 22) 33154400 FAX: (00 91 22) 25800829 / 25828358

Installation and Maintenance Manual S400D-230/110V UPS 5 ***NORTH ZONE*** Gurgaon Plot no-2 udog, Vihar phase-iv, Gurgaon, Haryana, India-122016 Tel: 91-0124-3315500 Fax: 91-0124-3315480 Lucknow NO.-05, 3rd floor, Raja Ramkumar Plaza, On Top Of City Mart, 75, Hazratganj, Lucknow - 226001. Tel: 0522-33154000, 9838074281 Fax: 0522-2239877 Chandigarh SCO 58, 2 ND Floor, Sector 47 – C, Chandigarh - 160047 Tel: 0172-3931893 Fax: 0172-5016531 Guwahati Institution of Enginners Building (3rd floor), Near Lakhtakia Overbridge, Panbazar, Guwahati - 781 007.

Tel: 91-361-2734485 Fax: 91-361-2734486 Allahabad Emerson Network Power , 18/4, Tagore town, Bhansi Bhavan, In front of old LIC building, Allahabad Tel: 9838074007 Fax: Varanasi Ananat Complex, D-64/132 KA, SIGRA,Varanasi- 221010 Tel: 9838074007 Fax:

Installation and Maintenance Manual S400D-230/110V UPS 6 ***WEST ZONE*** Mumbai 414-424, 'b' wing, "Bhaveshwar arcade", opp. Shreyas cinema, LBS Marg, Ghatkopar (west), Mumbai-400086. Tel: 91-22-67208800 Fax: 91-22-67208805 Pune Office No. 7, II nd Floor, Pratibha Towers, Opp. Jog Center, Pune - Mumbai Road, Wakdewadi, Shivaji Nagar, Pune - 411 016 Tel: 020-33154024 Fax: 020-66235001 Baroda 39/2, Arunodaya Society, Alkapuri, Baroda - 390 005.

Tel: 91-265- 3929500 Fax: 91-265-2343937 Ahmedabad 205, Sukhsagar complex, beside Fortune Landmark Hotel, Usmanpura, Ashram Road, Ahmedabad. Gujarat – 380 013 Tel: 079 – 27560230/40 Fax 079-7-27560230 Nagpur 69, Hindustan Colony, Vivekanand Nagar Post, Wardha Road, Nagpur-440015 Tel: 0712-25634997 Fax: 0712-25634997 Vikroli Dheeraj Kawal, 1st floor, Near Vikroli Station, LBS Road, Vikroli(w) Tel 022-40780308, 40780303 Fax 022-40110183 Bhopal Emerson Network Power , Plot No. 18, Second floor , Liberty chamber , Near Batra Hospital, Zone 1 , Maharana Pratap Nagar, Bhopal, MP - 462011 Tel 9993590589 Indore 109, Ratnamani Complex, 7/1 New Palasra, Indore - 452 001 Tel: 0731-4023806 Fax: ***EAST ZONE*** Kolkata Advantage Tower, 7th Floor, Plot EN27, Sector-V, Salt Lake, Kolkata-700091 Tel: 91-33-33154000 Fax: 91-33-33154001 Jamshedpur Ground Floor, Contractor’s Area, Kashi Kanj, Road no.2, Bistupur, Jamshedpur-831001 Tel: 0657-6546636 Fax: Bhubaneswar Plot No.

267, AN Plaza, Rasulgarh, Bhubaneshwar, BHUBANESHWAR - 751 010 Tel: 0674-2586003 Fax: 0674-2580058

Installation and Maintenance Manual S400D-230/110V UPS 7 Instructions for safe use: Note that the S400D series of UPS is a highly sophisticated piece of instrument designed to meet the critical power requirements of you valuable load. Hence it becomes imperative that this UPS be installed by a service personnel trained by EMERSON NETWORK POWER (INDIA) PVT LTD in the installation and operation of this instrument. Failure to observe this condition will invalidate any implied warranty. This manual provides complete information required for safely operating [by a qualified personnel] the S400D UPS that you have purchased.

Any attempts to operate the UPS should be carried out only after the operator has completely read this manual.

I. If you encounter any problem with the procedure contained in the manual you should seek immediate assistance from the dealer / distributor from whom you have purchased this unit or contact the nearest ENP (I) service office. In case of a emergency you can get in touch with the “ Technical Support Department " at EMERSON NETWORK POWER (INDIA) PVT LTD Plot no. C/20, Road No. 19, Wagle Industrial Estate, Thane (West) - 400 604, Phone No: (022) 67208000,67208200,67208800. FAX No.: (022) 25824286, 25828358. II. The Customer Sales and Service wing can also arrange for service contract and full commissioning service.

III. The S400D UPS and its accessories must be installed by an ENP (I) qualified technician only. IV. The S400D UPS must be properly earthed at all time. The S400D UPS has been designed for indoor UPS. It should be protected from rain or excessive moisture and installed in a clean environment, free from inflammable liquids, asses or corrosive substances. Do not stand beverage containers, plants or any other product containing liquid, on the top of the unit. V. Do not place any type of magnetic storage media on the top of the unit as this may cause data corruption.

VI. The S400D UPS has been designed to protect your load and itself under such a condition it will be not advisable to provide supply to the load by bypassing the UPS via the maintenance bypass.

Please consult the manual for finding out the cause of supply disruption before resorting to any further course of action.

