Chloride CP3150 Series Owner'S Manual Download Page 1

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CHLORIDE

POWER PROTECTION

THREE-PHASE Uninterruptible Power System

Owner’s Manual

CP3150

Series

P/N 913-576 Rev A

Summary of Contents for CP3150 Series

Page 1: ...CHLORIDE POWER PROTECTION THREE PHASE Uninterruptible Power System Owner sManual CP3150 Series P N 913 576 Rev A ...

Page 2: ...ii UserandOperatingManual Chloride Power Protection 28430 North Ballard Drive Lake Forest IL 60045 Toll Free Phone 800 239 2257 Toll Free Fax 800 833 6829 Phone 847 990 3228 Fax 847 549 7917 ...

Page 3: ...F CONFORMITY The manufacturer CHLORIDE POWER PROTECTION Head office at 28430 North Ballard Drive Lake Forest IL 60045 USA HEREBY DECLARES THAT THE PRODUCT CP3000 CONFORMS TO THE FOLLOWING REGULATIONS UL1778 FCC PART 15 ...

Page 4: ...SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE CP3000 SERIES THAT SHOULD BE FOLLOWED DURING INSTALLATION AND MAINTANANCE OF THE UPS BATTERIES OPTIONS AND ACCESSERIES ...

Page 5: ...RAGE Delivery Unpacking Handling Storage CHAPTER 2 PREPERATIONS FOR INSTALLATION Environmental Conditions Access area Floor loading CHAPTER 3 UPS INSTALLATION Installation data Specifications Suggested cable sizes Terminations Protection devices Electrical connections CHAPTER 4 BATTERY CABINET INSTALLATION Battery connections ...

Page 6: ...switch and power control unit breaker Operating modes Operational procedures CHAPTER 6 PARALLEL OPTION Introduction Theory of Operation Planning Installation CHAPTER 7 CONNECTIVITY Interface slots Communication slot adaptability RAU RLY DRV AS400 RS232 ManageUPSnet Adapter LIFE 2000 Industrial contacts CHAPTER 8 MAINTENACE ...

Page 7: ... Input Output and Battery Cabinet Wire Terminations for Single Input Table 3 Input Output and Battery Cabinet Wire Terminations for Dual Input Table 4 Full Load Heat Rejection Table 5 Weight Specifications Illustration A UPS Dimensions Illustration B Battery Cabinet Dimensions Illustration C Battery Cabinet Top Dimensions ...

Page 8: ...not intended for outdoor use The operating environment should be maintained within the parameters stated in the manual Keep the cabinet doors closed and locked to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit The UPS system contains its own power source Lethal voltages are present even when the UPS is disconnected from utility power If service or ro...

Page 9: ...se receptacles are to be connected to earth ground at the service equipment FCC Compliance ATTENTION Changes or modifications to this unit not expressly approved by the party responsible or in FCC compliance could void the user s authority to operate the equipment This equipment was tested and complies with the limits for a Class A digital device pursuant to Part 15 of FCC Rules These limits are d...

Page 10: ...ing documentation UNPACKING Care should be taken when removing the packaging in order to avoid damaging the equipment Remove the outer packaging and inspect for damage Shipping brackets are used to attach the UPS and battery cabinets to the skid Remove these brackets by removing the shipping bolts attached to the skid and the bolts attached to the cabinet Use a fork lift to lift up the cabinet fro...

Page 11: ...binet has been fitted with casters to allow ease of installation near the final location It is recommended that the UPS and battery cabinets be moved with a pallet jack or fork lift over long distances The lower side skirts have been intentionally left off to allow fork access under the UPS or battery cabinets Refer to Figure 2 Handling Figure 2 Handling ...

Page 12: ... to temperature above 77 F 25 C Each increment of 15 F 8 C above 77 F 25 C reduces the expected battery life by 50 See battery manufacturer s recommendations The ideal environmental temperature range is 59 F to 77 F due to the battery life design at 77 F Each increment of 15 F above 77 F reduces the expected battery life by 50 See battery manufacturer s recommendations UPS without batteries 4 F to...

Page 13: ...by 50 See battery manufacturer s recommendations MECHANICAL DIMENSIONS The area must have sufficient space for the installation to be carried out Access doors must be sufficiently large to permit passage of the unit The UPS has been designed to provide front or top access for maintenance purposes Refer to appendix A for UPS and Battery Cabinet dimensional drawings FLOOR LOADING It is necessary tha...

