CleanSource SMS UPS

Important Safety Instructions - Save These Instructions

2128 W. Braker Lane, BK 12 - Austin, TX 78757 - www.activepower.com

CleanSource SMS UPS

CS SMS 60 Hz / UPS 300; UPS 150CS SMS 50 Hz / UPS 250i; UPS 150i

Operation and Installation Manual

60333-EN Rev. L

Active Power, a Division of Piller Power Systems Inc. 2017 Copyrighted: This document and

the information contained are copyrighted and cannot be copied in whole or in part without the

express written consent of Active Power, a Division of Piller Power Systems Inc.

This manual contains important safety instructions for CleanSource Uninterruptible Power Systems (UPS). These instructions should be followed during the operation and maintenance of the flywheel energy storage system.

The installation and use of this product must comply with all national, federal, state, municipal or local codes that apply.

WARNING: The system must be installed with an appropriately rated service disconnect. Connect only Class 2 limited energy circuits to DB-9 and RJ11 communication connectors.

Flywheel energy storage units may contain hazardous AC and DC voltages and require a thorough system check before applying electrical power. Only persons certified by Active Power, a Division of Piller Power Systems Inc. should apply power to the system, initial pre-start check and initial motor-up.

The flywheel units should be handled with care to avoid damage to moving and electrical components and injury resulting from mishandling. Under no circumstances should the flywheel system be moved while the flywheel rotor is turning or before the protective bearing retainers are installed. Active Power, a Division of Piller Power Systems Inc. reserves the right to change specifications without prior notice.

This product may be covered by one or more of the following United States patents: 5,731,645; 5,932,935; 5,905,321; 5,920,138; 6,166,472; 5,969,457; 5,955,816; 6,029,538; 5,929,548; 6,208,056.

TABLE OF CONTENTS

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 1

FCC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CE - EMC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Product Use Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Hazard Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fire Prevention and Explosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Grounding Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FCC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

UPS Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SYSTEM SPECIFICATIONS (UPS 150i, 250i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SYSTEM SPECIFICATIONS (UPS 150, 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CSView Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Diagnostic Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Remote Notification and Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Paging/E-mail for UPS Alarms & Notices & Remote Monitoring Via CSView . . . . . . . . . . . . . . . . . . . . 15

Ethernet Option - Internet Invocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Internet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E-mail Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Modem Option - Paging Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dual Communication - Modem and Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Modems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Static Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PRODUCT IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Location of Serial Number Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

TOUCHSCREEN USER INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Navigating the System Cabinet Touchscreen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Using the Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CleanSource UPS SMS Operation and Installation Manual i

Display Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Getting to Know the Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

System Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Notices and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Emailing and Exporting Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Exporting Events by Email . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Exporting Events to a USB Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Telemetry (System and UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

System Diagram Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Normal Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Notice Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Alarm Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Accessing UPS Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Acquiring and Managing System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

System Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

UPS Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

System Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

UPS Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Service Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

SMTP and Email Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

SMTP (Simple Mail Transfer Protocol) Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Notifications Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Email Notification Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

BASIC OPERATIONAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

System Cabinet Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

System Cabinet Manual Controls - Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

System Cabinet Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Rebooting the Touchscreen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

UPS Startup (Single Input - No Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

UPS Shutdown (Single Input - No Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

ii CleanSource UPS SMS Operation and Installation Manual

UPS Startup (Single Input - 3 Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

System Pre-Startup Procedure (Before Applying Electrical Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

System Startup Procedure (Single Input - 3 Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

System Bypass (Single Input - 3 Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Removing the System from Bypass (Single Input - 3 Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

System Shutdown Procedure (Single Input - 3 Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Emergency Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Emergency Power Off (EPO) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Performing Emergency Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remote Emergency Power Off (REPO) Button (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Lockout/Tagout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

UPS Reset After Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Modes Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Online Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Bypass Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Automatic Voltage Regulation (“AVR”) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Air Filter - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Flywheel - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Vacuum Pump Oil - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Bearing - Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Controller Board Battery - Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Reference Information Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Telemetry Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Three-Phase Telemetry Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Single-Phase Telemetry Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Control Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

System Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

UPS Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

PRODUCT IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Location of Serial Number Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

User Interface Panel Key Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

INSTALLATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

EQUIPMENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

CleanSource UPS SMS Operation and Installation Manual iii

Anchor Bolt Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

System Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Seismic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

WIRING CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

AC Power Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

NEC Customer Conductor Sizing Requirements (480 Volt Rated Products) . . . . . . . . . . . . . . . . . . . . .81

NEC Customer Conductor Sizing Requirements (380, 400, 415 Volt Rated Products) . . . . . . . . . . . . .82

Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Control Wire Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

System Input/Output Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

System Input/Output Daughter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Remote Emergency Power Off (REPO) Contacts (J7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Dry Contact Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

GenSTART Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

GenSTART Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

REMOTE STATUS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Remote Emergency Power Off (REPO) Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Normally Open Contact Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Normally Closed Contact Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Maintenance Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Four-Wire Input and Output (480 Volt 60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Three-Wire Input and Output (380 - 415 Volt 50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Ready Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Seismic tie-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

INITIAL SETUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Single Input - No Switches Initial Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

SIngle Input - 3 Switches Initial Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

iv CleanSource UPS SMS Operation and Installation Manual

SYSTEM SPECIFICATIONS (UPS 150i, 250i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

SYSTEM SPECIFICATIONS (UPS 150, 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

APPLICABLE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

60 Hz North American Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

International Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

CleanSource UPS SMS Operation and Installation Manual v

vi CleanSource UPS SMS Operation and Installation Manual

LIST OF FIGURES

Figure 1. Cabinet Front View (Typical) ........................................................................................ 8Figure 2. System Diagram ........................................................................................................... 9Figure 3. CSView ....................................................................................................................... 13Figure 4. Selections and Access for Your Touchscreen UPS Display ....................................... 18Figure 5. System Cabinet Touchscreen Panel and Manual UPS Controls ................................ 19Figure 6. System Cabinet Touchscreen User Interface Panel (Typical) .................................... 20Figure 7. Overall Menu Selections ............................................................................................. 21Figure 8. Menu Selections - Guest ............................................................................................ 22Figure 9. Log In/Out Window and Keypad ................................................................................. 23Figure 10. Event Screen ............................................................................................................ 24Figure 11. Exporting Events by Email ........................................................................................ 25Figure 12. Using Virtual Keypad to Enter Recipient Address .................................................... 26Figure 13. Telemetry Selection Screen ...................................................................................... 27Figure 14. Typical System Diagram Display .............................................................................. 28Figure 15. Normal Operating Status Indicator on Home Page .................................................. 29Figure 16. Event - Notice ........................................................................................................... 29Figure 17. “Notice Message” Status Indicator ............................................................................ 30Figure 18. “Alarm Message” Status Indicator ............................................................................ 30Figure 19. “Alarm Message” Operating Status Indicator on Home Page ................................... 31Figure 20. Touch to Select UPS Detail ...................................................................................... 32Figure 21. UPS Detail Screen (Load Protected) ........................................................................ 33Figure 22. Example SystemTelemetry Screen .......................................................................... 34Figure 23. System Diagram ....................................................................................................... 35Figure 24. UPS Diagram Selection on System Diagram Screen ............................................... 36Figure 25. UPS Detail Screen .................................................................................................... 37Figure 26. System Summary Information Screen ...................................................................... 38Figure 27. Service Notification Screen (Admin) ......................................................................... 39Figure 28. Configuration Selection ............................................................................................. 41Figure 29. Configuration Selections (Admin) ............................................................................. 41Figure 30. SMTP Email Configuration (Admin) .......................................................................... 42Figure 31. Entering Email Configuration Parameters (Admin) ................................................... 43Figure 32. Configuring Notifications - Notification Screen (Admin) ............................................ 44Figure 33. Entering Notification Email (Admin) .......................................................................... 45Figure 34. Notification Conditions .............................................................................................. 45Figure 35. SMS Touchscreen Panel and Manual UPS Controls ............................................... 47Figure 36. Single Input - No Switches One Line Diagram ......................................................... 49Figure 37. User Interface Panel ................................................................................................. 50Figure 38. Single Input - 3 Switches One Line Diagram ............................................................ 51Figure 39. User Interface Panel ................................................................................................. 52Figure 40. Single Input - 3 Switches Front View ........................................................................ 53Figure 41. EPO Button ............................................................................................................... 55Figure 42. Remote Emergency Power Off (REPO) Button ........................................................ 56Figure 43. CleanSource UPS Single Input - 3 Switches ............................................................ 56Figure 44. Emergency Power Off Reset Button ......................................................................... 57Figure 45. Online Mode ............................................................................................................. 58Figure 46. Online Discharging Mode ......................................................................................... 59Figure 47. Bypass Mode ............................................................................................................ 59

CleanSource UPS SMS Operation and Installation Manual vii

Figure 48. Controller Board - Lithium Battery ............................................................................ 62Figure 49. User Interface Panel Key .......................................................................................... 75Figure 50. Anchoring Cleats and Bolts (Example Only) ............................................................ 77Figure 51. Customer Interface Board Locations (Typical) ......................................................... 87Figure 52. System Input/Output Board (Typical) ....................................................................... 88Figure 53. System Input/Output Daughter Board (Typical) ........................................................ 89Figure 54. Remote Emergency Power Off Contacts (J7) .......................................................... 90Figure 55. GenSTART Module .................................................................................................. 95Figure 56. Remote Status Panel ................................................................................................ 96Figure 57. Remote Status Panel J5 Connector Orientation ....................................................... 98Figure 58. Remote Emergency Power Off (REPO) Button ........................................................ 99Figure 59. Remote EPO Button Contacts .................................................................................. 99Figure 60. Single Input - No Switches One Line Diagram ....................................................... 101Figure 61. User Interface Panel ............................................................................................... 102Figure 62. Single Input - 3 Switches One Line Diagram .......................................................... 103Figure 63. Single Input - 3 Switches, Front View ..................................................................... 103

CleanSource UPS SMS Operation and Installation Manual viii

LIST OF TABLES

Table 1. Safety Symbols .............................................................................................................. 4Table 2. UPS 150i-250i 50 Hz Series Ride Through Times ....................................................... 11Table 3. UPS 150-300 60 Hz Series Ride Through Times ........................................................ 13Table 4. Lithium Battery Specifications ...................................................................................... 62Table 5. Three Phase Telemetry Parameters ............................................................................ 63Table 6. Single Phase Telemetry ............................................................................................... 63Table 7. Control Setpoints ......................................................................................................... 65Table 8. System Conditions ....................................................................................................... 65Table 9. Error Messages ............................................................................................................ 67Table 10. UPS Conditions .......................................................................................................... 70Table 11. 25 Degree Celsius, Three Conductors per Conduit (3-Wire Product) ........................ 81Table 12. 25 Degree Celsius, Four Conductors per Conduit (4-Wire Product) .......................... 81Table 13. 40 Degree Celsius, Three Conductors per Conduit (3-Wire Product) ........................ 82Table 14. 40 Degree Celsius, Four Conductors per Conduit (4-Wire Product) .......................... 82Table 15. 25 Degree Celsius, Three Conductors per Conduit (3-Wire Product) ........................ 83Table 16. 25 Degree Celsius, Four Conductors per Conduit (4-Wire Product) .......................... 83Table 17. 40 Degree Celsius, Three Conductors per Conduit (3-Wire Product) ........................ 84Table 18. 40 Degree Celsius, Four Conductors per Conduit (4-Wire Product) .......................... 84Table 19. Lugs and Dies for Connections Secured with 1/2” Bolts ............................................ 85Table 20. System Input/Output Board Reference Designators .................................................. 88Table 21. System Input/Output Daughter Board Reference Designators .................................. 89Table 22. Control Wiring ............................................................................................................ 91Table 23. Function List for Input Contacts ................................................................................. 93Table 24. Default Function Assignments for Input Contacts ...................................................... 94Table 25. Function List for Output Contacts .............................................................................. 94Table 26. Default Function Assignment for Output Contacts ..................................................... 95Table 27. GenSTART Module Summary Specifications ............................................................ 96Table 28. Remote Status Panel Specifications .......................................................................... 97Table 29. Remote Status Panel Connections ............................................................................ 98Table 30. Remote EPO Button Specifications ........................................................................... 99Table 31. UPS 150i-250i 50 Hz Series Ride Through Times ................................................... 106Table 32. UPS 150-300 60 Hz Series Ride Through Times .................................................... 108

CleanSource UPS SMS Operation and Installation Manual ix

CleanSource UPS SMS Operation and Installation Manual x

IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation and maintenance of the CleanSource UPS products.

WARNING

This product contains hazardous AC and DC voltages and is to be installed and serviced by trained and qualified personnel only, in accordance with national and local regulations.

This product should be operated by trained personnel only.

Low Voltage terminals marked SELV / NEC-Class-2 should be connected to circuits of the same classification only. These circuits must be isolated from other circuits.

In case of fire involving electrical equipment, only carbon dioxide fire extin-guishers, or those approved for use in electrical fire fighting should be used.

Extreme caution is required when performing maintenance.

Be constantly aware that the system contains DC as well as AC voltages.

Check for voltage with both AC and DC voltmeters prior to making contact.

The flywheel units should be handled with care to avoid damage to moving and electrical components and injury resulting from mishandling. Under no circumstances should the flywheel system be moved while the flywheel rotor is turning or before the protective bearing retainers are installed.

The controller board uses a lithium battery.

WARNING: There is a danger of an explosion if the battery is incorrectly installed.

When replacing the battery, replace with the same or equivalent type recom-mended by the manufacturer. Dispose of the used battery in accordance with local laws as applicable.

If you require assistance for any reason, call the toll-free Active Power Customer Support number: 1-800-288-5081. Please have the following information available:

Model Number:

Serial Number:

kW Rating:

Date Purchased:

Location:

Input Voltage:

Output Voltage:

Event Log File: (via e-mail: [email protected] or fax to 512-836-4511ATTN: Active Power Field Service)

!

CleanSource UPS SMS Operation and Installation Manual 1

FCC Compliance

IMPORTANT: Only specific models of UPS equipment comply with the limits for a Class A digital device, this is the pursuant to Part 15 of the FCC Rules.

This equipment complies with the limits for a Class A digital device, this is pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates radio frequency energy. This radio frequency energy can radiate from the unit.

If the equipment is not installed and used in accordance with this manual, interference that is harmful to radio communications may occur. Operation of this equiment in a residential area is likely to cause harmful interference. If interference does occur, the user will be required to correct the problem at their own expense.

CE - EMC Compliance

WARNING: This is a product for commercial and industrial application in the second environment - installation restrictions or additional measures may be needed to prevent disturbances.

Product Use Policy

Active Power UPS products are UL 1778 listed equipment. If you desire to use our UPS products in situations that may require listing to another standard, please contact your local authorities having jurisdiction and Active Power to ensure the proper application of our products.

SAFETY PRECAUTIONS

Read this manual thoroughly, paying special attention to the sections that apply to you before working with this system. Retain this section for use by installing personnel.

Under typical operation and with all doors closed, only normal safety precautions are necessary. The area around the system should be kept free from puddles of water, excess moisture, or debris.