Installation and Maintenance Manual S400D-230/110V UPS 8 VII. Do not operate the UPS before the ENP (I) Approved service personnel has commissioned the unit. He will validate the installation work and install the required site information in to the micro-controller memory. This information is required to substantiate any warranty claims that might be made. VIII. When working on the unit it must be remembered that the unit will be having live voltage at all time unless it is isolated from the mains supply and the batteries. It is hence necessary that the safety and precautionary notes contained in various sections of this manual be read and thoroughly understood before touching any of the internal components of the UPS.

Pay special attention to the safety warnings concerning the handling and fitting of the UPS batteries. IX. Weight and mobility hazards: The S400D units should be handled using proper lifting aids during transportation and installation. Pay attention to the handling tips provided in the installation instructions. X. Contact qualified service personnel’s if any of the following conditions are observed A. Power cables have been damaged B. Fluids have been spilt on the unit or battery.

Installation and Maintenance Manual S400D-230/110V UPS 9

Installation and Maintenance Manual S400D-230/110V UPS 10 CHAPTER 1 GETTING THE UPS CONNECTED 12 1.1 Safety Warnings 12 1.2 Equipment’s Accessories 12 1.2.1 UPS 12 1.3 Installation Considerations 12 1.3.1 Environmental Considerations 13 1.3.2 Access Considerations 13 1.3.3 Weight Considerations 13 1.3.4 Electrical Considerations 13 1.3.5 Battery Considerations 14 1.4 Installation Procedure 14 1.4.1 Unpacking and visual examination of UPS 14 1.4.2 Final Positioning of UPS 15 1.4.3 Installing Batteries in Battery Cabinet 17 1.5 Power connection points on the UPS 20 1.5.1 External Power cable connections for Single Module 21 1.5.2 External Power Cable connections for Parallel Module (1+1) 23 CHAPTER 2 OPERATING INSTRUCTIONS 28 2.1 Introduction 28 2.2 Operator control switches 28 2.2.1a Main control rotary switch (S1) 29 2.2.1b Output & Maintenance Bypass MCBs ‘S7’ and ‘S8’ 30 2.2.2 Run / Standby switch (S2) 31 2.2.3 Black Start Disable Switch (S4) 31 2.3 Operating procedure 32 2.3.1 Important notes 32 2.3.2 Initial condition 32 2.4 UPS Startup Process (For single Module) 32 2.5 Load Power Down / Up Procedure 34 2.5.1 LOAD POWER DOWN PROCEDURE (for the single module) 34 2.5.2 LOAD POWER UP PROCEDURE (for Single Module) 35 2.6 UPS Shut Down Procedure (for Single Module) 35 2.7 UPS Startup Procedure [for (1+1) parallel module] 36 2.8 Load Power Down/Up Procedure for PARALLEL module 37 2.8.1 Load power down procedure 37 2.8.2 Load power up procedure 38 2.9 UPS Shutdown Procedure for (1+1) Parallel Systems 38

Installation and Maintenance Manual S400D-230/110V UPS 11 2.10 Alarms and Indications 39 2.10.1 Normal operation 39 2.10.2 Mains failure 40 2.10.3 Other fault or alarm conditions 40 2.11 Operator Trouble shooting Guide 41 CHAPTER 3 MAINTENANCE 42 3.1 Daily or Routine Checks 42 3.2 Monthly Checks 42 3.3 Scheduled Maintenance Checks 43

Installation and Maintenance Manual S400D-230/110V UPS 12 1.1 Safety Warnings • The equipment must be installed by a Company’s approved qualified person. • Do not switch on the electrical power to the UPS equipment before the arrival of the commissioning engineer.

• Special care should be taken when working with the battery associated with this equipment. When connected together the terminal voltage exceeds 300Vdc and this is potentially lethal. • Eye protection & hand glows should be worn while working with batteries to prevent any injuries from accidental electrical arcs or chemicals. • If a battery leaks electrolyte, or is otherwise physically damaged, it should be contained in a container resistant to sulphuric acid.

1.2 Equipment’s Accessories This section describes the parts, which are supplied along with the UPS. These parts have to be examined on receipt of the system. 1.2.1 UPS The UPS is mounted on a wooden base palette and fixed on to the same. The unit is wrapped in polythene sheets and enclosed in corrugated box. Enclosed along with each unit are • Battery and Bypass fuses (if not fitted on fuse base) • Communication kit (optional) • Paralleling flat cable (optional) 1.3 Installation Considerations In this section we will have a look at a certain point which need to be considered while choosing a location for UPS and the process of Installation.

Installation and Maintenance Manual S400D-230/110V UPS 13 1.3.1 Environmental Considerations The internal ruggedness and external aesthetics of the S400D unit allows the UPS to be installed in an office environment or in a general plant room. Wherever the UPS is installed ensure the following points: • The location must be cool, dry and clean with adequate ventilation to keep the ambient temperature below 450 C. If the UPS is supplied with Sealed Maintenance Free Batteries, place the batteries in Air Conditioning atmosphere. Not keeping the batteries in controlled temperature of 25-270 C will drastically reduce its life.

• The installation location must be kept clear of contaminants such as excessive moisture, inflammable or combustive vapours, chemical fumes and corrosive gasses or liquids.

• If needed install extractor fans in the room to aid air circulation. Use suitable air filtration system for locations where the UPS is to operate in dusty environments. 1.3.2 Access Considerations The UPS is forced cooled with the aid of internal cooling fans. Cooling air enters the UPS from the front and is exhausted through the ventilation grills located at the back of the UPS. Hence you must allow a minimum gap of 150mm behind the equipment to allow for adequate airflow. The unit requires access from all four sides and top for the purpose of troubleshooting or maintenance. Hence ensure that all sides and top of UPS are easily accessible.