Page 14: ...may be lethal Internal components are powered even when the power switch is in the OFF position Even with the battery disconnected and the unit unplugged energy is stored in high voltage capacitors and represents a severe shock hazard U N L E S S M A N U F A C T U R E R S S P E C I F I C A T I O N S T A T E S O T H E R W I S E INSTALLATION DATA Ambient temperature 32 F to 104 F 0 C to 40 C Relativ...

Page 15: ...ssary to remove the protection panel located on the front of the UPS behind the front doors On the UPS and Transformer cabinet power cables can be brought in from the top or bottom through the access plates and routed through the cable raceway Refer to Figure 4 Front View UPS LOWER PROTECTION PLATE CABLE RACEWAY PLATE Figure 4 Front View UPS ...

Page 16: ...d a separately derived source If this is the case a jumper will be provided and connected between ground and the neutral terminations Therefore in this configuration an input neutral will not be required The BY PASS is phase rotation sensitive Clockwise phase rotation is required for the input and bypass The neutral requirements for the By Pass input are solely dependent on the load requirements I...

Page 17: ...8 Figure 6 Input Transformer Cabinet 208 480V ...

Page 18: ...n pre wired on each shelf The battery tray interconnects should only be connected by a factory trained and authorized service representative It is recommended that the battery cabinet be located adjacent to the UPS or additional battery cabinets Battery cabinet cables have been provided for layouts where the UPS and Battery cabinets are adjacent to each other Optional extended run time cabinets ca...

Page 19: ...10 Figure 8 Battery Cabinet Electrical Connections ...

Page 20: ...nd battery cabinet must be connected with the most positive of the battery cabinet connected to the positive termination in the UPS The most negative of the battery cabinet must be connected to the negative termination of the UPS See Figure 6 UPS Electrical Connections for DC connection within the UPS Figure 9 Multiple Cabinet Connections ...

Page 21: ...trol as needed LED s Light Emitting Diode inform the user about three operating parameters of the UPS 1 2 3 below The LCD Liquid Crystal Display will provide detail on messages alarms values and operating conditions of the UPS And finally buttons that control the inverter and shutdown the entire system Chapter 5 CONTROL PANEL Figure 10 Control Panel ...

Page 22: ... is solid the UPS is operating with a fault condition When blinking it indicates a warning condition INVERTER ON OFF When this button is pushed the Inverter is turned either on or off ENTER This button allows access to menus on the LCD display ESCAPE This button escapes from any menu on the LCD display CANCEL AUDIBLE ALARM This button silences current alarm EQUIPMENT POWER OFF This button turns of...

Page 23: ...n allows the user to scroll left on the LCD RIGHT ARROW This button allows the user to scroll right on the LCD DOWN ARROW This button allows the user to scroll down on the LCD UP ARROW This button allows the user to scroll up on the LCD ...

Page 24: ...s a graphical user interface providing power blocks representing the Rectifier Battery Inverter and By Pass The power path will be highlighted providing the user with an understanding of which power blocks are active and that which is supplying the critical load BY PASS INPUT RECTIFIER INPUT INVERTER BATTERY ...

Page 25: ... Pwr App Power L1 App Power L2 App Power L3 Values Displayed Voltage L1 Voltage L2 Voltage L3 Current L1 Current L2 Current L3 Frequency Total Real Pwr Real Power L1 Real Power L2 Real Power L3 Total App Pwr App Power L1 App Power L2 App Power L3 Values Displayed Voltage Current Residual Capacity Expected Run Time Temperature No Faults No Warnings Message 1 of 3 Mains Failure No Faults No Warnings...

Page 26: ...nd DOWN arrows to toggle through current screen The Actual Values screen s function is to allow access to various parameters at different locations of the UPS Parameters displayed are By pass Input Rectifier Input UPS Output Battery and DC Bus Shown for By pass input The By pass Input screen displays parameters regarding the By pass input Parameters displayed are Voltage L1 Voltage L2 Voltage L3 a...

