IPM balancedpower plus Installation And Operation Manual Download Page 1

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INSTALLATION

and

OPERATION MANUAL

for

International Power Machines

BalancedPower

Plus

10-300 kVA

Uninterruptible Power System

(UPS)

SAVE THESE IMPORTANT

SAFETY INSTRUCTIONS

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

International Power Machines

10451 Brockwood Road
Dallas, Texas 75238-1641
Phone: (214) 342-6100

Service Hotline (800) 777-8922

Summary of Contents for balancedpower plus

Page 1: ...System UPS SAVE THESE IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety instructions that should be followed during installation and maintenance of the UPS and Battery Cabinets Inte...

Page 2: ...t IPM 24 HOUR SERVICE HOTLINE Phone 800 777 8922 Outside US 919 871 1800 Fax 214 342 6115 When calling for service assistance have the following information and a record of readings and alarm lights f...

Page 3: ...that the monitor panel be inspected visually every eight hour shift to see that lights are operat ing and no alarm conditions exist If any unusual conditions exist call facility mainte nance personne...

Page 4: ...e Battery Cabinet s 2 4 2 4 Signal Wiring 2 5 2 4 1 Remote Control TB 1 2 5 2 4 2 Optional Remote Status Panel TB2 2 6 2 4 3 Optional RS232 Communication J6 J9 2 6 2 4 4 Optional Modem Connection J10...

Page 5: ...button 3 9 3 4 6 Emergency Power Off Pushbutton 3 10 3 5 System Controls 3 10 3 6 UPS Operating Procedures 3 11 3 6 1 System Startup Procedure 3 11 3 6 2 Alarm Identity History 3 14 Table 3 1 Typical...

Page 6: ...urer s Torque Specifications 4 12 Section V Spares Training Maintenance 5 1 Spare Parts Page 5 1 Level A Spares 5 2 Level B Spares 5 3 Level C Spares 5 4 5 2 Training 5 5 5 3 Continuing Maintenance 5...

Page 7: ...lation and correction of problems that are signaled by the Control Monitoring Alarm Panel 4 Be thoroughly familiar with the safety precautions outlined in Sections II and IV of the manual 5 Do not tak...

Page 8: ...al damage during movement 6 Inspect the exterior packaging for obvious damage such as punctures or gashes that are indicative of damage to the unit If evidence of damage exists save the packaging mate...

Page 9: ...Page vi BP 15 150 2 9X 5 95 3 phase UPS Warranty...

Page 10: ...ystem manual and shall follow all operating instructions therein C Any necessary repairs made during the period of this warranty shall be made by IPM or by others with IPM s written concurrence D All...

Page 11: ...t transformer Rectifier Charger Inverter Static Bypass Switch Bypass Breaker Output Transformer System Control Logic and Circuitry Digital Monitoring Panel Battery DC Disconnect A one line diagram in...

Page 12: ...static bypass switch will close and transfer the load directly to ac power without interruption This transfer is automatically inhibited in the event the UPS bypass input is not within specified tole...

Page 13: ...igid specifications to determining whether or not the static bypass switch should be activated The control logic is for all practical purposes the brain of the UPS 1 7 Digital Monitoring Panel The UPS...

Page 14: ...a maximum of 9 characters The numerals 0 through 9 and letters A through F may be employed The first character of the password indicates the privilege level of the password The higher the privilege le...

Page 15: ...e personnel can take steps to solve a UPS problem remotely before the user is aware that there is a problem An internal modem and a dedicated telephone line are required Phone Home Alarm Reporting can...

Page 16: ...back and access passwords and be calling from the proper associated phone number An internal modem and a dedicated telephone line are required Dial Back Security can be activated only with a Field Se...

Page 17: ...on can result in excessive maintenance problems For environmental considerations please see the Installation Information at the end of this section Operating temperature range for batteries is 0 C to...

Page 18: ...ttom corners of the UPS cabinet Access to the inside of the cabinet is not required Refer to Figure 2 1 An optional pedestal mount may replace leveling feet and casters a First screw the leveling foot...

Page 19: ...SECTION II Installation Page 2 3 BP 10 150 12 95 2 2 Mechanical Preparation of UPS continued b DO NOT REMOVE THE RED GLASTIC GUARD PANEL FROM THE LEFT SIDE OF THE UPS...

Page 20: ...e in the floor of the cabinet to receive them c Screw in each leveling foot until it is a minimum of 0 75 in 1 9 cm above the floor level Tighten locking nut to keep it there 2 If an IPM battery cabin...