Being mounted on castors, it is possible to install the UPS as a Mobile unit, provided that its input and output power cables are held in suitably flexible conducts. This type of installation allows the UPS to be flush fitted as a part of an equipment suit and pulled forward for service access when required. 1.3.3 Weight Considerations The weight of the UPS makes it difficult to move the equipment over certain floor surface such as carpets. This should be taken into consideration during the positioning of the equipment for installation, and when deciding whether or not to install the UPS as a Mobile unit.

1.3.4 Electrical Considerations Follow the table given below to select Power cables for S400D UPS external connections. The table shows current ratings when UPS is loaded to its 100% capacity. Note: - Since UPS has 150 % overload capacity, select the cables considering the 150% overload capacity for 60 seconds.

Installation and Maintenance Manual S400D-230/110V UPS 14 Table for current ratings for UPS loading to 100% - S400D UPS 10 kVA 10 kVA 20 kVA 5 kVA Rating 110V 230V 230V 230V Nominal Input Current at 415VAC 15A 15A 30A 19A Maximum Battery Current (Discharge) 30A 30A 60A 18A Maximum Output Current (100%) 91A 44A 87A 22A Maximum Bypass Current (100%) 91A 44A 87A 22A Note: 1.

For Common Bypass UPS, Input cable rating should be same as Output cable rating. 2. S400D UPS with 110V output does not support the common Bypass. 3. S400D UPS can be used for 220V, 240V also as per customer requirement. 4 .S400D 5kVA UPS nominal input current at 24A battery charging current. 1.3.5 Battery Considerations The UPS has been designed for the use with various variety of batteries. If the batteries are being installed at a distance from the UPS ensure that the cable used is such that the total voltage drop in the cable does not exceed 3 Volts. In case the batteries are being installed in a separate room ensure that DC isolators of adequate rating is mounted on each Battery rack.

These isolators should be easily accessible. These will be useful for isolating the Batteries from UPS for safe maintenance. 1.3.5.1 Float/ Boost Charging Specifications of S400D 1.3.5.1.1. Definitions 1. FBC – Float/ Boost Charger. 2. SMF – Sealed Maintenance Free Batteries. 3. Ni-Cd – Nickel Cadmium Batteries. 4. Lead-Acid – Lead Acid (Wet Cell) Batteries. 5. VRLA – Valve regulated Lead Acid 6. EOD: End of Discharge Voltage 7. VPC: Volts per cell 1.3.5.1.2. Float/ Boost Voltage Levels Following table shows the float voltage and boost voltage levels for different types of battery cells/ Block.

*For Boost charging in SMF/VRLA, VPC value depends on Manufacturers Specifications/ recommendation; also applicable only if cyclic operation of the battery is selected. NA : Not Applicable. Battery Type V / Cell Rectifier Voltage No.of Cells /block No. Of Blocks total cells V / Block Float Normal Boost Float Normal Boost SMF/VRLA 2.25 NA 2.35 * 351 NA 367 6 26 156 12 Lead Acid Wet cell 2.18 2.4 2.7 314 346 389 6 cells per block / 1 cell 24 blocks / 144 cells 144 12v per block / 2v per cell Ni-Cd 1.42 NA 1.55 351 NA 383 1 247 247 1.2

Installation and Maintenance Manual S400D-230/110V UPS 15 Rectifier Voltage in S400D will be automatically generated depending on the type of Battery selected from the MIMIC LCD display.

SMF Battery can be selected to charge (a) In NON-Cyclic mode as “CVCC”, and (b) In Cyclic mode as “FBC” 1.3.5.1.3. Battery charge current limit The Battery Charge current limit is settable from MIMIC LCD display. In S410D UPS, Battery current limit is adjustable from 1A to 4A. In S420D UPS, Battery current limit is adjustable from 1A to 7A. In S400D 5kVA UPS, Battery current limit is adjustable from 1A to 24A. 1.3.5.1.4. End of Discharge EOD for SMF/ VRLA : 1.67V / cell EOD for Lead Acid Wet cell: 1.80V/ cell EOD for Ni-Cd: 1.05V/ cell.

1.3.5.1.5. Over voltage protection for the battery The batteries will get isolated by the DC Contactor if the DC Voltage is above (V boost+10V) 1.4 Installation Procedure In this section we will study the procedure for installation of the UPS. 1.4.1 Unpacking and visual examination of UPS Remove the packing and all the packing derbies, base pallet, as per the Instruction sheet attached on the UPS cabinet. Carry out a through external visual check of the UPS to verify that it is complete and free of shipping damage. Report any such damage to the shipper immediately.

Note: - Before installing the UPS ensure that you have received all the accessories as mentioned in the purchase order or packing list.

1.4.2 Final Positioning of UPS 1. Move the UPS to the final position but leave adequate room for working. 2. Remove the Top and Front cover as shown in figure 1.1. Locate the Bypass fuses (if available) and Battery fuses packed separately and retain for fitment at a later stage. 3. Remove both side covers and open the top PCB tray. Carefully examine the interiors of the whole UPS for signs of shipping damages, general component loose connection etc. Report any damage immediately.

4. Fix the stabilizing bracket again in a new orientation with adjustable jacking feets facing the ground as shown in figure 1.2.

Installation and Maintenance Manual S400D-230/110V UPS 16 Fig.1.1 Opening of top, front and side covers 5. Ensure that the brackets are properly seated in their locating channels and secured correctly as they support large proportion of the equipment weight once the feet’s are screwed down.

Installation and Maintenance Manual S400D-230/110V UPS 17 1.4.3 Installing Batteries in Battery Rack Arrange the Batteries inside the Battery rack as shown in figure 1.3.