Page 27: ...3 Frequency Total Real Power Real Power L1 Real Power L2 Real Power L3 Total App Power App Power L1 App Power L2 App Power L3 Press down or up arrows to view other entries Press ESC to exit UPS OUTPUT Voltage L1 Voltage L2 The UPS Output screen displays parameters regarding the UPS Output Parameters displayed are Voltage L1 Voltage L2 Voltage L3 Current L1 Current L2 Current L3 Frequency Total Rea...

Page 28: ...S Parameters displayed are By pass Input Rectifier Input UPS Output Battery and DC Bus Shown for DC Bus The DC Bus screen displays parameters regarding the inverter s DC bus Parameters displayed are Voltage Total Voltage and Voltage Press down or up arrows to view other entries Press ESC to exit The Main Menu screen s function is to provide the user the selection options for viewing various inform...

Page 29: ...creen press ESC button MAIN MENU Actual Values Inverter Alarms Rectifier Alarms About Display Settings Press to select RECTIFIER ALARMS No Faults No Warnings The Main Menu screen s function is to provide the user the selection options for viewing various information about the UPS This is the highest level for menu To return to previous screen press ESC button Press the ENTER button to select scree...

Page 30: ...e display Sub menus displayed are Language and Contrast Shown for Language sub menu To return to previous screen press ESC button The Language screen will display a selection of multiple languages in which will change the text of the display LCD to the appropriate language desired Press Down or UP arrow to desired language To return to previous screen press ESC button Message 1 of 3 By pass Mains ...

Page 31: ... to provide the user the selection options for viewing various information about the UPS This is the highest level for menu To return to previous screen press ESC button Press the ENTER button to select screen Use the UP and DOWN arrows to toggle through current screen Shown for About sub menu The About screen shows the software revision manufacturer and support information including the hotline T...

Page 32: ...tdown Battery Operation DSP Not OK signal processor defective Battery Rest time Exceeded Rectifier Precharge not OK Battery Under Voltage Inverter Desaturation Commissioning or Test Mode Over current cutoff Battery Switch not Engaged UPS Out of Tolerance Ventilator Lifetime Exceeded Output Overload Connection to charger lost Backfeed Fault Battery Charge Inhibit Bypass Defective Battery Temperatur...

Page 33: ...Inverter filters mains interruptions disturbances and provides a stable interference free supply to the load The summary alarm LED on the control panel is not illuminated in this mode If a mains failure occurs while in On Line operation the UPS switches to Battery Operation The On Battery and Summary Alarm LEDs are illuminated If an overload condition occurs at the output the UPS switches to By pa...

Page 34: ...ed to the batteries without interruption In this mode the load is supplied entirely by the batteries via the inverter If the power fails the UPS indicates a fault condition In Battery operation the On Battery and Summary Alarm LEDs on the control panel are illuminated If an overload condition occurs at the output the UPS switches to By pass operation if available Path of Current ...

Page 35: ... has been restored The batteries are charged according to the specific battery model provided by the battery manufacturer s specifications Within the battery autonomy period the UPS provides information regarding the remaining battery autonomy via the Liquid Crystal Display At the same time that the batteries are being recharged the inverter continues to supply the load Path of Current ...

Page 36: ... of an overload condition manual inverter shut off or the unlikely event that the inverter should fail The by pass is automatically activated in order to ensure that there is no interruption in the load supply In By pass operation the On By pass and Summary alarm LEDs on the front panel are illuminated The UPS returns to online operation automatically once the fault has been corrected This will ha...

Page 37: ...ance Bypass is used to supply the load during maintenance operations CB1 and SW1 can be used to supply power to the UPS for testing or startup without affecting the output In the Maintenance By pass Position all power is removed except for the fans and power transformers in some models Note In Maintenance By pass operation the Display and LED s do not illuminate Path of Current ...

Page 38: ...he output is not interrupted MAINTENANCE BY PASS PROCEDURE 1 Press INVERTER OFF for 3 seconds or until the audible alarm is heard and Inverter mimic shows the inverter section is off 2 Switch SW3 on Turn off CB1 SW1 SW2 and the Battery Cabinet circuit breaker Note The order is important so that the output is not interrupted Note For the 208VAC output UPS 4X2 SW2 can remain on to energize the fans ...