Special safety precautions are required for procedures involving handling, installation, and maintenance of the system. Observe all safety precautions in this manual before as well as during performance of all maintenance procedures.

This equipment contains several circuits that are energized with high voltage. Only test equipment designated for troubleshooting should be used. This is particularly true for oscilloscopes. Always check with an AC and DC voltmeter to ensure safety before making contact or using tools. Even when the power is turned Off, dangerously high voltages may exist at the capacitor banks.

WARNING - Arc Flash Hazard And Electric Shock Hazard: To reduce the risk of arc flash and electrical shock injury to personnel, always comply with NFPA 70E, OSHA, and all other applicable electrical safety regulations when servic-ing any Active Power equipment.

!

2 CleanSource UPS SMS Operation and Installation Manual

Prior to performing service that requires opening a tool, access door, or removing a dead front panel, this equipment must be isolated from all sources of power.

General Hazard Information

Attach a “Do Not Operate” warning tag or a similar warning tag to the keyswitch or to the controls before the system is serviced or before the system is repaired. Attach the warning tags to the system and to each operator control station.

• Do not allow unauthorized personnel on the system, or around the system when the system is being serviced.

• Wear protective glasses, and other protective equipment, as required.• Do not wear loose clothing or jewelry that can snag on controls or on other parts of

the system.• Report all necessary repairs.

Unless other instructions are provided, perform the maintenance under the following conditions:

• The system is stopped and is disconnected from power. Ensure that the system can-not be powered or ensure that power cannot be applied to the system.

• Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

• Remove all tools, electrical cords, and any other loose items from the system before starting the system.

Fire Prevention and Explosion Prevention

• Make sure that the room is ventilated properly.• Keep the floor clean of debris.• Store oily rags and other flammable material in protective containers.• Do not smoke in areas that contain flammable material.• Store all lubricants in properly marked containers. Store the protective containers in a

safe place.• Do not allow flammable materials to accumulate.• Wiring must be kept in good condition. • Wires must be properly routed and securely attached. • Routinely inspect the wiring for wear or for deterioration. Loose wiring, unattached

wiring, or unnecessary wiring must be eliminated. • All wires and all cables must be of the recommended gauge. Do not use a wire or a

cable that is physically smaller than the recommended gauge. • The wires and cables must be connected to a fuse or to a circuit breaker, as required.

Do not bypass fuses and/or circuit breakers. Arcing or sparking could cause a fire.

The following practices will help prevent arcing and sparking:

• Use only recommended wiring.• Secure all connections.


Grounding Practices

Proper grounding is necessary for optimum performance and reliability. Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can cause electrical activity that may degrade the electronics and communications. Ensure that all grounds are secure and free of corrosion.

FCC Compliance

This equipment complies with the limits for a Class A digital device, this is pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates radio frequency energy. This radio frequency energy can radiate from the unit. If the equipment is not installed and used in accordance with this manual, interference that is harmful to radio communications may occur. Operation of this equip-ment in a residential area is likely to cause harmful interference. If interference does occur, the user will be required to correct the problem.

Caution/Warning See Service Manual

Risk of Electric Shock Floating Heat Sink.Test Before Touching

Ground Wait 5 Minutes After Disconnecting AllSources Of Power Before Removing

Panels Or Servicing

Telecommunication Connection No Telecommunication Connection

Table 1. Safety Symbols

!

5


No User Serviceable Parts Inside On

Off Input

Output Positive Terminal

Negative Terminal Neutral

DC Current Alternating Current

Phase Lithium Battery

Safety Extra Low VoltageConnections Only

Bypass Input

This System Intended For Use With3-Wire Grounded Wye Star Service

This System Intended For Use With aDelta Service

This System Intended For Use With aImpedance Grounded Service

This System Intended For Use With a4-Wire Grounded Wye Star Service

Table 1. Safety Symbols (Continued)

+

- N

Li

3W

3W Z 4W


High Leakage Current - Earth ConnectionIs Essential Before Connecting The Supply

MMU Modules Are Connected In Parallel.Voltage May Be Present At The Output

Of This Module WhenThe Input Power Has Been Removed.

This Product Receives Power FromMore Than One Source

Bypass Switch

Input Isolation Switch Output Isolation Switch

Caution - See Service Manual

Warning Bypass Switch Shut Off

Table 1. Safety Symbols (Continued)

!

UPS

!

PART NO. 65164 REV A

CAUTION: DO NOT CHANGE BYPASS

BREAKER STATE (ON/OFF) PRIOR

TO READING MANUAL


ACRONYMS

AWG – American Wire Gauge

EPO – Emergency Power Off

NEC – National Electric Code

SMS – Single Module System

UPS – Uninterruptible Power Supply

VAC – Alternating Current Voltage

VDC – Direct Current Voltage

SYSTEM DESCRIPTION

The CleanSource Uninterruptible Power Supply (UPS) is a fully integrated line-interactive system using a flywheel to store mechanical energy as rotating mass. When utility power is interrupted, the UPS converts mechanical energy stored in the flywheel to electrical energy. This energy is supplied to the external load until one of the following conditions occur:

• The standby generator assumes the load• The utility power is available again• The flywheel runs out of energy

Once utility power returns, the system transfers the load back to utility power without interruption. The UPS can be used in a wide range of commercial power applications. The systems provide voltage regulation and protection from power outages. This is done in order to provide well regulated power to cover critical loads, sags, surges or outages.

The figures that follow identify the main components in the systems and the location of the input, output, and converter nodes.

These nodes determine the system state. The input node and the output node are externally available to attach the system to a power source and to the load. The system uses the converter node internally. The the field coil currents use the DC bus as a power source. The system mode determines if the bus is used as a power source for the flywheel or as a power source for the utility converter.

The following list has descriptions of each component:

Input Contactor – A mechanical contactor controlling electrical flow into the UPS.

Output Contactor – A mechanical contactor controlling electrical flow from the UPS.

Bypass Contactor – An electrically operated contactor used to bypass the system.

Static Switch – The static switch is a thyristor device. The static switch is isolates the UPS from the utility grid when an out-of-tolerance condition occurs.

Flywheel Converter – The flywheel converter is a semiconductor device that is used to convert the voltage from the DC Bus into AC signals. When the power from the utility is not available, the flywheel converter will rectify AC signals from the flywheel to the DC Bus.


Utility Converter – The Utility Converter is a semiconductor device used to rectify AC voltage on the filter node into DC voltage. When utility power is lost, the utility converter converts the voltage from the DC Bus to the system operating voltage and frequency.

UPS Cabinet

Figure 1. Cabinet Front View (Typical)

Bypass Switch (Optional)

Output Isolation Switch

Input Isolation Switch

Input and Output Connectionswithout Optional MaintenanceBypass


Figure 2. System Diagram

BYPASS CABINET FLYWHEEL

MMU FLYWHEEL

CONVERTER

UTILITY

CONVERTER

500 A

CLASS J

INPUT

CONTACTOR STATIC

SWITCH

LINE

INDUCTOR

FILTERINDUCTOR

OUTPUT

CONTACTOR

F1-F3 K1 K2

INPUTISOLATION

SWITCH

OUTPUT

ISOLATION

SWITCH

BYPASS

CONTACTOR

K3

MAINTENANCE

BYPASS SWITCH

OPTIONAL

INPUT OUTPUT

200 A

CLASS J

SSF1-SSF3 K4

STATICSWITCH

CUSTOMER

MONITORING

CONNECTION

CUSTOMER INTERFACE

24-12 AWG

EPO-4 WIRES,

INPUT CONTACTS-12 WIRES,

OUTPUT CONTACTS-18 WIRES

RJ45 6-PIN (MODEM)

RJ45 8-PIN (NETWORK)

DB9 (SERIAL)

(OPTIONAL)

CUSTOMER

SUPPLIED

480 VAC

3 PHASE 60 Hz.3 WIRE AND GROUND

152 AAC NOMINAL320 AAC MAX CONTINUOUS

320 AAC MAX NON-CONTINUOUS

480 VAC

3 PHASE 60 Hz.

3 WIRE AND GROUND

181 AAC NOMINAL

F1-F3500 A

CLASS J


SYSTEM SPECIFICATIONS (UPS 150i, 250i)

M ODEL 150 i 250 i

RATING 150 kVA 250 kVA

135 kW 225 kW

INPUT

Voltage

Frequency-nominal

Input Current-nominal amps 216/205/198 355/337/325

Input Current-maximum amps 400 400

Non-Continuous Current 400 420

Power Factor

Harmonic Current Distortion

Linear Load

Non-linear Load

Surge Withstand

Walk-in

OUTPUT

Frequency-nominal

Current 228/217/209 380/361/348

Voltage-nominal amps

Voltage regulation

Steady State

Flywheel Mode

Transient

Voltage Distortion

Overload Capability-normal operation

1000%

Up to 150%

Up to 125%

PHYSICAL DATA

Efficiency 97% 98%

Heat Rejection (BTU/Hr) 18524 19946

Nominal/Worst case

Depth

Width

Total Height

Weight

Cable Access

ENV IRONM ENTAL

Temperature

Operating

Storage

Humidity

Altitude

Audible Noise

Emissions and Immunity

(1) +/-10% max at 380V

<3% at 100% linear load

0.99 at rated load and nominal voltage

50 Hz +/- 10% max (programmable) (2)

380/400/415 +10%/-15% (programmable) (1)

plus or minus 1% for plus or minus 10% input and balanced or unbalanced loads

Same as input

Input synchronized 50 Hz +/-0.1 Hz

1 to 10 seconds (programmable)

Meets IEEE 587/ANSI C62.41

<8% at 100% non-linear load

10 minutes

2 minutes

10 milliseconds

<3% linear loads and <5% for 100% non-linear loads

plus or minus within 50 mSec for 100% load step

plus or minus 1% for steady-state balanced or unbalanced loads

0 degrees C to 40 degrees C (32 degrees F to 104 degrees F)

Top

5500 lb (2500 kg)

78 in (1980 mm)

64.6 in (1, 641 mm)

34.0 in (865 mm)

(2) Weights and dimensions are for 4-wire configurations

<70 dBA at 1 m (3.28ft)

FCC Class A, Subpart J of Part 15

up to 1000 m (3281 ft.) (derated operating temperature range for higher elevations)

5% to 95% (non-condensing)

'-25 degrees C to 70 degrees C (-13 degrees F to 150 degrees F)


Table 2. UPS 150i-250i 50 Hz Series Ride Through Times

UPS 150i

% Load kW Ride-Through Time

100% 135 24 seconds

75% 101 33 seconds

50% 68 47 seconds

25% 34 80 seconds

UPS 250i


100% 225 15 seconds

75% 169 20 seconds

50% 112.5 30 seconds

25% 57 56 seconds


SYSTEM SPECIFICATIONS (UPS 150, 300)

M OD EL 150 300

R A T IN G 150 kVA 300 kVA

120 kW 240 kW

IN P UT

Voltage

Frequency-nominal 60 Hz

Input Current-nominal amps 152 299



Power Factor

Harmonic Current Disto rtion

Linear Load

Non-linear Load

Surge Withstand

Walk-in

OUT P UT

Frequency-nominal

Current 181 361


Voltage regulation

Steady State

Flywheel M ode

Transient

Vo ltage Distortion

Overload Capability

1000%

Up to 150%

Up to 125%

P H YSIC A L D A T A

Efficiency 97% 98%


nominal/worst case

Depth

Width

Total Height

Weight

Cable Access

EN VIR ON M EN T A L

Temperature

Operating

Sto rage

Humidity

A ltitude

Audible No ise


(1) +/-10% max at 380V


34.0 in (865 mm)

58.6 in (1,488 mm)

78 in (1980 mm)

<70 dBA at 1 m (3.28ft)

FCC Class A , Subpart J o f Part 15

4900 lb (2223 kg)

Top or Bottom




plus or minus 1% fo r steady-state balanced o r unbalanced loads

plus or minus 5% for 100% load step


10 milliseconds

2 minutes

10 minutes

(2) Weights and dimensions are fo r 4-wire configurations

480 +10%/-15% (programmable) (1)

0.99 at rated load and nominal vo ltage



M eets IEEE 587/ANSI C62.41


Input synchronized (no rmal operation) nominal +/-0.2% free running

Same as input



Table 3. UPS 150-300 60 Hz Series Ride Through Times

CSView Software

Figure 3. CSView

CSView is optional data monitoring software that tracks all UPS operating parameters in real time and presents the parameters on a computer monitor. CSView gives you access

UPS 150

% Load Ride-Through Time

100% 27 seconds

75% 36 seconds

50% 52 seconds

25% 87 seconds

UPS 300


100% 14 seconds

75% 19 seconds

50% 28 seconds

25% 52 seconds


to a wide range of data, including input/output currents and voltages, temperatures, system component states and event logs. The information is displayed in graphical and a text formats.

CSView includes remote notification capabilities, historical plots, event logging, expandable windows, and system diagnostic aids.

Diagnostic Capabilities

CSView is a diagnostic tool that remotely or locally downloads the UPS event history log useful for analyzing “Alarm” or “Notice” conditions. The software also allows the user to cancel paging notification events remotely.

CSView is based on a Client/Server architecture. A CSView software license includes both the UPS server and client capabilities that enable access via an Ethernet connection between the server and client.

• CSView is compatible with Windows OS.

The following input measurements are monitored and displayed by CSView:

• Three-phase line voltage• Three-phase current• Frequency• Total power (kW)• Total kVA• Input power factor

The following output measurements are monitored and displayed by CSView:

• Three-phase line voltage• Three-phase current• Frequency• Total power (kW)• Total kVA• Output power factor

Internal system measurements monitored and displayed by CSView:

• Cabinet air temperature• Air inlet temperature• Static Switch temperature• Positive DC bus voltage• Negative DC bus voltage

• Flywheel tachometer (RPM)• Percent energy available• Vacuum level• Top field coil current• Bottom Field coil current• Lower bearing force• Lateral bearing vibration• Axial bearing vibration


• Top field coil temperature• Bottom field coil temperature• Armature temperature• Top field coil Insulated Gate Bipolar Transistor (IGBT) temperature• Bottom field coil Insulated Gate Bipolar Transistor (IGBT) temperature• Top bearing temperature• Bottom bearing temperature• Motor timing advance setting

The following internal system component states are monitored and displayed by CSView:

• Input contactor state• Output contactor state• Bypass contactor state• Flywheel converter status• Utility converter status• Input relay states• Output relay states• Fan status• Fuse status• Gen Start status

Remote Notification and Monitoring

Paging/E-mail for UPS Alarms & Notices & Remote Monitoring Via CSView

With the Remote Notification and Monitoring option, the UPS can notify various personnel of UPS Alarm or Notice conditions via modem and/or Ethernet. This feature allows faster service response and faster management reporting. Off-site monitoring capability enables remote real-time system views and diagnosis for analysis in minutes.

Ethernet Option - Internet Invocation

Up to four persons and Active Power Service personnel can receive immediate contact via e-mail when notice or alarm events are recorded by the UPS system. E-mail messages contain the UPS model, serial number, physical location, and explanation of triggering event that caused the message to be generated. E-mail messages are broadcast to all recipients.