Secure the batteries to their final position. Pay attention to the polarity of each individual block of battery. Interconnect the batteries using the battery links supplied. Pay careful attention to the polarity of connection. Please ensure that the positive terminal of any battery should be connected to the negative terminal of the next battery.

Installation and Maintenance Manual S400D-230/110V UPS 18 NOTE: Observe Battery Polarity carefully. Fig. 1.3 Battery Arrangement & Cable connections

Installation and Maintenance Manual S400D-230/110V UPS 19 Fig. 1.4 Battery cabinet & UPS Using Power cable, connect the +ve terminal of extreme battery (battery no. 28) to the +ve terminal of Battery isolator, and –ve terminal of extreme battery (battery no. 1) to the –ve terminal of Battery isolator. Keep F1 and F2 of UPS open and connect cable from battery isolator +ve to Battery +ve terminal of the UPS.

Connect cable from battery isolator -Ve to the Battery –ve terminal of the UPS.

Mount Temperature Sensor PCB on one of the battery, connect other end of the temperature sensor PCBs wire to the Socket below S2 switch, on the back side of UPS.

Installation and Maintenance Manual S400D-230/110V UPS 20 1.5 Power connection points on the UPS Figure 1.5 illustrates the front side of power connection points on the S400D unit. Fig. 1.5 Front side Power connectors for the External connection Note: There are additional terminal blocks provided in the UPS. The reason for having two identical sets of power terminals is to provide flexibility in power cable inter-connection in the case of a 1+1 system.

This will be evident when we discuss power cabling for a 1+1 system.

For the individual UPS system following are the Input / Output / battery cables • UPS Input: 3 phase, 4 wire with pin type lug for UPS terminals connection. • Bypass input: Single Phase - 2 wire with pin type lug for UPS terminal connection. • UPS Output: Single Phase - 2 wire with pin type lug for UPS terminal connection. • Battery: DC - 2 wire with pin type lug for UPS terminal connection. • Earth: 6mm2 green wire Note: All UPS are dispatched as common bypass by shorting R phase (U1) to bypass live (U3) and input neutral (N1) to bypass Neutral (N3) through links.

Installation and Maintenance Manual S400D-230/110V UPS 21 1.5.1 External Power cable connections for Single Module Fig 1.6 Input, Bypass, Load and Battery Power connections for Common and Split Bypass CAUTION S410D UPS with 110Vac does not support common bypass.

Before giving input supply to the UPS ensure the split bypass connections. 1. Three phase input supply connection. Connect 3-phase supply of the Mains to 3 PHASE input terminals – U1, V1, W1 and N1 of MCB in UPS. Connect the other end of cable coming from U1 terminal to R phase, V1 terminal to Y phase, W1 terminal to B phase and N1 terminal to Neutral of input circuit breaker.

2. Load connection Connect Output load cable to U2 & N2 terminals on the front side of the UPS. Connect the other end of U2 cable (live) and N2 cable (neutral) to the Load breaker. 3. Common bypass connection from main supply By default the UPS is configured in common bypass mode by shorting input U1-U3 & Neutral N1-N3. OR

Installation and Maintenance Manual S400D-230/110V UPS 22 3. Split bypass from external supply Remove Shorting links (*) as shown in figure 1.6. These shorting links are connected at Input (U3 – U1) and Neutral (N1 – N3). Connect input phase of Bypass to U3 and input neutral to N3 terminal of UPS.

4. Battery connection Note: Ensure that the Battery fuse switch (F1 & F2) of the UPS are kept open. Connect the Battery cables to +ve and –ve terminals on the front side of UPS. The other end of +ve terminal (UPS) is connected to positive terminal of Battery Isolator, and –ve terminal (UPS) is connected to negative terminal of Battery Isolator, which is located near or on the Battery rack.

5. Battery Temperature Sensor On the backside of the UPS below S2 switch there is a battery sensor plug. Remove the plug and connect Battery sensor PCB wires plug into the socket. Mount Battery temperature PCB on one of the Battery inside the Battery rack. 6. Remote Stop If Remote Stop is used there is a REMOTE STOP Socket on the backside to the UPS. Remove the plug from the socket and connect Remote stop wire plug into the socket. Connect other end of the wire to Remote stop Switch. 7. Earth Connections Connect dedicated Earth connections to the UPS on the Earth terminals provided on the front side of UPS.

Note: Voltage between Earth and Neutral should be 5V

Installation and Maintenance Manual S400D-230/110V UPS 23 1.5.2 External Power Cable connections for Parallel Module (1 +1] Fig. 1.7 Parallel module cable connections with Split Bypass. 1. Three phase input supply connection of UPS 1 Connect 3-phase supply of the Mains to 3 PHASE input terminals – U1, V1, W1 and N1 of MCB for UPSI. Connect the other end of cable coming from U1 terminal to R phase, V1 terminal to Y phase, W1 terminal to B phase and N1 terminal to Neutral of input circuit breaker. 2. Three phase input supply connection of UPS 2 Connections for the Input supply to UPS 2 should be done in similar way, as for UPSI.

Note: There could be two different or one single 3 phase input supply breakers for both the UPS’s. 3. Load connection of UPS 1 Connect Output load cable to U2 & N2 terminals on the front side of the UPSI. Connect the other end of U2 cable (live) and N2 cable (neutral) to the Load breaker.

Installation and Maintenance Manual S400D-230/110V UPS 24 4. Load connection of UPS 2 Connect Output load cable to U2 & N2 terminals on the front side of the UPS2. Connect the other end of U2 cable (live) to U2 terminal of UPSI, and N2 cable (neutral) to the N2 terminal of UPSI.