Page 39: ...stem is automatically regulated by the controllers of the individual UPS modules The UPS conditions the raw main power and supplies continuous clean three phase power to the critical load loads The UPS will continue to supply clean power without interruption at the output when the utility power fails In the event of a main power failure the UPS will continue to supply clean power from the batterie...

Page 40: ...factor to consider is the total size of the parallel UPS configuration The output power rating of the UPS should be specified according to the power demand of the protected loads Some margin of error should be allowed for potential expansion and possible inaccuracy in calculations or measuring the actual load requirements The battery should be sized according to the desired backup time Note that t...

Page 41: ... right front of the UPS Access to this channel is from the top or bottom depending on the type of installation See chapter 3 figure 5 Route the communication cables through the cable channel to the terminal blocks X130 and X140 The cable is exiting module from terminal X130 of UPS1 and connected to terminal X140 of the next module UPS2 See figure 2 for correct closed loop connection of the communi...

Page 42: ...hen connecting the communication bus the shield of the communication cable must be grounded to the UPS on each end of the cables Parallel communications raceway Figure 13 Raceway for Parallel Communication Wires ...

Page 43: ...located at the upper right front of the UPS behind the front door and dead plates Fig 14 Parallel Communication Terminal Blocks Location NOTE Installation of the parallel kit must be completed by Authorized Technical Personnel Parallel Communication Terminal Blocks ...

Page 44: ...ots have been designed to allow installation of the AS400 card LIFE 2000 card R A U card Remote Alarm Unit RS232 card and Manage UPS Net adapter card These interface slots are located behind the front panel located in the middle right section See Figure 5 UPS Electrical Terminations Figure 15 Interface Slots Chapter 7 CONNECTIVITY ...

Page 45: ...ommendations of those communication options and were to insert them z Preferred position Optional position Figure 16 Communication Card ManageUPS Net Card Mop UPS RS232 Card LIFE 2000 Modem Card AS400 Card Remote Alarm Unit Card or Industrial Contact Driver Card Slot 1 z Slot 2 z Slot 3 z Slot 4 z Slot 5 z ...

Page 46: ... The voltage free contacts are rated at 30V 5A max Figure 17 RAU Remote Alarm Unit or Relay or Driver Card The RAU RLY DVR PCB terminal layout is as follows Pin 1 is AC Fail Pin 2 is Low Batt Pin 3 is On Bypass Pin 4 is Inv Fail Pin 5 is Sum Alarm Pin 6 is Common Return Pin 7 is 16V RAU Pin 8 is 24V ISO Pin 9 is 24V Ret Pin 10 is 24V Ret Note These outputs can be changed from N O to N C directly o...

Page 47: ...ents of IBM AS 400 and other computing systems Figure 18 AS400 Relay card The interface communication pin layout is as follows Pin 1 is Bypass Pin 2 is Summary Alarm Pin 3 is Shutdown Pin 4 is Shutdown Pin 5 is the common for all contact on internal relays Pin 6 is Low Battery N C Pin 7 is Low Battery N O Pin 8 is AC Fail N C Pin 9 is AC Fail N O ...

Page 48: ... signals Figure 19 RS232 Card The interface COM is isolated from all power circuits Pin 5 GND This connection point serves as a reference for all signals Pin 2 RXD Standard configuration of an RS 232 interface Pin 3 TXD Standard configuration of an RS 232 interface ...

Page 49: ...pointers are written to disk while the system is supplied from UPS battery power Figure 20 Manage UPS Net Adapter MopUPSPROFESSIONAL for Windows provides this function and offers other features useful to network administrators including Automated responses to a variety of events email messaging paging running script files etc Logging of various events and UPS status information to files Real time ...

Page 50: ...pically once a week EMERGENCY when something goes wrong or when parameters are out of tolerance MANUAL when requested by the Customer BIDIRECTIONAL when requested by the service center During the calls the service center shall Identify the connected UPS Recognize the kind of call Request the data stored in the UPS since the previous connection Request information from the UPS on line selectable Th...

Page 51: ...42 INDUSTRIAL CONTACT CARD Figure 22 Industrial Contact Card and Bracket The contacts are rated at 120VAC 2A ...

Page 52: ...gency switch which opens when activated and is held open mechanically when operated Make sure switch is de activated closed before connecting to the outer terminals of the EPO terminal block REPO Hi and REPO Low Remove the jumper wire between the inner terminals Disable It is recommended to use twisted wires for this low voltage connection ...