• E-mail requires Ethernet connection to a Local Area Network (LAN) with SMTP e-mail server.

• Network monitoring requires static IP address to be assigned to each UPS.• E-mail server must be able to receive mail from a non-authenticated source on the

LAN.


Ethernet Interface

Using the Ethernet Connection option, multiple CSView users connected to a Local Area Network (LAN) can monitor the operation of the UPS at the same time.

Internet Interface

With Ethernet Connection option, the UPS allows for Internet connection for monitoring via Local Area Network (LAN).

• Network monitoring requires IP address statically assigned to UPS.• Internet monitoring requires a LAN connection to Internet.

E-mail Notification

An Ethernet connection enables e-mail messages to be broadcast to all those on the receipt list at one time for all Notice and Alarm events.

• E-mail requires Remote Notification option and connection to a Local Area Network (LAN) with SMTP e-mail server.

Modem Option - Paging Notification

Paging can be configured to broadcast calls to all listed on paging receipt or in an “escalation” mode if no return call is made in a given time. The system uses automatic redial and rotation sequence after set delays for up to 200 call attempts until UPS is contacted using CSView via Internet or phone line to ensure the UPS issue is addressed. Users may individually enable or disable paging for alarm events or notice events sepa-rately.

• Numeric Paging - System will leave UPS code number, call back number and notice or alarm code to indicate severity of problem.

• Alphanumeric Paging - System will provide description of product, cause of alarm, serial number, location and callback number.

The modem option requires an analog phone line connection. CSView option recommend-ed for confirmation.

Dual Communication - Modem and Ethernet

For multi-path communications capability, both the Ethernet Option and Modem Option can be applied to the same UPS system.

Modems

Modem Specifications

• 56kps download capability ITU V.90 industry standard technology• Connects with all major modem protocols• Carrier loss redial enables the modem to automatically redial the last number called if

a loss of carrier is detected.• Remote configuration allows modem settings to be configured from a remote location.


• Dial security Including dialback secures your network by verifying authorized callers and modems prior to passing a remote originated call or initiates dialback based on device configuration.

Supported Standards And Protocols

• ITU V.90 at up to 56 Kbps technology• TU-T V.34 at 33.6 Kbps or 28.8 Kbps• V.32 turbo at 19.2 Kbps (21.6 Kbps between Courier modems with ASL)• ITU-T V.32bis at 14.4 Kbps• ITU-T V.32bis at 14.4 Kbps• HST at 16.8 Kbps• Backward compatible with most ITU-T and Bell standards

Static Bypass Switch

This ensures a no break transition from normal operation to bypass operation in the event of a catastrophic internal UPS failure or overload. Silicon Controlled Rectifiers (SCR) are used to instantaneously connect the bypass source to the output. Thus the output contactor is commanded to open and bypass contactor (which is in parallel with the static switch) is commanded to close. This results in a “make-before-break” switch operation.

PRODUCT IDENTIFICATION INFORMATION

Location of Serial Number Label

The system serial number label is affixed to the outside of the cabinet door. The serial number will be a seven digit number starting with the number 5(50XXXXX).

TOUCHSCREEN USER INTERFACE

Navigating the System Cabinet Touchscreen Display

The access level you have been assigned can limit or expand the amount of freedom you have to manage the UPS system. The following paragraphs explain access levels.

NOTE: Use your finger, a pencil eraser, or a similar small, soft object to touch the keypad. Avoid touching the screen with your fingernails or a sharp object.

There are two levels of access for the touchscreen display. They are:

• Guest• Admin

Guest - This is the default access level. All read-only screens are available at Guest level. No login is needed for Guest access at the UPS. Guests can see all settings and operational statuses but may not make any modifications.

IMPORTANT: Remote access via a web browser does require a login, even for Guest.

Administrator - An Administrator may make changes to the SMTP settings and email notifications on the Configuration page.


Guest and Administrator level accounts may be added. Once an Administrator level account has been added, the default account is disabled. If accounts are deleted, an Administrator level account must be the last one on the system. Once the last entered Administrator level account is deleted, the default account is re-enabled.

The following illustration shows the order and access of the various screens used to control and manage the UPS.

Figure 4. Selections and Access for Your Touchscreen UPS Display

The following instructions explain the types of information found on the System Cabinet touchscreen display.

Using the Touchscreen

The System Cabinet Touchscreen User Interface Panel allows the operator to monitor the operation of the UPS.

IMPORTANT: The System Cabinet Touchscreen User Interface Panel DOES NOT allow the operator to:

• Stop the system in an emergency• Place the system into bypass• Reset the system• Silence the horn

The operations listed above must be performed manually from the manual control panel directly below the touchscreen on the System Cabinet door.

Log In System

Diagram

Event Log Telemetry UPS

Diagram

System

Summary

Service

Notification

Configuration Accounts Service

Config

Admin System

Detail

All

Alarm

Notice

Export

System

UPS

UPS Preventive

Maintenance

Date

SMTP

Notifications

Guest System

Detail

All

Alarm

Notice

Export

System

UPS

UPS


Figure 5. System Cabinet Touchscreen Panel and Manual UPS Controls

Display Contrast Adjustment

Once power is applied to the system, the touchscreen should be active. If the Home screen is not displayed or there is no text visible, touch the screen. There is a backlight time-out feature that turns the screen backlight off to save power. Touching the screen re-illuminates the display backlight. After touching the screen and the screen is still dark, contact Active Power service.

Touchscreen

USB Interface

EPO ButtonHorn Silence Button

Three (3) Position Keyswitch- Bypass- Online- Reset


Figure 6. System Cabinet Touchscreen User Interface Panel (Typical)

Getting to Know the Touchscreen

The touchscreen is easy to use by lightly touching a selection with your finger.

The touchscreen is divided into two interactive sections: Task, State, Information and Task/Information.

NOTE: In certain conditions there may be combinations of State and Task/Information as explained in the following paragraphs.

UPS StateGreen - OKRed - Alarm

System State

Green - Functioning - No Alarms - No NoticesMessage - Load Protected

Red - Load Unprotected - AlarmsMessage - Load Unprotected

Thin line shows no power flowing (off bypass)

Yellow - Functioning - NoticesMessage - Load Protected or Not

Thick line shows power flowing

K3


System Navigation

Touching the appropriate heading allows you to go to any screen listed on the system Menu. Your system’s Menu information may differ somewhat from the following illustration.

Primary selections are displayed down the left of the screen. The following is an illustration of the master selections.

NOTE: The selections vary depending on the access level for the password entered.

Figure 7. Overall Menu Selections

State

Information/Task

Information/Task

Information/State

Information

Information/Task

Information/Task

Information/Task

Task

Menu Button

Task

Tech Only


Figure 8. Menu Selections - Guest

Each one of the Menu selections are explained in the following paragraphs.

State

Information/Task

Information/Task

Information/State

Information

Menu Button

Task


Menu Button

The Menu Button symbol takes you back to the menu when in you are in any of the screens selected from the main menu.

Example: You have selected Configuration. Notice that when you make the Configuration selection, that the UPS mode and state are displayed on the left where the Menu was displayed. To return to the menu touch the Menu button.

Login

Touching the Login selection allows you to log ON or OFF the system from any screen.

See the following illustration.

Figure 9. Log In/Out Window and Keypad

To log in or out of the system perform the following steps.

1. Touch the Login selection.

2. Select the user name field/password field to display the virtual keypad.


3. Enter your user name and password as appropriate from the virtual touchscreen key-pad.

Event Log

Touching the Event Log in the selection window takes you to the system Event Log. See the following illustration.

Figure 10. Event Screen

Notices and Alarms

The Event Log screen allows you to select for display All Events, Alarm and Notice. You may also email the events log to an email address. This is a very useful way to transfer information for remote diagnostics to a qualified Active Power technician.

Notice Messages – System errors that are not critical will generate Notice Messages. When this condition exists, the system will not go to Bypass mode. However, a service technician may be required to fix the problem.

A Notice Message causes the “NOTICE” banner to display on the touchscreen. The system also emits an audible alarm. These messages are displayed in the Event Log. The Event

Events Logged

Arrows take you up ordown throughthe Events logged


Log may be accessed from the touchscreen display. The Event Log may also be accessed in CSView.

Examples of the events that generate Notice Messages are in the following list:

• Fan Failures• Abnormal Thermal Conditions

Alarm Messages – System errors that are critical generate Alarm Messages. Alarm Messages indicate that the system has experienced a critical event and operator action is required. An Alarm Message will cause the “ALARM” message to be displayed. The system also emits an audible alarm. These messages are printed to the Event Log. The Event Log may also be accessed in CSView. Examples of the events that generate Alarm Messages are in the following list:

• Multiple Fan Failures• Extreme Thermal Conditions• Overload Conditions• Emergency Power Off Event

Emailing and Exporting Events

The following Screen is the Export Events Screen.

Figure 11. Exporting Events by Email

Exporting Events by Email

To email an event log perform the following steps.

1. Touch All.


2. Touch Export.

3. Touch the Email ID address line.

4. Enter the recipient’s Email ID with the virtual keyboard.

5. Touch Email.

Figure 12. Using Virtual Keypad to Enter Recipient Address

NOTE: Setting up Email addresses for automatically exporting events is explained in the paragraph entitled, “Notifications Configuration”.

Exporting Events to a USB Device

To export to a USB device perform the following steps.

1. Connect the USB device to the USB port on the front of the System Cabinet below the touchscreen display.

2. Touch the Event Log selection in the Menu.

3. Touch Export.

4. Touch To USB.

The system writes information to the USB device which may then be distributed as appropriate.

IMPORTANT: Do not remove the USB device until all information has been transferred. The system displays a message when the transfer is complete.

Virtual Keypad


Telemetry (System and UPS)

The telemetry screens allow you to see the current UPS performance in industry standard measured values and units. Telemetry screens are accessed through the selection window on the left of the display.

1. Touch Telemetry.

The following screen appears.

Figure 13. Telemetry Selection Screen

The first telemetry displayed is the System telemetry. You may either touch the Previous or Next buttons to scroll through the telemetry data or touch the page numbers at the bottom of the screen.

UPS telemetry screen is available by touching the appropriate selection button at the top of the screen.

Guest


System Diagram Access

The System Diagram screen that is usually shown on the touchscreen display.

Touching System Diagram on the left menu bar allows you to go to System Diagram.

The following is a typical System Diagram display for a UPS system.

Figure 14. Typical System Diagram Display

Status Indicators

Status indicators alert the operator to the status of the system. They also alert the operator of notice and alarm messages. System status and any messages will be displayed on the touchscreen display.

K3


Normal Status

During normal operation the flywheel status indicators are green. There are two kinds of status indicators:

• Stripe color at the top of the screen and message (Alarm or Notice when appropri-ate)

• Flywheel status indicator

Figure 15. Normal Operating Status Indicator on Home Page

The following table details the meaning of the green indicator:

Notice Status

The system displays a Notice on a screen similar to the following.

Figure 16. Event - Notice

When there is a “Notice Message” the status indicator goes from green to yellow. By touching this Notice indicator the Event Log screen is displayed.

System errors that are not critical will generate a Notice. This notice may or may not require operator intervention. A Notice message will also cause the system to display the “NOTICE” banner and the affected status indicator displays a YELLOW flywheel symbol. The system will also emit an audible alarm. The Event Log displays the type of event that caused the notice, the time and date.

Status Indicator Color

Protects Load Alarm Notice Communication

Green Yes No No Yes - OK

Green Indicatorfor NormalOperation


If the notice indicates the system is not protecting the load, there will be a message under the System Overview column stating that the load is unprotected.

Figure 17. “Notice Message” Status Indicator

Alarm Status

When there is an “Alarm Message” the operating status indicator goes from green or yellow to red. The Alarm event presents a screen similar to the following.

Figure 18. “Alarm Message” Status Indicator

Alarms alert the operator when the system is not performing optimally or when operator actions are needed. When an alarm occurs, the operator should check the display to determine if action is required. System errors that are critical to the operation of the UPS generate Alarms. An Alarm message will causes the “ALARM” message to display and the status indicators to display a red flywheel symbol. The system will also emit an audible alarm.

By touching the Alarm notice the Event Log screen appears.



Yellow No No Yes Yes - OK

Yellow No No No Yes - OK

Yellow Yes No Yes Yes - OK

Yellow IndicatorUPS may or maynot protect load.


If the alarm indicates the system is not protecting the load, there will be a message under the System Overview column stating that the load is unprotected.

Figure 19. “Alarm Message” Operating Status Indicator on Home Page

For further detailed information about the UPS, you need to touch the UPS icon to display information.

Accessing UPS Information

You can access the information for the UPS by touching the UPS icon. For example, if the UPS icon is displayed as red, you can touch the icon to access the UPS diagram for that information. See the following illustration.



Red No Yes No Yes

Red No Yes Yes Yes

Red Yes Yes No Yes

Red Yes Yes Yes Yes

Gray No Indication No Indication No Indication Bad

Red IndicatorUPS may or maynot protect load


Figure 20. Touch to Select UPS Detail

1. Touch the UPS icon for detailed UPS information.

A screen similar to the following appears.

Touch Iconfor UPS Detail

UPS

K3


Figure 21. UPS Detail Screen (Load Protected)

You may also touch the UPS button to bring up a series of screens that show the data describing the UPS performance. See the following screen.

2

K1 K2

Guest


Figure 22. Example SystemTelemetry Screen

Acquiring and Managing System Information

The UPS provides and tracks system information when operating. The following para-graphs explain how to access the information.

System Detail

Access system details by touching the System Diagram selection in the selection window on the left.

.

Guest


Figure 23. System Diagram

The System Diagram shows the system:

• System Input (Line Volts, Current, Power, etc.)• System Output (Line Volts, Current, Power, etc.)• kVA• kW• Hz• PF• Percent energy• Percent load

UPS Detail

UPS Details can be accessed from the selection window.

K3


Figure 24. UPS Diagram Selection on System Diagram Screen

1. Touch UPS icon.

The following illustration shows a typical UPS Detail screen.

K3


Figure 25. UPS Detail Screen

K1 K2

Guest


System Summary

The System Summary screen displays both System Information and UPS Information. See the following.

Figure 26. System Summary Information Screen

System Information

• Install Date - Date system installed• Location - Location (for example Cryo Lab)• Display Version - Display software version• Serial Number - Display serial number• Firmware Version - System firmware release version• FPGA Version - Current system FPGA version• CIO Firmware Version

Guest


UPS Information

• UPS• Serial Number - Serial number of the UPS system• Location - User defined UPS Identification• State - Online, Offline, Startup, etc.• Mode - Bypassed, Online• Discharges - Number of discharges• Alarm - Alarm, No Alarms

Service Notification

The service notification page allows the entry of maintenance and replacement dates for your UPS. The service notification page also allows you to enter service contact information.

The following illustration shows the service notification screen.