5a. Split bypass supply connection of UPS 1 Note: - for S400D 110V UPS, bypass should be supplied by 110V separate AC source. Remove shorting links between R phase (U1) & Bypass live (U3) and input Neutral (N1) and bypass neutral (N3). Connect Bypass cables to U3 & N3 terminals on the front side of the UPSI. Connect the other end of cable coming from U3 terminal to the live phase and N3 to the neutral of the Bypass supply breaker. 6a. Split Bypass connection of UPS 2 Connect Bypass cables to U3 & N3 terminals on the front side of the UPS2. Connect the other end of cable coming from U3 terminal to U3 terminal of UPSI, and the cable coming from N3 terminal to the N3 terminal of UPSI.

OR 5b. Common Bypass supply connection of UPS 1 Note: - common bypass in not supported by S400D 110V UPS Common bypass is factory set by shorting R phase (U1) to bypass live (U3) and input neutral (N1) to bypass neutral (N3). External cable connection is not necessary.

6b. Common Bypass connection of UPS 2 Common bypass is factory set by shorting R phase (U1) to bypass live (U3) and input neutral (N1) to bypass neutral (N3). External cable connection is not necessary.

Installation and Maintenance Manual S400D-230/110V UPS 25 Fig. 1.8 Parallel module cable connections with Common Bypass (Note: S410D with 110Vac doesn’t common Bypass.) 6. Separate Battery Connection of UPSI – Battery 1 & UPS2 – Battery 2 Note: Ensure that the Battery fuse switch of the UPS is kept open. Connect the Battery cables to +ve and –ve terminals on the front side of UPSI.

The other end of +ve terminal (UPSI) is connected to positive terminal of Battery Isolator, and –ve terminal (UPSI) is Connected to negative terminal of Battery Isolator, which is located near the Battery rack. Repeat same cabling for UPS 2 battery connections as UPS 1 battery connections.

7. Battery Temperature Sensor (UPSI & UPS2) On the backside of the UPS below S2 switch there is battery sensor plug. Remove the plug and connect Battery sensor PCB wires plug into the socket. Mount Temperature sensor PCB on one of the battery inside the Battery cabinet 8. Remote Stop (UPSI and UPS2) If Remote stop has to be used, there is a Remote Stop Socket on the backside of the UPS 1. Remove the plug from socket and connect Remote stop wires plug into the socket. Connect other end of the wire to Remote stop switch. Repeat the same procedure for UPS 2.

Installation and Maintenance Manual S400D-230/110V UPS 26 9.

Earth Connections Connect dedicated Earth connections to both the UPS - UPS 1 and UPS 2 on the Earth terminals provided on the front side. Note that the unit that you receive has been set to work as per the requirements specified by you in the purchase document. In such a case use the information provided in the following paragraph as a means of cross checking the settings. DO NOT DISTURB ANY SETTING IF YOU HAVE ANY DOUBT ABOUT THE SAME AND /OR ARE NOT WELL AWARE OF THE IMPLICATIONS OF CHANGING ANY PARTICULAR SETTINGS. IN CASE OF DOUBT ASK The regional office representative or Technical Support at Head office.

Installation and Maintenance Manual S400D-230/110V UPS 27 CHAPTER 2 CHAPTER 2 CHAPTER 2 CHAPTER 2 OPERATING INSTRUCTIONS 2.1 Introduction This chapter describes the procedure for operating the UPS. Note that here the following conditions are assumed – • It is assumed that the UPS has been properly installed by Company’s trained service personnel and needs no further internal settings. • Batteries are connected. • The input, bypass and battery fuse are OK and their respective fuse holders are open. (If not base mounted fuse) In this chapter we will have a look of the following major issues • Operator controls.

• Startup and shut down procedure. • Interpretation of alarm conditions and actions to be taken. In the latter part of this chapter we will have a look at the operation of the UPS when connected in parallel. 2.2 Operator control switches S400D uses both DSP based and powerful H8 micro controllers for controlling the power, display & annunciation and communication. The firmware has been designed so at to make the system operation fully automatic and reduce the operator involvement at start up and shutdown to the bare minimum. In fact in the event of any negligence on the part of the operator the UPS system controller takes care of the system with appropriate alarm.

However, ensure that the UPS system is operated by a qualified technician who has read this manual and fully understood the operation of the system.

As described in the last chapter here are five switches which are used to control the operation of the UPS viz., Output MCB S7, Maintenance Bypass MCB S8 Run / Standby switch (S2) Black start disable switch (S4)

Installation and Maintenance Manual S400D-230/110V UPS 28 2.2.1 Output & Maint Bypass MCBs ‘S7’ and ‘S8’ UPS Position (Output MCB ‘S7’ ON) Ensure that the MCB ‘S8’ is OFF and then turning ON MCB ‘S7’ the load is connected to the output of the UPS i.e. from the inverter, thus depending on the status of the static switch the load will either be on Static Bypass source or on the Inverter.

This is the position in which the switch should be for Normal operation. Maintenance bypass (Maintenance Bypass MCB ‘S8’ ON) Note: - for S400D 110V UPS, bypass should be supplied by 110V separate AC source. While on maintenance bypass the load will be connected directly to the bypass supply source and will be isolated from the output of the static switch assembly. To switch ON MCB ‘S8’ first keep the UPS in Bypass mode and then Switch ON this MCB ‘S8’.

This MCB ‘S8’ is used for powering the critical load from the bypass source while the UPS can be shutdown by the service personnel for the sake of maintenance or trouble shooting the UPS system. Do note that this MCB ‘S8’ should be ON only in emergency situations where the UPS has to be shut down for maintenance or troubleshooting of the UPS and is not for normal supply of power to the load.