Page 53: ...atest respect for the environment The typical battery life cycle is 3 to 5 years at an ambient temperature of 77 F but is also dependent on the frequency and duration of mains failures A battery test should be carried out periodically 6 to 12 months in order to ascertain the general condition of the batteries PRECAUTIONS During maintenance disconnect the battery trays so that no more than eight ba...

Page 54: ...om OFF to ON After 5 hours turn OFF the Power Control Unit For additional external cabinets charge for a minimum of 5 hours per battery cabinet Then remove the UPS connections in the opposite sequence described in Chapter 3 Note the date recharging was carried out on the Battery Cabinet or on its packaging CLEANING Switch off the UPS by pressing the Inverter OFF button and disconnect from the main...

Page 55: ...ring Recommendations Table 2 Input Output and Battery Cabinet Wire Terminations for Single Input Table 3 Input Output and Battery Cabinet Wire Terminations for Dual Input Table 4 Full Load Heat Rejection Table 5 Weight Specifications Illustration A UPS Dimensions Illustration B Battery Cabinet Dimensions Illustration C Battery Cabinet Top Dimensions Appendix A INSTALLATION TABLES AND ILLUSTRATIONS...

Page 56: ...ut circuit breaker ratings 3 Pole A AC 250 300 Max input current 3Ph 1 gnd A AC 224 270 Nom input current 3Ph 1 gnd A AC 161 190 Minimum conductor size number per phase AWG or kcmil 1 2 2 0 2 AC Input To UPS Rectifier 480V 480V Recommended input circuit breaker ratings 3 Pole A AC 250 300 Nom input current 3Ph 1 gnd A AC Minimum conductor size number per phase AWG or kcmil 208V 208Y 120 Recommende...

Page 57: ...6V 309 370 DC Input 480V DC Minimum conductor size number per pole AWG or kcmil 3 0 2 4 0 2 Refer to the following notes when planning your installation 1 Wire sizes ratings and circuit breaker sizes are recommended always consult NEC codes 2 Consult Local and National electrical codes for acceptable wiring practices 3 Wires specified are Copper type 75 Deg C 167 Deg F rated based on ambient tempe...

Page 58: ... 8 Hex A 4AWG 500MCM 2 375 1 2 Hex B 4AWG 500MCM 2 375 1 2 Hex AC Input to UPS Input Transformer C 4AWG 500MCM 2 375 1 2 Hex A 6AWG 350MCM 375 3 8 Hex B 6AWG 350MCM 375 3 8 Hex AC Output to Critical Load C 6AWG 350MCM 375 3 8 Hex 2 for 208V Output Neutral N 6AWG 350MCM 4 275 5 16 Hex Positive 6AWG 350MCM 2 375 3 8 Hex Battery Negative 6AWG 350MCM 2 375 3 8 Hex Battery Cabinet Ground Only Battery C...

Page 59: ... Ground Ground Earth 2AWG 600MCM 4 500 1 2 Hex Note The cable sizes are defined as minimum cable sizes Input and output conductors are based on NEC 310 16 for insulated copper conductors rated at 75 C in ambient temperature of 40 C 104 F Grounding conductors are based on NEC 250 95 for copper wire UPS input and output cables should be run in separate conduits It is recommended that the external ca...

Page 60: ...VA 56 931 45 556 34 670 CP3150 125kVA 47 442 37 963 28 892 Table 5 Weight Specifications Weight Specifications CP3150 150kVA 125kVA Weight lbs Floor Loading lbs 480in 480out 2564 4 at 641 480in 208out 3675 4 at 919 208in 208out 3675 4 at 919 K Battery Cabinet 3900 8 at 488 Input Transformer Cabinet 1300 4 at 325 ...

Page 61: ...52 Illustration A ...

Page 62: ...53 Illustration B ...

Page 63: ...54 BATTERY CABINET TOP DIMENSIONS Illustration C ...

Page 64: ...d improvement We thank you in advance for any such suggestions that may be forwarded to the addresses listed in the last page This document is for information only It is the policy of this company that its products are continually improved therefore CHLORIDE POWER PROTECTION reserves the right to alter any or all of the information contained herein without prior notice CHLORIDE POWERPROTECTION 284...

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