Figure 27. Service Notification Screen (Admin)

Preventative maintenance dates and bearing replacement dates are set by the service tech. The places they are set are not user-accessible. PM covers everything except

UPS

UPS

Guest


bearings, so the tech must enter a target date for the next expected PM tasks. These tasks may not be the same each time. On each visit the tech will update target dates as needed.

Users logged in at operator-level or above can enter the Scheduled Maintenance Date. This is the date that they have scheduled a service visit. The display assumes that all required service will be performed at once.

The display reminds users that service is needed 180days, 90 days, 30 days, 7 days, and 1 day before service is needed. It reminds them in three ways:

The Service Notification screen will preempt the current screen (except for the event screen when there is an active alarm or notice).

A SERVICE REQUIRED button will appear on the status window, see below. This button will take you to the Service Notification screen. It will stay up until all required service has been scheduled.

It sends an email to those who have selected service emails. An email is sent whenever any service item changes state (see below).

Once service is scheduled, reminders are not made until 7 days before the scheduled date.

The possible service states for each service item are:

Service not required within 180 days (Not Due)

Service is scheduled

Service is overdue

Service needed within 180 days




Service needed within 1 day

Service Date is not entered

SMTP and Email Configuration

The configuration screen allows the Admin to set up the SMTP and Email configurations for the system. Guests cannot configure the following:

• SMTP Configuration and authorization• Email Configuration

1. Select Configuration from the list of buttons in the selection display. See the following.


Figure 28. Configuration Selection

Touching Configuration takes you to the following screen. Please note that there are two (2) configuration selections from which you may select.

• SMTP• Notifications

Figure 29. Configuration Selections (Admin)

SMTP (Simple Mail Transfer Protocol) Configuration

When you enable system email, you are allowing the display to automatically send notices to a designated destination email address. See the following illustration.

Configurationselection

K3

(Admin)


Figure 30. SMTP Email Configuration (Admin)

1. Touch the required entry field.

The virtual keypad appears.

Guest


2. Enter the parameters required to allow the display to communicate notices.See the following screen.

Figure 31. Entering Email Configuration Parameters (Admin)

3. Save the Email configuration by touching the Update button.

4. Test the Email configuration by entering a test Email address and touching the Test Email button.

NOTE: The UPS has a completely independent Email configuration accessible through CSView. The capabilities provide redundancy for the email notification system.

Notifications Configuration

The email notification setup allows the UPS to notify someone when a condition has triggered the sending of an alarm or notice. See the following screen.

Guest


Figure 32. Configuring Notifications - Notification Screen (Admin)

Email Notification Setup

To setup notification for a particular person perform the following:

1. Touch the Notify window.

The following screen appears.

Guest


Figure 33. Entering Notification Email (Admin)

1. Enter the email address where the notification is to be sent.

2. Select the conditions the for sending the notifications. See the following.

Figure 34. Notification Conditions

3. Touch Update.

Guest


BASIC OPERATIONAL PROCEDURES

CAUTION

The following procedure assumes that the system installation inspection and initial startup have been performed by Active Power Certified service person-nel. An Active Power authorized representative must perform the initial system startup to ensure proper system operation.

WARNING

Before performing maintenance or servicing this equipment ensure that the proper lockout/tagout procedures are followed as needed when performing service or repairs required for your installation.

System Cabinet Manual Controls

The UPS system has manual controls on the System Cabinet. The following instructions describe the operation of the manual controls. See the following figure.

!

!


Figure 35. SMS Touchscreen Panel and Manual UPS Controls

System Cabinet Manual Controls - Detail

System Cabinet Manual Controls

1. Keyswitch – Used to control the operation of the system. The keyswitch is used under the following conditions:

• Reset or restart the system after an error, or any Emergency Shutdown mode is activated.

• Lock the system into the Bypass or Online position when the key is turned to that position and is removed from the keyswitch.

NOTE: This function only prevents manual operator intervention. The system will still switch to Bypass automatically if necessary.


The keyswitch has the following positions:

• Bypass - This position is used to transfer the system to bypass during certain main-tenance procedures. This position offers no protection from problems with the incoming power.

• Online - The keyswitch will be in this position during the normal operation of the system. This position provides protection for problems with incoming power.

• Reset - This position is used to reset the system after any shutdown condition. The reset position is a spring loaded position that returns the key to the online position when released.

2. Emergency Power Off (EPO) Button - This button is red and is labeled “EPO.” The EPO button is used to place the system in the shutdown mode.

NOTE: When the EPO button is used, the entire system is secured. Power is not supplied to the load. However, voltage is still present on the input terminals. The critical load will lose protected power unless the customer has provided a protected external bypass.

3. Horn Silence Button - Pressing the Horn Silence Button silences the aural alarm.

Rebooting the Touchscreen Display

Should you need to reset the display and you have Administrator privileges, do the following:

1. Touch the Navigation screen icon.

2. Select Configuration from the selection bar at the right of the screen.

3. Touch the Next Screen button until Screen 3 of 3 (3/3) appears.

4. Touch the Reboot button.

5. Answer Yes to the prompt.

6. The touchscreen reboots and returns to operation.

OPERATION

CAUTION

The following procedure assumes that the system installation inspection and initial startup have been performed by Active Power Certified service person-nel. An Active Power authorized representative must perform the initial system startup to ensure proper system operation.

!


UPS Startup (Single Input - No Switches)

Figure 36. Single Input - No Switches One Line Diagram

1. Apply facility power to the System Input Node.

2. Connect the System Output Node to the facility load circuits.


MMU FLYWHEEL

CONVERTER

UTILITY

CONVERTER

500 A

CLASS J

INPUT

CONTACTOR STATIC

SWITCH

LINE

INDUCTOR

FILTER

INDUCTOR

OUTPUT

CONTACTOR

F1-F3 K1 K2

INPUT

ISOLATION

SWITCH

OUTPUT

ISOLATION

SWITCH

BYPASS

CONTACTOR

K3

INPUT OUTPUT

200 A

CLASS J

SSF1-SSF3 K4

STATICSWITCH

CUSTOMERMONITORING

CONNECTION

CUSTOMER INTERFACE 24-12 AWG

EPO-4 WIRES, INPUT CONTACTS-12 WIRES,

OUTPUT CONTACTS-18 WIRES RJ45 6-PIN (MODEM) RJ45 8-PIN (NETWORK)

DB9 (SERIAL)

(OPTIONAL)

CUSTOMERSUPPLIED

480 VAC

3 PHASE 60 Hz.

3 WIRE AND GROUND

152 AAC NOMINAL

320 AAC MAX CONTINUOUS


480 VAC

3 PHASE 60 Hz.3 WIRE AND GROUND

181 AAC NOMINAL

F1-F3

500 A

CLASS J


Figure 37. User Interface Panel

3. Turn the UPS keyswitch to the “Online” position (see Figure 37).

The system enters the “Bypassed-Auto Start” state and begins charging the flywheel. When the flywheel reaches a rate of 4000 RPM, the system shifts to the “Online” mode. The system is operational.

4. Confirm that the UPS is “Online” by observing the status on the Touchscreen.

UPS Shutdown (Single Input - No Switches)

WARNING

Before performing maintenance or service on the system ensure that the proper lockout/tagout procedures are followed.

When the flywheel is spinning, the following components are energized: the DC bus and armature leads.

1. Turn the UPS keyswitch to the “Bypass” position.

!


2. Confirm that the UPS is in “Bypass” by observing the status on the Touchscreen.

Note: This system is not equipped with a Bypass Switch. Power is lost to the supported load when the customer supplied LOAD circuit breaker is opened (de-energized).

3. Remove facility power from the System Output Node.

4. Remove facility power from the System Input Node.

5. Allow the capacitor banks to bleed down for approximately 5 minutes. Doing so dissi-pates any residual energy in the DC bus, armature leads, and fuses.

UPS Startup (Single Input - 3 Switches)

Figure 38. Single Input - 3 Switches One Line Diagram

200 ACLASS J

SSF1-SSF3 K4

STATIC

SWITCH

CUSTOMER

MONITORINGCONNECTION

CUSTOMER INTERFACE

24-12 AWG

EPO-4 WIRES,



RJ45 6-PIN (MODEM)


DB9 (SERIAL)

(OPTIONAL)

CUSTOMERSUPPLIED

480 VAC

3 PHASE 60 Hz.

3 WIRE AND GROUND

152 AAC NOMINAL



480 VAC

3 PHASE 60 Hz.

3 WIRE AND GROUND

181 AAC NOMINAL

F1-F3500 A

CLASS J


MMU FLYWHEEL

CONVERTER

UTILITY

CONVERTER

500 A

CLASS J

INPUTCONTACTOR STATIC

SWITCH

LINEINDUCTOR

FILTERINDUCTOR

OUTPUT

CONTACTOR

F1-F3 K1 K2

INPUT

ISOLATION

SWITCH

OUTPUT

ISOLATION

SWITCH

BYPASS

CONTACTOR

K3

MAINTENANCE

BYPASS SWITCH

OPTIONAL

INPUT OUTPUT


System Pre-Startup Procedure (Before Applying Electrical Power)




Figure 40. Single Input - 3 Switches Front View

Note: The Bypass, Output Isolation, and Input Isolation switches are not intended for operator access. These switches are to be operated by personnel trained and qualified to service this equipment.

2. Open (de-energize) the Output Isolation Switch.

3. Open (de-energize) the Input Isolation Switch.

4. Open (de-energize) the Bypass Switch.

System Startup Procedure (Single Input - 3 Switches)



3. Close (energize) the Input Isolation Switch.

4. Close (energize) the Output Isolation Switch.

5. Turn the UPS keyswitch to the “Online” position.

The system enters the “Bypassed-Auto Start” state. The system begins charging the flywheel. When the flywheel reaches a rate of 4000 RPM, the system shifts to the “Online” mode. The system is operational.







System Bypass (Single Input - 3 Switches)



Note: If the System does not go to Bypass “DO NOT PROCEED” with this procedure. Equipment damage and load interruption may occur. Call the nearest technical service technician.

Note: Closing the Bypass Switch will ensure that power to the critical load is not interrupted.

3. Close (energize) the Bypass Switch.



6. Allow the capacitor banks to bleed down for approximately 5 minutes to dissipate any residual energy in the DC bus and armature leads.

Removing the System from Bypass (Single Input - 3 Switches)



3. Open (de-energize) the Bypass Switch.


5. Confirm that the UPS is in “Online” by observing the status on the Touchscreen.

System Shutdown Procedure (Single Input - 3 Switches)

NOTE: The flywheel energizes the following components when spinning: the DC bus and armature leads.



Note: Continuing with this procedure disconnects and de-energizes the critical load on the UPS output. Refer to the “System Bypass Procedure” if this is not desired.



5. Remove facility power from the System Input Node.

6. Allow the capacitor banks to bleed down for approximately 5 minutes to dissipate any residual energy in the DC bus and armature leads.

Emergency Shutdown Procedure

An Emergency Shutdown can be initiated by the:

• Emergency Power Off (EPO) Button• Remote Emergency Power Off (REPO) Button (via dry contacts)


Upon activation of Emergency Shutdown the entire system is secured. Power is not supplied to the load, however, voltage is still present on the input terminals.

Emergency Power Off (EPO) Button

Figure 41. EPO Button

Performing Emergency Power Off

• Press the red EPO push button located on the User Interface panel.

This push button is protected by a clear plastic cover to prevent accidental contact.

WARNING

Pressing this button will cause the UPS to instantly disconnect from the load.!


To restart the UPS after pressing the EPO push button follow the procedure, “UPS Reset After Emergency Shutdown”, before restarting the UPS.

Remote Emergency Power Off (REPO) Button (Optional)

Figure 42. Remote Emergency Power Off (REPO) Button

The Remote Emergency Power Off push button functions the same way as the Emergency Power Off push button on the User Interface panel.

Lockout/Tagout Procedure

Use accepted Lockout/Tagout procedures when working on the UPS.

Note:

Lockout/Tagout procedures prevent injury to personnel and damage to equipment.

Figure 43. CleanSource UPS Single Input - 3 Switches

Energized Switch Position De-Energized Switch Position

Locked Out/Tagged Out


UPS Reset After Emergency Shutdown

CAUTION

Do not attempt to restart the UPS after an Emergency Shutdown until the cause of the emergency has been identified and corrected.

Figure 44. Emergency Power Off Reset Button

You must reset the Emergency Power Off Reset Button when any Emergency Shutdown mode is activated. The button is behind the left door of the UPS.

To reset the UPS:

1. Cycle the System Cabinet Emergency Power Off Reset Circuit Breaker from the “Off” to the “On” position until it clicks and remains in the “On” position.

2. Cycle the key switch on the User Interface Panel from the “Bypass” to the “Online” position.

The UPS is reset.

Modes Of Operation

The UPS functions automatically to supply AC electrical power to the critical load. There are several operation modes that allow it to accomplish this. Most of the operating modes have several states that occur in that mode. The mode and the state are displayed on the Touchscreen. The Touchscreen display is located on the front panel. The operating modes are listed below:

• Online Modes• Bypass Modes• Automatic Voltage Regulation (AVR) Mode

The UPS continually monitors itself and the incoming utility power, and automatically switches between these modes as required, without operator intervention. The detection

!

Emergency PowerOff Reset CircuitBreaker


and switching logic inside the UPS ensures that operating mode changes are automatic and transparent to the critical load.

Online Modes

Figure 45. Online Mode

Online – Online mode is the standard operating mode for the system. The load is protected when the system is in this mode. The system is capable of discharging in order to support the load.

Online Charging – The system enters this state when the flywheel reaches 4000 RPM. The system is charging in this state. The system can sustain discharge in this state.

Online Standby – When the speed of the flywheel reaches 7700 RPM, the system is in the Online standby state. This is the rated idle speed for the flywheel.


Figure 46. Online Discharging Mode

Online Discharging – The system enters this state when the unit is supplying power to the load. If power is disrupted, the system changes to this state.

Bypass Modes

Figure 47. Bypass Mode


Bypass – Bypass mode directly connects incoming utility power to the system load. When in bypass mode, the system load is unprotected. The load can be affected by incoming power disruption. The system enters bypass mode through one of the following events:

• Start-up• The Keyswitch (Manual)• Fault Recovery Failure

Repeated errors causing the system to oscillate between bypass and online modes can lock the system into the bypass mode. When the system is locked in bypass mode, the user must change the system mode. Use the keyswitch to change the system mode.

Bypassed-Verify Signals – When in this state, the system verifies that the correct telemetry is present. This state is used when you are starting the system and during error recovery.

Bypassed-Auto Start – This is the default state at start-up. The system cannot immediately protect the load after the system is started. During the normal operation, the system will enter Automatic Voltage Regulation (“AVR”) mode.

Automatic Voltage Regulation (“AVR”) Mode

The Automatic Voltage Regulation (“AVR”) Mode can be entered by one of the following events:

• Start-up• Flywheel Error

Automatic Voltage Regulation Auto Start – The system remains in the “AVR” mode until the system is charged and able to sustain discharge. During the Automatic Voltage Regulation Auto Start state, the flywheel must achieve a rate of 45 RPM before changing to the Automatic Voltage Regulation Charging state.