Installation and Maintenance Manual S400D-230/110V UPS 29 2.2.2 Run / Standby switch (S2) This switch allows you to turn OFF the UPS if required as a part of the day to day operation - at the end of the working day for example.

When the switch is in the STANDBY or OFF position the microcontroller switches OFF inverter, bypass and inverter static switch. Thus the load power is removed from the UPS output terminal but the rectifier remains ON so as to charge the batteries. In this position it will be noted that the upper and lower load LED’s on the front mimic panel will be OFF. When the switch is turned on to RUN or ON position the inverter turns ON and the output of the inverter is switched over to the load terminal. 2.2.3 Black start disable switch (S4) This switch is to Enable or disable the black start facility.

In case of mains failure UPS shutdown due to fully discharge of batteries. Here batteries still keep on discharging through black start & bleeder resistors. This can be avoided by switching OFF this switch i.e. black start Disabling. This switch can be accessed after removing the front panel.

Note: As per factory setting, this switch will be kept OFF

Installation and Maintenance Manual S400D-230/110V UPS 30 2.3 Operating procedure Usually the UPS can be considered to be one of the four selected operating states. : - Shutdown - Maintenance Bypass - Stand by - Normal operation The following Operating procedures enables you to start and stop the UPS (i.e. change from the ‘shutdown’ or ‘maintenance bypass’ condition to ‘normal operation’ and vice versa) in safe logical manner. The procedures take the form of charts containing a sequence of actions along with the appropriate equipment response (i.e.

LED indication and messages). We will have a look at how to start or stop the UPS in a safe and logical manner. 2.3.1 Important notes 1. The operator controls and indicators have been fully described in the previous section.

2. Audible alarms may sound at various points of the start up procedures. It can be cancelled at any time by pressing the alarm reset switch on the front display panel. 3. During the first 10 seconds of start-up LCD & Audible warning status are random. 4. When turning ON the UPS, if LCD display panel does not respond as indicated in the procedure then shut down the UPS immediately and follow trouble shooting charts. 2.3.2 Initial condition 1. UPS has been installed in all respects and all the necessary internal settings have been done.

2. The input, bypass and battery isolators are open.

3. MCB’s ‘S7’ & ‘S8’ are in OFF position. 4. Switch ‘S2’ is in OFF / STANDBY position 5. Batteries have been connected to the battery input terminal [Pay attention to the polarity of the Battery connection, keeping the battery fuse open] 6. 3 phase input supply has been connected with proper phase sequence. 2.4 UPS Startup Process (For single Module) Action Results 1. Remove the UPS front panel 2. MCB’s ‘S7’, ‘S8’ are in OFF mode. 3. Ensure that run stand by switch ‘S2’ on rear side of the unit is in ‘OFF’ position. 4. Ensure that UPS input supply, bypass and battery supply cable are connected but there is no power given to UPS.

Installation and Maintenance Manual S400D-230/110V UPS 31 5. Select F1, F2 battery fuses, F3 bypass fuse according to the rating of the UPS. 6. Switch on 3 phase input mains supply, also switch on the 3-phase input MCB of UPS. 7. Switch ON ‘Run standby switch’ ’S2’ on rear of the unit. 8. Connect multimeter across the upper terminals of Battery fuse switch on the front side of the UPS. Remove Top panel of the UPS Unit. Locate Micon board and Switch ON rectifier switch ‘SW3’. Hear turn ON sound of battery Contactor. At the same time monitor the soft start DC bus voltage, it should not increase beyond 356±1% VDC.

9. Check the polarity of Battery terminals, and the UPS Battery terminals With Multimeter. Ensure positive is connected to positive and negative is connected to negative terminal. Switch ON the Battery isolator.

10. Close Battery Fuse F1, F2. By DC clamp meter measure battery charging current in battery cables, it should not be more than 3.0A (Factory set). Note: Set Battery charging current as per AH capacity of the Battery. 11. Connect multimeter across the OUTPUT terminals of the UPS. Ensure the polarity. Switch ON the Inverter Switch ‘SW4’ on Micon Board. Inverter will turn ON. 12. Check Output voltage, it should not increase beyond 235VAC/115VAC. If necessary set this voltage to 230V/ 110V by R284 on the Micon board. 13. Close Bypass Fuse (& Switch ON Bypass MCB ‘S6’ if it is present), switch ON bypass supply.

(Note: In case of 20KVA UPS systems fuse is mounted on the Base instead of fuse holder). Hooter Sounds and LCD display will turn on. "Initialising S400D" will appear, followed by Default screen. Input LED will glow. Rectifier will turn On. Rectifier LED on LCD display will glow. On LCD display, Inverter LED and Inverter Load LED will glow. Output KVA, Voltage & frequency will be displayed on LCD display in main screen. Inverter will get synchronized with Bypass.

Installation and Maintenance Manual S400D-230/110V UPS 32 14. Locate Micon board & Switch ON Bypass Switch ‘SW5’.

15. By multimeter check is there any short circuit at load side. 16. Connect AC clamp meter in the load cables. Switch ON the MCB ‘S7’, Load will be connected to the UPS. Check the load current. 17. Check Input, Output. Bypass voltage & current readings on LCD Display. If necessary, set the output voltage by preset R244A and output current by preset R267A on Micon board.