Automatic Voltage Regulation Charging – The system enters this state when the system starts to charge the flywheel. When the speed of the flywheel is 7700 RPM, the system enters the Online Stand-by state. Normally, the system enters the Online Charging state when the flywheel reaches 4000 RPM.

Automatic Voltage Regulation Verify Signals – When the system is in this state, the system verifies that correct system telemetry is present. This state is used when you are starting the system and the state is used during the recovery of flywheels errors.

MAINTENANCE

Air Filter - Cleaning

WARNING

Risk of electric shock or energy hazard is present when opening the cabinet doors. Parts inside this UPS are energized by the flywheel even when the AC power is disconnected.

Clean the filter after 90 days of operation. If the environment dictates, the filters should be cleaned more often.

!


Clean the filter when the following occurs:

• Excessive dust buildup• Excessive filter deflection due to blocked air flow• Steadily increasing system temperatures

Flywheel - Cleaning

WARNING

Risk of electric shock or energy hazard. Parts inside this UPS are energized by the flywheel even when the AC power is disconnected.

Dust on the flywheel housing surfaces reduces heat transfer. Routinely cleaning air filters will minimize dust buildup on these surfaces. Refer to Maintenance Section, “Air Filter - Cleaning”. If the fins show heavy dust deposits, the system should be de-energized. Wipe the dust off with a clean damp rag. When you clean the air filter, check for dust accumulation.

Vacuum Pump Oil - Change

The vacuum pump oil should be changed once per year. If storage is anticipated, or if vacuum pump shutdown is anticipated for more than 30 days, the vacuum pump oil reservoir should be drained and filled with new oil. Contact Active Power Customer Support at 1-800-288-5081 for vacuum pump oil change.

Bearing - Replacing

Replace bearings periodically. The recommended interval is estimated at 4 years. The bearings are contained in removable cartridges. The cartridges are replaced at the same time as the bearings. The cartridges must be accurately positioned for proper operation.

Your system notifies you with a message displayed on the control panel that the bearing change is due.

Only trained personnel may perform the replacement. Contact Active Power Customer Support at 1-800-288-5081 for bearing replacement.

Controller Board Battery - Replacing

The controller board uses a lithium battery. The battery has an estimated life of 5 years. When replacing the battery, replace with the same number and type as installed.

WARNING

Do not dispose of the battery in a fire. The battery may explode.

!

!


Figure 48. Controller Board - Lithium Battery

Reference Information Section

Telemetry Parameters

From the top level of the display, you can scroll through the logs and the telemetry data. Scroll with the soft keys. The keys are located at the bottom of the display and the right side of the display.

Nominal Voltage 3.0 V

Typical Voltage 3.1 – 3.3 V

Rated Capacity 200 mAh on 15 kÙ to 2.0 V at 21°C (70°F)

Average Weight 0.106 oz. (3.0 g)

Volume 0.061 in.3 (1.00 cm3)

Terminals Fiat, PC Pins

Oper. Temp. Range

-40°C to 60 ° C (-40°F to 140°F)

NEDA/ANSI 5004LC

Table 4. Lithium Battery Specifications

Lithium Battery


Three-Phase Telemetry Points

Single-Phase Telemetry Points

Three-Phase Telemetry Points

“Input Line Voltage AB, BC, and CA” This is the measurement of the input voltages from phase to phase.

“Current In Phases A, B, and C” This is the input current to the system, measured for each phase A, B, and C.

“Input Power This is a calculated value based on the input phase to phase voltages and input currents.

“Input kVA Phases A, B, and C” This is a calculated value based on the input phase to phase voltages and input currents.

“Output Line Voltage AB, BC, and CA” This is a measurement of output voltages from phase to phase.

“Current Out Phases A, B, and C” This is the output current from the system, measured for each phase A, B, and C.

“Output Power Phases A, B, and C” This is a calculated value based on the output phase to phase voltages and output currents.

“Output kVA Phases A, B, and C” This is a calculated value based on the output phase to phase voltages and output currents.

Table 5. Three Phase Telemetry Parameters


“Frequency” This is a measurement of the frequency as seen on phase C.

“Output Power” This is the sum of the output power on phases A, B, and C.

“Total Output kVA” This is the sum of the output kVA on phases A, B, and C.

“Output Power Factor” This is a calculated based on the output phase to neutral voltages and the output currents.

“Input Frequency” This is a measurement of the input frequency as seen on phase C.

“Total Input Power” This is the sum of the input power on phases A, B, and C.

“Total Input kVA” This is the sum of the input kVA on phases A, B, and C.

“Input Power Factor” This is calculated based on the input phase to phase voltages and the input currents.

“Cabinet Temp” This is an air temperature measurement taken in the cabinet.

“Air Inlet Temp” This is an air temperature taken at the air inlet to the cabinet

“Static Switch Temp” This is the temperature of the static switch heat sink.

Table 6. Single Phase Telemetry


“Positive DC Bus Voltage” This is the positive DC bus voltage produced by the input rectifier.

“Negative DC Bus Voltage” This is the negative DC bus voltage produced by the input rectifier.

“Tachometer” This the flywheel tachometer.

“Percent Energy” This is a calculated value that represents the usable energy stored in the flywheel.

“Vacuum Gauge” This measurement indicates the vacuum level in the flywheel housing.

“Top Field Coil Current” This measurement indicates the current through the top field coil of the flywheel.

“Bottom Field Coil Current” This measurement indicates the current through the bottom field coil of the flywheel.

“Bottom Bearing Force”

This is a calculated value based on the top and bottom flux density measurements. This value represents the amount of weight unloaded from the bottom bearing by the field coils.

“Lateral Vibration” This measurement is the lateral vibration measured by the flywheel accelerometers.

“Axial Vibration” This measurement is the axial vibration measured by the flywheel accelerometers.

“Top Field Coil Temp” This is the measured temperature of the top field coil in the flywheel housing.

“Bottom Field Coil Temp” This is the measured temperature of the bottom field coil in the flywheel housing.

“Armature Temp” This is the measured temperature of the main armature in the flywheel housing.

“Top Field Coil IGBT Temp” This is the measured temperature of the top field coil “IGBT”.

“Bottom Field Coil IGBT Temp” This is the measured temperature of the bottom field coil “IGBT”.

“Top Bearing Temp” This is the measured temperature of the top flywheel bearing.

“Bottom Bearing Temp” This is the measured temperature of the bottom flywheel bearing.

“RPS Advance”This value describes the calibration setting of the commutation sensor. The commutation sensor is used to measure the rotor position.


Table 6. Single Phase Telemetry (Continued)


Control Set Points

System Conditions

Control Set Points

“Field Current Setpoint” This is the current setpoint for the bottom field.

“Rotor Speed Setpoint” This is the desired flywheel speed.

“Motor Current Limit” This is the upper limit for the amount of current used in the motor armature.

“Discharge FC @7000 Setpoint” This sets the amplitude of the field current profile during discharge.

“Voltage Ref. Setpoint” This is the target for the output voltage of the machine.

Table 7. Control Setpoints

MessageSupportLoad

Status Description

Modem: Paging Cancelled. Y Normal Paging was cancelled via CSView, Modem, or User Interface.

Modem: Page Failed:_. Y Normal The pager was not able to be dialed, check the phone line and number.

Email Sent OK. Y Normal e-mail message sent to server,

EPO Activated (Serial Data). N Error EPO activated via internal serial link.

Modem: Page Sent OK:_. Y Normal Paging was successful.

Email Send Failure. Y Error Unable to send e-mail to mail server, check Mail Server IP,

Cleared Password Enables. Y Service Password cleared via CSView,

Invalid Access Passcode Entered. Y Service

The incorrect Access passcode was entered. A modem connection must be established, a service password must be entered, and then the access passcode can be entered.

MODBUS: Task Suspending. The Modbus option is enabled but disconnected.

MODBUS: Connection Made. The Modbus option is enabled but disconnected.

Accepted service mode password authorized for 30 minutes. Y Normal Service engineer’s password has been

accepted.

Remote EPO Activated. N Error Remote EPO is received by remote panel (hard wired).

Table 8. System Conditions


Remote Access Enabled. Y NormalAll condition have been met for remote access and the access code has been entered at the User Interface.

_Password accepted authorized for 30 minutes. Y Normal Password accepted.

MODBUS: Disconnected. The Modbus option is enabled but disconnected.

Unknown System Message Type Received:_.

This message may appear only during a power-down

Time Changed Y Service Time change entered via CSView and accepted.

Discharge blocked N Service Discharge locked out by service engineer (manual mode).

Discharge Open. Y/N Service Service engineer has removed the discharge lock out.

EPO Activated. N Error EPO activated via the EPO button on the front door panel.

Event Log Erased. Y Service Event log was erased.

Remote EPO (Serial Data). N Error Remote EPO is received by internal serial link.

Timeout waiting for Static Switch to walk-in. N Error Static switch failed to walking in AC to utility

converter, check the static switch module.

Modem Telemetry terminated. Y/N Normal Call ended.

_Field Service password accepted for 30 minutes. Y Normal Service engineers password accepted.

Password key had expired. Y Normal Internal timer causes the password to expire.

Invalid password key entered. Y Error Invalid password has been entered.

APS date is invalid please reset. Y Error Password access cannot be granted until date and time are set.

Phase Rotation Bits in invalid state. N Error At start-up the input phases were in an illegal state. Phase rotation must be clockwise.

Modem telemetry initiated Y/N Normal Call received over the modem.

System will not auto-start calibration not complete. N Service Start-up or service condition is waiting for

completion of calibration.

MessageSupportLoad

Status Description

Table 8. System Conditions (Continued)


Error Messages

MessageSupportLoad

Status Description

Input Current Overload Cleared high phase:_ Y Normal Overload Condition Cleared.

Input Overload phase_ of rated input current Y/N Error Overload Condition. Reduce the load.

System_ Fuse Failure. A control power fuse in the system cabinet is open. Call Active Power Customer Service.

Output Current Overload 30 Sec.A:_ B:_ C:_ Y/N Error Overload Condition. Reduce the load.

Input Current Overload 30 Sec.A:_ B:_ C:_ Y/N Error Overload Condition. Reduce the load.

Output Current Overload Cleared high phase:_ Y Normal Overload Condition Cleared

Overload Cleared Power at_ KW Y/N Error Overload Condition Cleared

Bypass Phase Range Err: A:_ B:_ C:_

In a dual source system the bypass source is available but not within Spec. Call Active Power Customer Service.

Output Current Bypass Overload A:_ B:_ C:_ Y/N Error Overload Condition. Reduce the load.

Output Current Overload 10 Min.A:_ B:_ C:_ Overload Condition. Reduce the load.

System Fuse Failure A control power fuse in the system cabinet is open. Call Active Power Customer Service.

Input Current Overload 10 Min.A:_ B:_ C:_ Y/N Error Overload Condition. Reduce the load.

Operator switched system keyswitch Online Y Normal Operator turned the keyswitch to the On-

Line position.

Starting walk-in to input source Y Normal Walk-in of load to the input source after discharge.

Starting voltage phase match Y Normal Phase matching after discharge.

Zigzag K5 contactor error ErrorIn a 4-w system, the neutral contactor did not close during a discharge. Call Active Power Customer Service.

Zigzag Circuit Breaker open error ErrorIn a 4-w system, the zigzag circuit breaker is not closed. Call Active Power Customer Service.

Zigzag Controller lost frequency lock

In a 4-W system, the Zigzag controller cannot detect a frequency. This could be a power-down message. Call Active Power Customer Service.

Zigzag Overload Relay Trip The Zigzag Overload Relay has Tripped. Call Active Power Customer Service.

Table 9. Error Messages


Bypass Static Switch Fuse has failed

A Static bypass option fuse is open. Call Active Power Customer Service.

Output Under Voltage: A:_f B:_f C:_ Y Discharge System supporting load with flywheel energy.

Output Over Voltage: A:_B:_ C:_ Y Discharge System supporting load with flywheel energy.

Output Current Overload 2 Min.A:_ B:_ C:_ Y/N Error Overload Condition. Reduce the load.

Ground Fault Detected A ground fault was detected on a 3-W system.Call Active Power Customer Service.

System PS_ OKAY Normal The system cabinet control power supplies are O.K.

Zigzag Circuit Breaker Trip Error The Zigzag Circuit Breaker is open. Call Active Power Customer Service.

Zigzag Fuse Blown In a 4-W system, the Zigzag neutral fuse is open. Call Active Power Customer Service.

Utility walked in to output power level Y Normal Message at the end of discharge indicating

utility power restored.

Discharge ended max. duration exceeded at_0 RPM Y Normal System was discharged for the maximum

duration (2 minutes).

Operator switched UPS to Bypass at_0 RPM N Normal Operator turned the keyswitch to the

Bypass position.

Overload Cleared_ rated KW Overload Condition Cleared

10 Min. Overload_ rated KW Overload Condition. Reduce the load.

Output Overload phase_ of rated output current Overload Condition. Reduce the load.

2 Min. Overload_ rated KW Overload Condition. Reduce the load.

Input Power has counterclockwise phase rotation N Service

Phase rotation is C, B, A. This is incorrect and must be corrected before continuing with startup. Call Active Power Customer Service.

Input Power has clockwise phase rotation Y Normal Phase rotation is A, B, C. This is correct.

LOAD IS DISABLED Phase Rotation Error N Error

Phase rotation is C, B, A. This is incorrect and must be corrected before continuing with startup. Call Active Power Customer Service.

Under Frequency Detected @_ Hz Y Discharge Line frequency out of tolerance, flywheel is supporting the load. Call Active Power Customer Service.

Over Frequency Detected @_ Hz Y DischargeFrequency has deviated outside of the specification, the flywheel is supporting the load.Call Active Power Customer Service.

30 Sec. Overload_ rated KW Overload Condition. Reduce the load.

MessageSupportLoad

Status Description

Table 9. Error Messages (Continued)


Input Over Voltage: A:_ B:_ C:_ Y Discharge Line voltage is out of tolerance, the flywheel is supporting the load

Password has expired Y Normal Password needs to be updated

Timeout waiting for_ to change N Error Contactor did not close when command was sent. Call Active Power Customer Service.

System PS_ Failure N Error System Power Supply Failure. Call Active Power Customer Service.

UPS in Bypass N Normal/Error

Normal message if keyswitch is in the Bypass position, otherwise this message is associated with an error state. Call Active Power Customer Service.

Discharge Enabled Y Normal System is at 4000 RPM or above and can support the load

Discharge complete Duration:_ sec. Y/N Normal System completed a discharge and recorded a time

Discharging Y Normal System supporting load with flywheel energy

UPS Online Y Normal Flywheel reached discharge enable speed, UPS on-line

System Power Up N Normal Start-up Message

Input Under Voltage: A:_ B:_ C:_ Y Discharge Line voltage out of tolerance, flywheel is supporting the load

Discharge Disabled N Normal System is not at speed to support the load

Fast Voltage Trip Discharging at_ RPM Y Discharge System supporting load with flywheel

energy

System Fan_ OKAY Y Normal System Fan Failure Cleared

System Fan_ Failure Y Error System Fan Failure. Call Active Power Customer Service.