18. To check battery connections, switch OFF 3 phase input supply. Check inverter is running on battery 19. Check UPS output voltage & current on LCD display when UPS is running on battery. 20. Switch ON 3-phase input again. Check battery current by DC clamp meter again. It should not be more than set value. Bypass LED on LCD display will glow. Output KVA, Voltage & frequency will be displayed on LCD display main screen. On LCD Display, input & rectifier LED will be switched OFF and battery LED will glow. On LCD Display, Input & rectifier LED will glow.

2.5 Load Power Down / Up Procedure: 2.5.1 Load power down procedure (for the single module) Note: You should follow this procedure if you want to shut down your load for a short period or at the end of working day.

Action Response 1. Open the front cover of the UPS 2. Put Switch the MCB ‘S7’ in OFF position. 3. Switch OFF ‘ON\STANDBY’ switch‘S2’. 4. Close the front cover of UPS Load will turn OFF Inverter, bypass & load will turn OFF. 2.5.2 Load power up procedure (for single module)

Installation and Maintenance Manual S400D-230/110V UPS 33 Action Response 1. Switch ON ‘ON\STANDBY’ Switch ‘S2’. 2. Open the front cover of UPS. Switch ON the MCB ‘S7’. 3. Close the front cover of UPS. Inverter, bypass & load LED will glow. Load will be connected to the UPS. 2.6 UPS Shut Down Procedure (for Single Module) Following steps are to be followed if you want to shut down the UPS. Action Response 1. Open front panel. Switch OFF MCB ‘S7’. 2. Remove the UPS Top cover locate Micon Board, switch OFF SW5. Bypass will be switched OFF.

3. Switch OFF inverter switch ‘SW4’ on micon board.

Inverter will be switched OFF. Note: inverter & Bypass can be switched OFF only by switching OFF STANDBY switch S2 mounted on the backside of UPS. (no need to follow steps 2,3). 4. Switch OFF rectifier switch ‘SW3’ on Micon board. Rectifier will be switched OFF. 5. Switch OFF 3-phase input supply& bypass supply. Open the input breaker of UPS. Also open bypass fuse switch F3. 6. Open the battery fuse F1, F2 LCD Display will be switched OFF. 7. Close the front cover of UPS. Load will turned OFF.

On LCD display Bypass LED will turn OFF. On LCD display inverter & inverter load LED will turn OFF. On LCD Display the rectifier LCD will be turned OFF ON LCD Display input LED will turn OFF 2.7 UPS Startup Procedure [for (1+1) parallel module]

Installation and Maintenance Manual S400D-230/110V UPS 34 Note 1: Switch ON the UPS as per start up procedure mentioned in section 2.4 for single module. Note 2: Switch OFF the UPS individually as per UPS shut down procedure mentioned in section 2.6 for single module. After ensuring the above procedure following steps are to be followed, Action Response 1.

Switch OFF Load Externally (by load breaker). 2. Do not Switch ON the MCB ‘S7’. 3. Locate parallel Interface board 100216120044 at the backside (inside the box) of the UPS I & Dummy Interface Board - 100204120018 at the backside of the UPS II. Connect paralleling flat cables (supplied along with UPS system) one end to parallel interface boards connector CN2 of UPS I. Connect other end of the flat cable to Dummy interface boards connector CN2 of UPS II.

4. Switch ON 3-phase power supply at a time to both the UPS (UPS I & UPS II). 5. Follow single module switch ON procedure to switch on UPS I. As the UPS I turns ON, follow same procedure to turn ON UPS II. Keep battery fuses (F1, F2) open. Check voltage between UPS I o/p L (U2) and UPS II o/p L (U2). It should not be more than 6VAC. If necessary set o/p voltage of UPS I & II to 230/ 110(in case of S400D, 110V UPS) VAC to get this value less than 6V. 6. If the voltage difference is less than 6V then Switch OFF UPS I & then UPS II as per the single module switch OFF procedure.

7. Connect the O/P shorting cables one end to output terminal U2-N2 of UPS I & the other end to the output terminal U2-N2 of UPS II respectively.

8. Connect True RMS AC clamp meter in Output shorting cable. On LCD Display Input LED of both the UPS will turn on. On LCD display in OPERATION – UPS MODE menu, Display will show UPS I & II are paralleled. Master UPS will be synchronised to Bypass & slave UPS will be synchronised to Master.

Installation and Maintenance Manual S400D-230/110V UPS 35 9. Switch ON 3 phase power supply at time to both the UPS (UPSI & UPS II). 10. Follow single module switch ON procedure to switch ON UPS I. As the UPS I turns ON, follow same procedure to turn ON UPS II. At the same time monitor the circulating current in the Output shorting cable. It should not be more than 10% of full load current (for 10KVA, 230V < 4.3A & for 20kVA, 230V

Installation and Maintenance Manual S400D-230/110V UPS 36 of UPS I & then of UPS II. This will switch OFF Inverter & Bypass but battery charger will remain ON to charge the batteries.

4. Close the front cover. Note: This will continue battery charging. Inverter & bypass LED of UPS I & UPS II will turn OFF. 2.8.2 Load power up procedure Action Response 1. Remove front cover of both the UPS. Switch ON / STANDBY Switch ‘S2’ of UPS I & then of UPS II. UPS I & UPS II turns ON. 2. Switch ON the MCB ‘S7’ of UPSI. Check total LOAD will be on UPS I. 3. Switch ON the MCB ‘S7’ of UPS II. Check 50% load sharing between UPS I & UPS II.

4. Close the front cover. Inverter & bypass LED of UPS I & UPS II will turn ON. Inverter load LED of UPS I will turn On. Inverter load LED of UPS II will turn On. 2.9 UPS Shutdown Procedure for (1+1) Parallel Systems Following steps are to be followed if you want total shut down of the UPS. Action Response 1. Remove top & front cover of both the UPSI and UPS II. 2. Switch OFF MCB ‘S7’ of UPSI. Check total LOAD will transfer to UPS II. 3. Switch OFF MCB ‘S7’ of UPSII. Check total load will be switched OFF.

4. Locate Micon Board. Switch OFF ‘SW5’ “Bypass Switch” on Micon Board of UPS I.

Switch OFF SW4 “Inverter Switch” on Micon Board of UPS I Inverter will be Switched OFF. 5. Switch OFF ‘SW3’ “Rectifier Switch” on Micon Board of UPS I Rectifier of UPS -I. Rectifier will be switched OFF. 6. Repeat same procedure for UPS II. 7. Switch OFF ‘S2’ on the backside of Inverter load LED of UPS I will turn OFF Inverter load LED of UPS II will turn OFF.

On LCD Display Bypass LED of UPS I will turn OFF. On LCD display Inverter LED of UPS I will turn OFF. On LCD Display Rectifier LED of UPS I will turn OFF.

Installation and Maintenance Manual S400D-230/110V UPS 37 both the UPS. Switch OFF Input/ bypass supply of both the UPS. 8. Open fuses F1, F2 and F3 (& bypass breaker ‘S6’ in case S410D-110VAC) of both the UPS. 9. If required remove parallel flat cable between UPS I & UPS II. 10. Close top & side covers of both the UPS. Note:For 20KVA since bypass fuse is mounted on Fuse Base, Switch OFF Bypass breaker.

LCD Display of both the UPS will be switched OFF 2.10 Alarms and Indications What follows is a description of the status of the LED’s for various state of operation of the UPS. Do note that the verbose description of each of the UPS status is displayed on the LCD screen.

2.10.1 Normal operation The LED indications in this mode of operation is as follows LED Name Status 1 Input ON 2 Rectifier ON 3 Battery OFF 4 Inverter ON 5 Load [Inverter] ON 6 Load [Bypass] OFF 7 Bypass ON/OFF 8 Alarm OFF Do note that in this case the Bypass LED state depends on the status of the bypass and in no way poses a problem to the load. Parameters such as the output voltage, load and battery charge status can be read OFF the LCD display. 2.10.2 Mains failure

Installation and Maintenance Manual S400D-230/110V UPS 38 The LED indications in this mode of operation is as follows LED Name Status 1 Input OFF 2 Rectifier OFF 3 Battery ON 4 Inverter ON 5 Load [Inverter] ON 6 Load [Bypass] OFF 7 Bypass ON/OFF 8 Alarm ON There are two cases of mains failure – 1.

If the UPS looses mains supply at the input, LED1 will go OFF. 2. The mains voltage goes out of the acceptable input voltage specification the input LED will flash. Both these conditions have to be considered as mains failure since in both the cases the input supply is not deemed it for rectification as a result the rectifier will be switched OFF and the inverter will start supplying the load power by taking the battery power as the input supply source.

In both the above conditions a reset table audio alarm will be sounded. Here again the status of the Bypass LED depends on the presence or absence with in specification of the bypass supply. Do note that if the bypass supply is not present then the load power will be shutdown if the mains power fails to return before the batteries gets fully discharged. The beeping rate will increase as soon as the backup time reaches the set battery low time limit. As soon as this stage is reached you should immediately save your data and shutdown all the connected loads, because soon the battery will reach the end of discharge limit and shutdown the inverter.

2.10.3 Other fault or alarm conditions Fault conditions are those which has hindered the normal operation of the UPS e.g. rectifier failure or inverter failure etc. Alarm conditions are those conditions which do not affect the operation i.e. continued supply of load power, of the unit immediately but which may lead to the cause of disruption of load power, e.g. mains failure. In the case of S400D all these conditions are displayed on the LCD panel in the default screen. In case of multiple alarm or fault condition you can browse through the same using the UP/DOWN cursor keys.

2.11 Operator Trouble shooting Guide

Installation and Maintenance Manual S400D-230/110V UPS 39 The following section will give you a detailed interpretation of the status indicated by the LED and LCD display and the action to be carried out if the same is encountered. In any case seek qualified assistance - in the first instance this should be sought from the site engineer who will then contact the nearest ENP Customer support center for further assistance. The front panel display consisting of the LED mimic and the LCD display act as a excellent tool for diagnosing the present status of the system. Lets start with the LED display.

CHAPTER 3

Installation and Maintenance Manual S400D-230/110V UPS 40 MAINTENANCE In this chapter we will have a look at the various issues involved in the maintenance of the S400D unit. Maintenance of any unit ensures that you get the maximum out of the equipment and prevents any last moment crisis. The maintenance routine on the S400D unit can be differentiated in to the following categories based on the time interval between successive maintenance routine. • Daily checks • Monthly checks • Scheduled maintenance 3.1 Daily or Routine Checks Although the UPS is maintenance free the following checks will ensure the effective and trouble free working of the UPS.

• Ensure that the ventilation space around the front and back of the UPS is not obstructed. • Check that the ambient temperature of the room is with in 40 degree centigrade and that the room is well ventilated and dust free. • Check for any fault indications on the LCD/LED display. In case of any refer to the user manual or call for assistance. 3.2 Monthly Checks In this case carry out all the steps as mentioned in the above section – 3.1 Daily or routine checks and then carry out the following steps.

When the UPS is fully loaded log the UPS output voltage and load current. This will help in detecting any output voltage variation and will also help in keeping a track of the output load thus preventing any in-advert ant overload.

In case of a variation in output voltage outside the specified limit of the S400D unit contact the nearest ENP