High room temperature reported Y/N Error Room temperature is to high

Fire Alarm Detected Y Normal Customer supplied input to the SIO has closed

Building Alarm 4 Detected Y Normal Customer supplied input to the SIO has closed




Remotely switched UPS Online Y/N Normal Operator placed the UPS on-line via remote contacts

Remotely switched UPS to Bypass at_Of RPM N Normal Operator placed the UPS is Bypass via

remote contacts

MessageSupportLoad

Status Description



UPS Conditions

Discharging at_RPM_KW Y Normal System supporting load with flywheel energy

System will not auto-start AC Voltages not in range N Error Voltage out of range. Call Active Power

Customer Service.

High reported room temperature has cleared Y Normal High room temperature warning cleared

Input source is now the Utility Y/N Normal The input source is utility

Fast Voltage Trip Discharge @_RPM_KW Y Discharge System supporting load with flywheel

energy

Discharge Low Trip + DC Bus:_ DC Bus:_ Y Discharge System supporting load with flywheel

energy

Discharge Trip: Low phase_ Volts Y Discharge Fast Voltage Transient out of tolerance, flywheel is supporting the load

Input source is now the Gen Set Y/N Normal The input source is the generator

Discharge High Trip + DC Bus:_ DC Bus:_ Y Discharge System supporting load with flywheel

energy

System will not auto-start power level not in range N Error Power out of range. Call Active Power

Customer Service.

Discharge Trip: High phase_ Volts Y Discharge Fast Voltage Transient out of tolerance, flywheel is supporting the load

Output Overload_rated KW Y/N Error Overload Condition. Reduce the load.

MessageSupportLoad

Status Description

Online Mode Requires _MMUs only _ ready N Error

The load is more than the number of on-line MMUs can support. Check the status of the MMUs

Flywheel Master Enable Bit Low Error N Error

Error with the flywheel will not allow the flywheel to spin. Call Active Power Customer Service.

Static Switch Phase A Shorted N ErrorThe controller has detected a shorted main static switch. Call Active Power Customer Service.

Static Switch Phase B Shorted N Error The controller has detected a shorted main static switch. Call Active Power Customer Service.

Static Switch Phase C Shorted N ErrorThe controller has detected a shorted main static switch. Call Active Power Customer Service.

Table 10. UPS Conditions

MessageSupportLoad

Status Description



Operator switched MMU Offline at _Of RPM N Error

Operator switched the MMU offline. Place MMU back on-line by turning keyswitch to on-line position.

Verifying Flywheel signals and status N Normal Startup Sequence

MMU Overload 2 Min._ rated KW Y/N Error Overload Condition. Reduce the load.

MMU Overload _ rated KW Y/N Error Overload Condition. Reduce the load.

MMU Overload 10 Min._ rated KW Y/N Error Overload Condition. Reduce the load.

MMU Overload Cleared_rated KW Y Normal Overload Condition Cleared

MMU Overload 30 Sec._ rated KW Y/N Error Overload Condition. Reduce the load.

MMU Bypass Overload Level _KW Y/N Error Overload Condition. Reduce the load.

_ sensing failed N Error Contactor position sensing has failed. Call Active Power Customer Service.

Code update: failed device could not be programmed N Service

Firmware has failed to be loaded, check communication connection and setpoints. Call Active Power Customer Service.

RPS Advance Calibration Done Position: _ Y/N Service Startup/Calibration Message

Remote Access Jumper Installed Y Normal The necessary jumper for remote access has been installed

Remote Access Jumper Removed Y Normal The jumper for remote access has been removed

Code update: receiving data N Normal The firmware is being transferred to the UPS

Code update: updating flash N Normal The firmware is reprogramming the flash memory

Operator switched to Voltage Regulation Mode N Service System switched to voltage regulation mode

via CSView

Code update: abort requested N Service Service engineer requested abort of firmware upload

Spindown with Voltage Regulation N Service The flywheel is in spindown with voltage regulation

Code update: failed not in programming mode N Service Firmware not set to receive program upload.

Call Active Power Customer Service.

Code update: failed timed-out waiting for data N Service

Firmware has failed to be loaded, check communication connection and setpoints. Call Active Power Customer Service.

Connected: _ Y Normal CSView was connected

Disconnected: _ Y Normal CSView was disconnected

Voltage Regulation Only mode N Error Check for other error messages

Code update: successful N Normal The firmware was successfully reprogrammed

Discharge ended min. discharge RPM reached at _ RPM N Normal System was fully discharged

MessageSupportLoad

Status Description

Table 10. UPS Conditions (Continued)


T1 Control Power Failure N Error T1 fuses failure. Call Active Power Customer Service.

T2 Control Power Failure N Error T2 fuses failure. Call Active Power Customer Service.

Flywheel preheat not required temp = _ C N Normal Preheat is not required if flywheel is above

30C

Loaded _ Hz Default Operating Parameters Y Normal The default setting for a specific frequency

were loaded (50Hz or 60Hz)

Output Voltage Phase Error caused by Load Fault Y/N Error A fault occurred on the output of the UPS.

Call Active Power Customer Service.

Operator switched local keyswitch Online Y Normal Operator turned the keyswitch to the On-

Line position

Online Command received from CSView Y/N Service System placed in On-Line mode via CSView

Waiting on ground fault to be cleared N Error

Waiting on Zigzag Circuit Breaker reset N Error Call Active Power Customer Service.

MMU In Current Overload Clear high phase: _ Y Normal Overload Condition has cleared

Power Up N Normal Start-up Sequence

Discharge blocked N Service Discharge locked out by service engineer (manual mode)

Discharge open Y/N Service Service engineer has removed the discharge lock out

MMU Out Current Overload 10 Min. A: _ B: _ C: _ Y/N Error Overload Condition. Reduce the load.

MMU Out Current Overload 2 Min. A: _B: _C: _ Y/N Error Overload Condition. Reduce the load.

MMU Out Current Overload 30 Sec. A: _ B: _C: _ Y/N Error Overload Condition. Reduce the load.

MMU Out Current Overload Clear high phase: _ Y Normal Overload Condition Cleared

MMU In Current Overload 10 Min.A: _ B: _ C: _ Y/N Error Overload Condition. Reduce the load.

MMU In Current Overload 30 Sec.A: _ B: _ C: _ Y/N Error Overload Condition. Reduce the load.

MMU Out Current Overload high phase: _ Y/N Error Overload Condition. Reduce the load.

MMU In Current Overload high phase: _ Y/N Error Overload Condition. Reduce the load.

MMU waiting on flywheel error to clear N Error Flywheel Error

Error cleared energizing flywheel Y/N Normal Error is cleared and the flywheel will be energized

MessageSupportLoad

Status Description



MMU Out Current Bypass Overload A: _ B: _ C: _ Y/N Error Overload Condition. Reduce the load.

MMU In Current Bypass Overload A: _ B: _C: _ Y/N Error Overload Condition. Reduce the load.

MMU Inverter Current Overload A: _ B: _ C: _ Y/N Error Overload Condition. Reduce the load.

Cleared Invrtr Current Overload A: _ B: _ C: _ Y/N Error Overload Condition. Reduce the load.

MMU In Current Overload 2 Min.A: _ B: _ C: _ Y/N Error Overload Condition. Reduce the load.

Bottom Field Coil Fault N Error Field coil current error. Call Active Power Customer Service.

Top Field Coil Timeout N Error Field coil current error. Call Active Power Customer Service.

Bottom Field Coil Timeout N Error Field coil current error. Call Active Power Customer Service.

Overspeed Error N Error System reached speed higher than the setpoint. Call Active Power Customer Service.

RPS Error Y Error Call Active Power Customer Service.

Skiip 1 Error N Error Call Active Power Customer Service.



Error: Contactor _

Skiip A Error N Error Call Active Power Customer Service.

Skiip B Error N Error Call Active Power Customer Service.

Skiip C Error N Error Call Active Power Customer Service.

Closed K2 Y Normal Call Active Power Customer Service.

MMU Utility Phase C Error N Error Call Active Power Customer Service.

MMU Utility Phase B Error N Error Call Active Power Customer Service.

MessageSupportLoad

Status Description



INSTALLATION

INSTRUCTIONS


PRODUCT IDENTIFICATION INFORMATION

Location of Serial Number Label

The system serial number label is affixed to the outside of the cabinet door. The serial number will be a seven digit number starting with the number 5(50XXXXX).

User Interface Panel Key Location

Figure 49. User Interface Panel Key

Remove the User Interface Key from the top rail of the system cabinet and insert it in the keyswitch on the User Interface panel or place it in a safe location.

INSTALLATION CONSIDERATIONS

Install this UPS in accordance with the illustrations in this manual and the following procedures.

An Active Power authorized representative must perform the initial system check-out and start-up to ensure proper system operation. Equipment warranties will be voided unless system start-up is performed by a Active Power authorized representative. Contact your local Active Power sales representative or Active Power Customer Service at 1-800-288-5081 to arrange for system start-up.

User InterfaceKey Location


CAUTION

Read this manual thoroughly before attempting to wire or operate the unit. Improper installation is the most significant cause of UPS start-up problems.

It is preferable to install the system in a restricted location to prevent access by unauthorized personnel.

1. Proper planning will speed unloading, location, and connection of the UPS. Refer to the drawings in this manual.

2. Use the shortest cable runs possible, consistent with logical equipment arrangements and with allowance for future additions if planned.

3. Operating temperature range is 0oC to 40o C. Relative humidity must be less than 95% without condensation. Room ventilation is necessary. Ensure that the environ-mental conditioning system can accommodate the BTU load, even during utility out-ages.

4. Be certain that the floor at the final equipment location and along the route (inside the facility) to the installation site can support the UPS weight and the weight of any mate-rial handling equipment. The UPS module can weight up to 5700 pounds.

5. Plan the routing to ensure that the UPS can move through all aisleways, doorways, and around corners without risking damage. If the UPS must be moved by elevator, check the size of the door opening and the weight carrying capacity of the elevator.

EQUIPMENT LOCATION

1. Handle the UPS in accordance with WARNINGS in Unpacking Instructions. Use a suitable material handling device to move the cabinet(s) to its final location. Exercise extreme caution because of the uneven weight distribution.

2. Place the UPS in a reasonably clean, dust-free environment. Air must be free to circu-late around the cabinet. The UPS pulls air through the front doors of the unit and exhausts it out the top for cooling. Adequate ventilation, including air conditioning, must be provided to limit heat accumulation in hot weather. The ambient temperature for the unit must be between –20oC and 40oC (-4oF and 104oF). There is a 0oC mini-mum ambient temperature requirement for start-up of the unit. Once the UPS has been running for some time, it will keep itself warm enough in ambient temperatures as low as 0oC. However, bearing temperatures should be 20oC or higher at start-up. Preheating of the rotor will be performed by the flywheel system if necessary for colder environments.

3. Make sure that the floor can support the weight of the UPS and any other necessary equipment.

4. The required service clearance is 36” from the front of the UPS. The sides of the UPS can be placed against walls (assuming minimum distance from edge of floor). How-ever, when available, space behind the UPS will facilitate easier cable runs.

5. The ceiling height must be a minimum of 8 ft. The unit vents air out of the top. Loose ceiling tiles above the unit may be moved by the airflow.

6. The UPS should not be operated in a sealed room or container without specific cli-mate control that meets the minimum system specifications.

!


7. If you have purchased the CSView monitoring software, you may need to plan for the installation of the RS-232 or 485 cable from the system to the chosen local computer connection. For remote monitoring, a modem or Ethernet option and phone line or local network connection are required to interface to with CSView.

8. Plan to have appropriate communication cables installed to support the remote notifi-cation and monitoring option chosen.

9. Electrical connections can enter through the top or bottom of the Bypass cabinet.

SYSTEM INSTALLATION

Figure 50. Anchoring Cleats and Bolts (Example Only)

The UPS must be anchored to a concrete slab that is fully cured. The slab should be poured with a minimum of 3000 psi concrete. Existing slabs should be free from cracks and seams in the vicinity of the installation. Refer to the figures in the section for Anchoring in order to determine the requirements for the positioning of the slab.

The following tools and equipment are required:

• Transport system (forklift or pallet jack 3.0 ton capacity (typical width 20 ½” but needs to be less than 24”)

• 1/2” drive socket wrench• 3/4” socket, 1/2” drive• 36” extension bar, 1/2” drive• 15/16” open end wrench


• Anchor bolts (4 ea.)

Anchor Bolt Specifications

Install the anchors in accordance with the manufacturer’s specifications. The anchors must meet the following specifications:

• 5/8 X 6 inch length (min.) Hilti Kwik Bolt II stud expansion with 4 inch minimum embedment anchor bolts must be used for the proper interface to the frame.

• The maximum shear load capacity per anchor must be 7650.9 N (1720 lb.).• The maximum tensile load capacity per anchor is 3113.8 N (700 lb.).

When the thickness of the slab or the strength of the concrete is unknown consult “Section 1923 of the Uniform Building Code” or contact Active Power Customer Service.

CAUTION

The flywheel is shipped with bearing retainers installed to relieve the bearing of transient forces that may be encountered during shipping and handling. Do not attempt to remove the retainers or operate the unit until it is properly bolted to its floor anchors. The bearing retainers are to be removed only by Active Power certified personnel during the final inspection and before initial pre-startup.

System Anchoring

1. Locate position for drilling holes.

2. Drill core holes for anchor bolts.

3. Lift the system off of the ground using a forklift or pallet jack.

4. Remove the mounting cleats.

5. Bolt the mounting cleats to the floor.

6. Slide the system onto the mounting cleats.

7. Bolt the system to the mounting cleats.

System anchoring is complete.

Seismic Requirements

Zone 4 Seismic qualified Flywheel. Compliance with this standard is based on calculations.

Note:

A Seismic Anchoring Kit is available. Contact your Active Power sales representative.

WIRING CONSIDERATIONS

AC Power Wiring Connections

Refer to the drawings in this manual and any other drawings provided by Active power to wire this UPS. Determine AC currents for your system based on kVA, voltage, and options. Also refer to equipment nameplates for the model number, rating, and voltage.

!


CAUTION

All Power connections must be completed by a licensed electrician that is experienced in wiring this type of equipment. Wiring must be installed in accordance with all applicable local and national electrical codes. Improper wiring may cause damage to the equipment or injury to personnel.

Verify that all incoming high and low voltage power circuits are de-energized and locked out before installing cables or making electrical connections.

Install the system per the National Electrical Code (NEC) and local codes. Cable and conduit sizes are based on the information from the Table of Specifications for your particular unit.

The system is designed for the cable to enter the cabinet top or the bottom. Removable access plates should be cut in order to accommodate the conduit size. Input cables and output cables must be run in separate conduits.

The connection terminals are drilled for 1/2 inch hardware and spaced for one or two hole NEMA lugs. Connection terminals can be oriented for top entry or bottom entry. Doing so minimizes the number of bends. Space limitations require smaller parallel cables. Using smaller cables reduce the risk of damage to the unit while pulling the cable.

Note:

The lugs and the cable are not supplied. Refer to NEC Article 210-19 and the NEC Table 310-16 for the correct size of the cables. Refer to NEC Article 250-95 for the correct size of the ground. Refer to NEC Article 310-15 for the correct size of the neutral. The torque for the wire connections is 61 Nm (45 ft-lb.).

A service disconnect device must be installed. This device must be properly rated for the output power.

• All shielded cables, non-shielded cables, non-shielded control wires and non-shielded remote control wires must be housed in individual, separate conduit or cable tray. Placing multiple cables in the same conduit with other control or power wiring may cause system failure

• Observe local, state and national electrical codes. Verify utility power and its overcur-rent protection rating will accommodate the UPS input rating.

• A safety ground wire must be run from building ground to ground point in the UPS Module Cabinet. The grounding conductor shall comply with the following conditions of installation:

• The insulated grounding conductor must be sized in accordance with the NEC (in the USA) and local and national codes. It must be installed as part of the branch circuit that supplies the unit or system.

• The grounding conductor described above is to be grounded to earth at the service equipment or, if supplied by a separately derived system, at the supply transformer or motor-generator set.

• The attachment-plug receptacles in the vicinity of the unit or system are all to be of a grounding type, and the grounding conductors serving these receptacles are to be connected to earth ground at the service equipment.

• Observe clockwise phase rotation of all power wiring. Phase A leads, Phase B leads, and Phase C leads. A qualified electrician should check the phase rotation.

!


CAUTION

The weight of the power cables must be adequately supported to avoid stress on the bus bars and lugs.

• The installing contractor can remove the access plates from the top or bottom of the cable access areas of the UPS in order to cut entry holes for conduit.

CAUTION

After cutting holes in the access plates, be certain that no foreign matter (metal shavings, sawdust, insulation or wire fragments, etc.) remain inside the UPS. Likewise be certain to block any “extra” holes in the plates through which foreign matter could later enter the UPS.

• The following three-phase power cables are connected in the Bypass cabinet:

Input Cables

Output Cables

Ground Cables

Neutral Cables

Note:

Neutral cables are used only in four-wire systems.

WARNING

Underwriters Laboratories requires that this system must be installed with an appropriately rated service disconnect device for the output power (not supplied).

If required by local and/or national regulations, an appropriately rated service disconnect device for input and output power must be provided.

There are two 12-gauge galvanized steel panels that are removable. The panels are provided for the entry of cables into the UPS. One panel is located on top of the Bypass cabinet and the other panel is located on the bottom of the Bypass cabinet.

The three-phase AC input and three-phase AC output cables are connected to a plated copper bus bar. The holes are spaced for 2 hole NEMA lugs with barrels.

Note:

The AC cable and lugs are supplied by the customer.

The ground cable is connected to a plated copper bus bar. The bus bars are drilled for 3/8 inch hardware. The holes are spaced for 2 hole NEMA lugs with barrels.

Note:

The Ground cable and lugs are supplied by the customer.

The tab on the plated copper bus bar must be inverted in order for the cable to be installed from the bottom of the cabinet.

!

!

!


Overcurrent protection must be provided externally to the UPS. Overcurrent protec-

tion must conform to local and national codes.

NEC Customer Conductor Sizing Requirements (480 Volt Rated Products)

Note:

Refer to NFPA 70, National Electrical Code (NEC), 2002 edition. Requirements of local codes may vary from these shown. Compliance with all codes is the responsi-bility of the installer.

Table 11. 25 Degree Celsius, Three Conductors per Conduit (3-Wire Product)

Table 12. 25 Degree Celsius, Four Conductors per Conduit (4-Wire Product)

480V Rated Products25 degree Celsius, 3 conductors per conduit (3 wire product)

Wire Size,

AWG or kcmil UPS 300 UPS 150

4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 2 2

300 2 2

350 2 2

400 2 2

500 2 2

25 degree Celsius, 4 conductors per conduit (4 wire product)

Wire Size,


4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 na na

300 na na

350 2 2

400 2 2

500 2 2




NEC Customer Conductor Sizing Requirements (380, 400, 415 Volt Rated Products)

Note:

Refer to NFPA 70, National Electrical Code (NEC), 2002 edition. Requirements of local codes may vary from these shown. Compliance with all codes is the responsi-bility of the installer.


Wire Size,


4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 na na

300 na na

350 2 2

400 2 2

500 2 2


W ire Size,

AW G or kcmil UPS 300 UPS 150

4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 na na

300 na na

350 na na

400 na na

500 2 2




380, 400, 415V rated products25 degree Celsius, 3 conductors per conduit (3 wire product)

Wire Size,

AWG or kcmil UPS 150i UPS 250i

4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 2 2

300 2 2

350 2 2

400 2 2

500 2 2


W ire Size,

AW G or kcmil UPS 150i UPS 250i

4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 na na

300 na na

350 2 2

400 2 2

500 2 2




1. Use 75 degree C wire.

2. Recommended wire sizes are based on NFPA 70, National Electric Code (NEC) 2002 Edition. Local, national, or other applicable codes must also be observed


W ire Size,


4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 na na

300 2 2

350 2 2

400 2 2

500 2 2


W ire Size,


4 na na

3 na na

2 na na

1 na na

1/0 na na

2/0 na na

3/0 na na

4/0 na na

250 na na

300 na na

350 na na

400 na na

500 2 2


Table 19. Lugs and Dies for Connections Secured with 1/2” Bolts

WIRE SIZE PANDUIT LUG PANDUIT CRIMPDIE

BURNDY LUG BURNDY CRIMPDIE

250 LCD-250-12-X YELLOW 62 YA292LN YELLOW 16

350 LCD-350-12-X RED 71 YA312LN RED 18

400 LCD-400-12-6 BLUE 76 YA322LN BLUE 19

500 LCD-500-12-6 BROWN 87 YA342LN BROWN 20

1 LCD1-12-E GREEN P37 YA1C2LN GREEN 11

2 LCD2-12-Q BROWN P33 YA2C2LN BROWN 10

3 N/A N/A N/A N/A

4 N/A N/A YA4C2LN GRAY 8

1/0 LCD1/0-12-X PINK P42 YAV25L2NTCFX PINK 12

2/0 LCD2/0-12-X BLACK P45 YA262LN BLACK 13

3/0 LCD3/0-12-X ORANGE P50 YA272LN BLACK 13

4/0 LCD4/0-12-X PURPLE P54 YA282LN PURPLE 15


Cable Connection

Note:

Ensure that proper phase rotation is maintained at all times.

1. Route the AC power cables through the holes that are for the entry of the cable. The holes are punched in the galvanized steel panel.

2. Connect the three-phase AC input cables to the bus tab that is for power distribution. The bus tab is located in the bypass cabinet. Torque the cables to 61 Nm (45 ft-lb).

3. Connect the three-phase AC output cables to the bus tab that is for power distribution. The bus tab is located in the bypass cabinet. Torque the cables to 61 Nm (45 ft-lb).

4. Connect the ground cable to the plated copper bus tab that is located in the Termina-tion cabinet. Torque the ground cable to 61 N m (45 ft-lb).

Control Wiring

CAUTION

Control wiring must be stranded and run in individual separate steel conduit. Control wiring must be separated from power wiring. Route control wiring as far away from power cables as possible to minimize Electro Magnetic Inter-face (EMI).

Customer interfaces are accessible through dry contacts on the System Input/Output (SIO) Board located on the left component panel in the UPS cabinet.

The UPS has a total of six (6) input and six (6) form “C” output contacts available for customer use.

The UPS also accepts serial connection for monitoring and control.

!


Control Wire Terminal Connections

Figure 51. Customer Interface Board Locations (Typical)

To gain access to the dry contacts in the UPS cabinet:

1. Open the UPS cabinet door.

2. Remove the two (2) screws holding the access panel cover in place.

The dry contacts will be located on the SIO board on the left component panel.


System Input/Output Board

Figure 52. System Input/Output Board (Typical)

Table 20. System Input/Output Board Reference Designators

1. J7 Remote Emergency Power Off (EPO) Contacts 7. J10a Modem RJ11

2. J14 Remote Input Contacts 8. J9 Ether Net

3. J6 Remote Output Contacts 9. J1 RS-232/RS-485 9 Pin Connector

4. J12 Device Net 10. J8 UPSNET/CAN A

5. J16 Modem DB 9 11. J4 24 VDC Power in

6. J10 Modem RJ45


System Input/Output Daughter Board

Figure 53. System Input/Output Daughter Board (Typical)

Table 21. System Input/Output Daughter Board Reference Designators

1. J8 Backup UPS NET 3. J1 RS-485

2. J5 Remote Panel Out

4. J4 24 VDC Power In


Remote Emergency Power Off (REPO) Contacts (J7)

Figure 54. Remote Emergency Power Off Contacts (J7)

The Remote Emergency Power Off contacts allow for connection of a Remote Emergency Power Off (REPO) Button external to the UPS. The REPO Button is equivalent to the local Emergency Power Off Button. The REPO contacts (J7) are located on the System IO board.

Terminal J7 has two sets of contacts that operate independently of each other.

• Normally open (terminals 1 and 3)• Normally closed (terminals 2 and 4)Note:

The system is shipped with a jumper connected across the normally closed contacts (terminals 2 and 4). If the normally closed contacts are used remove the jumper. If the normally open contacts (terminals 1 and 3) are used do not remove the jumper.

WARNING

When the REPO Button is used, high voltage may still be present on the input terminals. Customer supplied input breakers may or may not be disabled.

The REPO Button circuit is considered a control circuit (EVL circuit) and the wiring must be routed separately from the Class 2 (SELV) wiring.

Use NEC Class 1 wiring methods. A dedicated conduit is required.

Jumper

J7

!


il

il

il

il

il

il

From Customer Optional Monitoring Interface(s)

To UPS Cabinet Connection Type Wire Type Description

System I/O Board J1

DB9 (female) 9 wire serial cable Monitoring Da-ta(1)

System I/O Board, J9

RJ45 8-pin Cat 5, 4-pair UTP-24 AWG (unshield-ed)

Ethernet(1,2)

System I/O Board, J14-7

Terminal Block 24-12AWG, Twist-ed Pair

Input 1-relay co(-) (1,2,3)


Terminal Block 24-12 AWG, Twist-ed Pair

Ground(1,2,3)






Ground(1,3)





Terminal Block 24-1 2AWG, Twist-ed Pair

Ground(1,2,3)






Ground(1,2,3)






Ground(1,2,3)






Ground(1,2,3)



Output 1-N.O.(1,2,3)



Common(1,2,3)



Output 1-N.C.(1,2,3)






Common(1,2,3)









Common(1,2,3)



Output 3-N.C(1,2,3)




Table 22. Control Wiring


Dry Contact Relays

All contacts can be configured with CSView to indicate if certain conditions exist. The contacts are located on the System I/O board.

Each input is intended to interface to a single-pole single-throw switch. The switch connects the pair of contacts or the switch disconnects the pair of contacts. The contacts that are user programmable have an operating parameter that is used to configure that contact.



Common(1,2,3)









Common(1,2,3)









Common(1,2,3)






Remote EPO Ground (1,4)



Remote EPO Ground (1,4,5)



Remote EPO N.O. (1,4)



Remote EPO N.C. (1,4,5)

(1) Cable(s) not supplied.

(2) Suitable for connections to NEC Class 2/SELV circuits only.

(3) Programmable discrete signals.

(4) Use NEC Class 1/ELV wiring methods.

(5) Remove factory jumper to use these terminals.

Table 22. Control Wiring (Continued)


The following list of functions can be assigned to the contacts for the remote input block by entering the parameter in the operating parameter for the associated remote input.

Function List for Input Contact

Function Description

0 Disabled - No function

1 On Genset - When the On Genset function is activated, operational settings can be made for Transient Voltage Detection, Maximum Input Current, and Walk-in Rate.

2 Remote Bypass - Remote switch of UPS to Bypass

3 Remote Online - Remote switch of the UPS to On-line condition - only if no errors are active.

4 Building Alarm 1 - an external Alarm output contact is triggered.




8 Fire Alarm - an external Alarm output contact is triggered.

9 Remote Silence - silences the buzzer, or a Notice or Alarm is active.

10 Genset Breaker Open - prints a Breaker Open message when the input is activated and a Breaker Closed message when the input is deactivated.

11 Abnormal Room Temperature - prints a message indicating that the input is activated or deactivated.

12 Synchronize to the External Source

13 User Notice Message 1 - used to configure the user text messages displayed by CSView.

14 User Notice Message 2 - used to configure the user text messages displayed by CSView.

15 User Alarm Message 1 - used to configure the user text messages displayed by CSView.

16 User Alarm Message 2 - used to configure the user text messages displayed by CSView.

17 User Normal Message 1 - generates event status

18 User Normal Message 2 - generates event status

19 GSO Group A Open - Monitor status of any installed GenStart Module

20 GSO Group B Open - Monitor status of any installed GenStart Module

21 GSO Group C Open - Monitor status of any installed GenStart Module

22 GSO Group D Open - Monitor status of any installed GenStart Module

23 Remote Spindown - Send UPS to Bypass Spindown

24 Online Inhibit - Inhibits Online Operation

Table 23. Function List for Input Contacts


The following tables show the function list for the input contacts and the default function.

Table 25 shows the function list for the output contacts and Table 26 shows the default function.

Table 25. Function List for Output Contacts

Default Function Assignments for Input Contacts

Contact Function Description

1 1 On Generator

2 2 Remote switch from UPS to Bypass

3 3 Remotely switch the UPS to Online status - this is done only if there are no errors active.

4 4 Building Alarm 1



Table 24. Default Function Assignments for Input Contacts

Function List for Output Contact

Function Description

0 No function1-100 Flywheel Percent Energy - the flywheel has the programmed percentage of usable energy available

and the system is online.101 Online (normal)102 On Bypass103 Flywheel Discharging104 A Notice condition on an Alarm condition is active.105 Alarm condition is active.106 Overload107 Cabinet over temperature108 External Alarm - this is activated by programming remote inputs to any of the Building Alarms or the

Fire Alarm functions.109 GSC unavailable110 Overload Bypass - the system is in Bypass because of an overload condition.111 Fusible Link Error - The fusible link for the DC Bus Capacitor is open.112 Fan Error113 Run Genset - Used with GenSTART. Enables manual start.114 Pulsed Start Genset - Used with GenSTART. Enables manual start.115 Pulsed Stop Genset - Used with GenSTART. Enables manual stop.116 ATS Command - Used with operating parameter ATS Command Level. When in discharge and when

total available system energy drops below preset level, the contact closes.117 Motoring


GenSTART Module

Figure 55. GenSTART Module

The GenSTART option provides a redundant starting power source for a generator set. The GenSTART increases the standby power system reliability by ensuring that the generator is able to crank to start, thus removing the common cause of generator set starting failures which are dead starting batteries. The GenSTART can parallel power from the starting batteries to provide one reliable DC power source to the starting motor.

The GenSTART receives 3-phase 380/400/415/480 VAC power from a reliable power source such as a UPS. The GenSTART converts the AC voltage into 24 VDC for the starter motor. Unlike batteries, the GenSTART indicates its functional status by the Customer Status Contact output.

The Customer Status Contact output is a normally open or normally closed contact that is energized to indicate the module is in normal operating status. Specifically, the contact is energized whenever AC power is applied to the module, the input breaker is closed, the thermal switches are closed, and all internal fuses are good. In this state, the normally open contacts are closed and the normally closed contacts are open.

Default Function Assignments for Output Contacts

Contact Function Description

1 101 Online (normal)

2 102 On Bypass

3 103 Flywheel Discharging

4 50 Flywheel Percent Energy

5 104 Notice condition or an Alarm condition is active

6 105 Alarm condition is active

Table 26. Default Function Assignment for Output Contacts


The GenSTART can be wall mounted (standard) or floor mounted with the optional floor mounting kit. In either installation, the module should be securely fastened, as detailed in this manual, to a support rated to accept the loads of the GenSTART option.

GenSTART Module Specifications

Note:

See GenSTART manual for full specifications.

Note:

Use customer input contact for GenSTART status if wanted/needed.

Note:

Need separate external overcurrent protection for each GenSTART.

REMOTE STATUS PANEL

The Remote Status Panel allows the user to monitor various functions through the use of eight status lights.

Figure 56. Remote Status Panel

GenSTART Module Summary Specifications

Nominal Voltage 24 VDC (+10%/-30%) at 0 - 1000 amperes DC

Cold Cranking Amperes 1725 amperes DC

Output Current Rating 1000 amperes DC

Input Voltage 380 - 480 VAC, 3-Phase

Output Voltage 24 VDC

Table 27. GenSTART Module Summary Specifications

Bypass Unavailable - Amber LED

UPS Notice - Amber LED

On-bypass - Amber LED

Discharging - Amber LED

UPS Overload - Red LED

Low DC Voltage - Red LED

UPS Alarm - Red LED

Off-line - Red LED

Lamp Test Switch

Alarm Silence

Horn


Specifications

Wiring Connections

The panel is designed for flush mounting or surface mounting in a panel box. Use 18 AWG or larger wire. The wire will consist of 3 conductors. The wire consists of a data conductor, a ground conductor, and a power conductor. There are 14 screw connections on the back of the status panel.

Remote Status Panel Specifications

Description Value

Input voltage to panel 15 to 45 VDC

Power requirements 6 watts maximum

Height 270 mm (10.62 inches)

Depth 86 mm (3.37 inches)

Width 86 mm (3.37 inches

Weight 1.14 kg (2.5 lb.)

Distance from UPS <305 m (1000 ft.)

Horn output 80 db (A) nominal

Temperature range −40 οC (−40 οF) to 70 ο C (158 ο F)

Humidity 0 to 100% relative humidity

Emissions and Immunity IEC 801-2,3 and 4, EN 5082-2 EEC Certification 89/39/EEC

Table 28. Remote Status Panel Specifications


Figure 57. Remote Status Panel J5 Connector Orientation

Remote Status Panel Connections

From: Remote Status Panel To: System Input/Output Daughter Board Connector (J5)

Terminal 1 “+24 VDC” Pin 1

Terminal 2 “Serial data in” Pin 5

Terminal 3 “Spare”



Terminal 6 “Jumper to 7”

Terminal 7 “Ground” Pin 3


Terminal 9 “Jumper to 6”



Terminal 12 “Lamp test (1)”

Terminal 13 “Horn silence (1)”

Terminal 14 “Horn output (1)”

Table 29. Remote Status Panel Connections


Remote Emergency Power Off (REPO) Button

The REPO button is used to initiate an Emergency Shutdown of the system and disconnect power from the UPS.

Figure 58. Remote Emergency Power Off (REPO) Button

Specifications

Table 30. Remote EPO Button Specifications

Installation

Figure 59. Remote EPO Button Contacts

Remote EPO Button Specifications

Description Value

Wire in conduit 18 AWG (minimum)

Maximum distance from UPS 152 m (500 ft.)

Normally open contacts - Green Pins 3 and 4

Normally closed contacts - Red Pins 1 and 2


Normally Open Contact Configuration

Route wires from pins 3 and 4 in the REPO button to the Remote Emergency Power Off Contacts J7 located on the SIO board. See “Remote Emergency Power Off (REPO) Contacts (J7)”.

Normally Closed Contact Configuration

Route wires from pins 1 and 2 in the REPO button to the Remote Emergency Power Off Contacts J7 located on the SIO board. See “Remote Emergency Power Off (REPO) Contacts (J7)”.

The connection of the REPO button is complete.

Maintenance Bypass

The maintenance bypass option allows complete system isolation without load interruption to perform maintenance on the UPS system.

Four-Wire Input and Output (480 Volt 60 Hz)

This option is used when a neutral connection is required.

Three-Wire Input and Output (380 - 415 Volt 50/60 Hz)

This option can be used when loads may be fed from a distribution transformer.

Ready Kit

This option provides a spare parts kit for repair of the UPS.

Seismic tie-down

This option provides tie-down brackets to secure the UPS cabinet to the floor.


INITIAL SETUP PROCEDURE

CAUTION

Only Active Power Certified service personnel should perform initial startup of the system upon commissioning.

The following procedures are preformed before application of electrical power to the system.

Single Input - No Switches Initial Set-Up

Figure 60. Single Input - No Switches One Line Diagram

!


MMU FLYWHEEL

CONVERTER

UTILITY

CONVERTER

500 A

CLASS J

INPUT

CONTACTOR STATIC

SWITCH

LINE

INDUCTOR

FILTER

INDUCTOR

OUTPUT

CONTACTOR

F1-F3 K1 K2

INPUT

ISOLATION

SWITCH

OUTPUT

ISOLATION

SWITCH

BYPASS

CONTACTOR

K3

INPUT OUTPUT

200 A

CLASS J

SSF1-SSF3 K4

STATIC

SWITCH

CUSTOMER

MONITORINGCONNECTION


EPO-4 WIRES,


OUTPUT CONTACTS-18 WIRES RJ45 6-PIN (MODEM)


DB9 (SERIAL)

(OPTIONAL)

CUSTOMER

SUPPLIED

480 VAC3 PHASE 60 Hz.

3 WIRE AND GROUND

152 AAC NOMINAL320 AAC MAX CONTINUOUS


480 VAC3 PHASE 60 Hz.

3 WIRE AND GROUND

181 AAC NOMINAL

F1-F3

500 A

CLASS J






The system enters the “Bypassed-Auto Start” state and begins charging the flywheel. When the flywheel reaches a rate of 4000 RPM, the system shifts to the “Online” mode. The system is operational.


The installation of the UPS is complete. Contact Active Power Customer Support at 1-800-288-5081 for system commissioning.


SIngle Input - 3 Switches Initial Set-Up

Figure 62. Single Input - 3 Switches One Line Diagram

Figure 63. Single Input - 3 Switches, Front View


MMU FLYWHEELCONVERTER

UTILITYCONVERTER

500 ACLASS J

INPUT

CONTACTOR STATICSWITCH

LINE

INDUCTOR

FILTER

INDUCTOR

OUTPUT

CONTACTOR

F1-F3 K1 K2

INPUTISOLATION

SWITCH

OUTPUTISOLATION

SWITCH

BYPASSCONTACTOR

K3

MAINTENANCE

BYPASS SWITCH

OPTIONAL

INPUT OUTPUT

200 A

CLASS J

SSF1-SSF3 K4

STATICSWITCH

CUSTOMER

MONITORING

CONNECTION


EPO-4 WIRES,



RJ45 6-PIN (MODEM)

RJ45 8-PIN (NETWORK) DB9 (SERIAL)

(OPTIONAL)

CUSTOMER

SUPPLIED

480 VAC

3 PHASE 60 Hz.

3 WIRE AND GROUND

152 AAC NOMINAL



480 VAC

3 PHASE 60 Hz.

3 WIRE AND GROUND

181 AAC NOMINAL

F1-F3500 A

CLASS J








3. Confirm Bypass Switch is open.




The system enters the “Bypassed-Auto Start” state. The system begins charging the flywheel. When the flywheel reaches a rate of 4000 RPM, the system shifts to the “Online” mode. The system is operational.



SYSTEM SPECIFICATIONS (UPS 150i, 250i)

M ODEL 150 i 250 i

RATING 150 kVA 250 kVA

135 kW 225 kW

INPUT

Voltage

Frequency-nominal

Input Current-nominal amps 216/205/198 355/337/325



Power Factor

Harmonic Current Distortion

Linear Load

Non-linear Load

Surge Withstand

Walk-in

OUTPUT

Frequency-nominal

Current 228/217/209 380/361/348


Voltage regulation

Steady State

Flywheel Mode

Transient

Voltage Distortion

Overload Capability-normal operation

1000%

Up to 150%

Up to 125%

PHYSICAL DATA

Efficiency 97% 98%


Nominal/Worst case

Depth

Width

Total Height

Weight

Cable Access

ENV IRONM ENTAL

Temperature

Operating

Storage

Humidity

Altitude

Audible Noise


(1) +/-10% max at 380V


0.99 at rated load and nominal voltage

50 Hz +/- 10% max (programmable) (2)

380/400/415 +10%/-15% (programmable) (1)


Same as input

Input synchronized 50 Hz +/-0.1 Hz


Meets IEEE 587/ANSI C62.41


10 minutes

2 minutes

10 milliseconds


plus or minus within 50 mSec for 100% load step

plus or minus 1% for steady-state balanced or unbalanced loads


Top

5500 lb (2500 kg)

78 in (1980 mm)

64.6 in (1, 641 mm)

34.0 in (865 mm)

(2) Weights and dimensions are for 4-wire configurations

<70 dBA at 1 m (3.28ft)

FCC Class A, Subpart J of Part 15





Table 31. UPS 150i-250i 50 Hz Series Ride Through Times

UPS 150i


100% 135 24 seconds

75% 101 33 seconds

50% 68 47 seconds

25% 34 80 seconds

UPS 250i


100% 225 15 seconds

75% 169 20 seconds

50% 112.5 30 seconds

25% 57 56 seconds


SYSTEM SPECIFICATIONS (UPS 150, 300)

M OD EL 150 300

R A T IN G 150 kVA 300 kVA

120 kW 240 kW

IN P UT

Voltage

Frequency-nominal 60 Hz

Input Current-nominal amps 152 299



Power Factor

Harmonic Current Disto rtion

Linear Load

Non-linear Load

Surge Withstand

Walk-in

OUT P UT

Frequency-nominal

Current 181 361


Voltage regulation

Steady State

Flywheel M ode

Transient

Vo ltage Distortion

Overload Capability

1000%

Up to 150%

Up to 125%

P H YSIC A L D A T A

Efficiency 97% 98%


nominal/worst case

Depth

Width

Total Height

Weight

Cable Access

EN VIR ON M EN T A L

Temperature

Operating

Sto rage

Humidity

A ltitude

Audible No ise


(1) +/-10% max at 380V


34.0 in (865 mm)

58.6 in (1,488 mm)

78 in (1980 mm)

<70 dBA at 1 m (3.28ft)

FCC Class A , Subpart J o f Part 15

4900 lb (2223 kg)

Top or Bottom




plus or minus 1% fo r steady-state balanced o r unbalanced loads

plus or minus 5% for 100% load step


10 milliseconds

2 minutes

10 minutes

(2) Weights and dimensions are fo r 4-wire configurations

480 +10%/-15% (programmable) (1)

0.99 at rated load and nominal vo ltage



M eets IEEE 587/ANSI C62.41


Input synchronized (no rmal operation) nominal +/-0.2% free running

Same as input



Table 32. UPS 150-300 60 Hz Series Ride Through Times

APPLICABLE STANDARDS

60 Hz North American Standards

60 Hz units configured for North American voltages shall comply with the following standards:

• UL1778

• FCC Rules and Regulations 47, Part 15, Subpart J, Class A• NEMA PE 1 – 1983

• NFPA 70 - National Electric Code • ASI C62.41, Category A & B• OSHA• CSA C22.2 No. 107.1Commercial and Industrial Power Supplies• Industry Canada ICE-003• Year 2000 compliance• UL1004 Electric Motors

International Standards

50 Hz or 60 Hz units configured for international voltages shall comply with the following standards:

• EEE 587-1980/ANSI C62.41 1980, Category A & B Recommended practice on surge voltages in low power circuits.

• 73/23/EEC Low Voltage Directive.• 89/336/EEC, EMC Directive.

UPS 150


100% 27 seconds

75% 36 seconds

50% 52 seconds

25% 87 seconds

UPS 300


100% 14 seconds

75% 19 seconds

50% 28 seconds

25% 52 seconds


• EN50091-1-1.• Applicable parts of EN60950, as referenced by EN50091-1-1.

EN50091-2

89.336/EEC

• Applicable parts, as referenced in EN50091-2 of the following:

801-2, level 3 (6KV air, 8KV contact). ESD standard

IEC 801-3, level 2. EMI standard

IEC 801-4, level 2. Transients

IEC 1000-2-2.


A

Abnormal Thermal Conditions , 25

Alarm Messages , 25

Alarms & Notice Log , 29

Arrow Keys , 23

D

Display Contrast, Adjusting , 19

Display, System Inputs , 38

Display, System Totals , 34

Display, Time and Date , 39

E

Extreme Thermal Conditions , 25

F

Fan Failures , 25

K

Key symbol , 23

Keyswitch , 47

M

Messages, Notice , 21

Modes, Emergency Shutdown , 17

Multiple Fan Failures , 25

N

Notice message , 29

S

Soft keys , 23

Status Indicators , 28

U

User Interface LCD, Navigating through the Sys-tem Cabinet , 34

User Interface Panel, System Cabinet , 18

User Interface, Multi-Module Unit , 48

V

vacuum pump oil , 61


ct to change

e trademarks

Single Module System (SMS)

Operations Manual

UPS 300 60 HzUPS 250i 50 HzUPS 150 60 HzUPS 150i 50 Hz

While every precaution has been taken to ensure accuracy and completeness of this literature, Active Power, Inc. assumes no responsibility, and disclaims all liability for damage resulting from use of this information or for any errors or omissions.

2017 Active Power, a Division of Piller Power Systems Inc. All rights reserved throughout the world. Specifications subjewithout notice.

CleanSource is a registered trademark of Active Power, a Division of Piller Power Systems Inc. All names referred to artrademarks of their respective owners.

Printed in U.S.A.

AP# 60333-EN Rev. L

Active Power, Inc.

2128 W. Braker Ln, BK 12

Austin, Texas 78758

Phone: 512-836-6464

FAX: 512-836-4511

E-mail: [email protected]

Technical Support

U.S.A.: 1-800-288-5081

Outside U.S.A.: 1-512-744-9290

E-mail: [email protected]

Web Site: www.activepower.com

CleanSource SMS UPS

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