Page 21: ...s 1 wiring method must be used for field wiring connections Make connections for all optional equipment to the terminal blocks on the lower front or right side of the UPS see installation drawings Ele...

Page 22: ...ire sizing 22 12 AWG 2 4 2 Optional Remote Status Panel TB2 Ten position terminal for direct connection between UPS and TB1 in the Remote Status Panel Terminal wire size 22 14 AWG recommended 16 AWG 2...

Page 23: ...arms Connector wire size 22 12 AWG 2 5 Power Wiring UPS to Battery Cabinet Use separate conduits for power and signal wiring When the battery cabinet is attached to the left side of the UPS there is a...

Page 24: ...together as described Repeat for any additional battery packs 2 7 Re assembly 1 Replace side cover s of battery cabinets attaching screws on inside removed in Paragraph 2 3 Step 3 Be very careful not...

Page 25: ...e proceeding TIGHTENING TORQUE FOR PRESSURE WIRE CONNECTORS Size of Wire Used Torque Specification AWG kcmil mm 2 lb in N m 6 4 13 3 21 2 110 12 4 3 26 7 150 16 9 2 33 6 150 16 9 1 42 4 150 16 9 1 0 2...

Page 26: ...ust be a 3 phase center grounded WYE with neutral grounded The ground connector must be connected to the UPS ground terminal For any other configurations consult IPM Applications Engineering 4 UPS Out...

Page 27: ...stem ground Ground studs are welded to the cabinet frame and are located near the cable entry points or power terminal 7 Replace the panel around the circuit breakers removed in Paragraph 2 2 Step 3 W...

Page 28: ...breaker to frame ground Verify that no short circuits exist to frame ground There may be a high impedance between the two cables connecting to the UPS cabinet and frame ground but no short circuit sh...

Page 29: ...ct circuit breaker 2 9 2 Battery Cabinet 2 8 Open the front doors of Battery Cabinet 2 the one next to Battery Cabinet 1 Connect the battery trays in the cabinet to each other as shown in Figure 2 3 T...

Page 30: ...WARNING Before reconnecting the top right hand tray to the tray immediately below in Battery Cabinet 2 measure the voltage between these un plugged connectors with a dc voltmeter It is expected that t...

Page 31: ...SECTION II Installation Page 2 15 BP 10 150 12 95 2 9 Activating the Battery Cabinet s continued 6 battery trays Figure 2 3 10 battery trays...

Page 32: ...n IV of this manual Maintenance for safety precautions to be taken whenever operating or working on the UPS 3 2 1 Cleanliness Litter or trash of any sort should not be allowed to accumulate in or arou...

Page 33: ...e extinguishers should be mandatory 3 3 Radio Frequency Energy Hazard WARNING This equipment generates uses and can radiate radio frequency and if not installed and used in accordance with instruction...

Page 34: ...uttons three 3 Parameter Adjust pushbuttons an ALARM SILENCE pushbutton and an EMERGENCY POWER OFF EPO pushbutton The Display Select buttons provide access to the various data and messages which are d...

Page 35: ...battery power and the alarm sounds alerting the operator to a brownout or power failure When the batteries run down the critical load will shut off unless steps are taken to correct the situation or...

Page 36: ...er Not Available red An indication that transfer to the static bypass switch is not possible This may be caused by the UPS bypass input power source being out of specification or a power outage Batter...

Page 37: ...scroll through the list depressing the or button successively see paragraph 3 6 2 On this screen the letters are read as follows xx month yy day of the month zz year uu hour on the 24 hour clock vv m...

Page 38: ...f the load on the UPS Link voltage 243 405 VDC 10 If there is an increase to about 246 410 VDC it indicates the batteries are being charged If the voltage goes above 256 426 VDC the rectifier will shu...

Page 39: ...between phases 3 4 2 9 Output Current A readout of the output current measured in amperes per phase 3 4 2 10 Date Displays today s date 3 4 2 11 Time A readout of the current time 3 4 2 12 UPS Mainte...

Page 40: ...buttons labeled and are used with Alarm Identity History procedures Paragraph 3 6 2 and to set or alter the parameters of the UPS See Page 3 3 regarding arrows 3 4 5 Alarm Silence Pushbutton Whenever...

Page 41: ...ted The EPO also may be activated remotely by a contact closure CAUTION Any time the UPS has been shut down by using the EPO the system should be carefully checked by trained facilities personnel befo...

Page 42: ...is important for safety and the protection and performance of the UPS that the step by step instructions for each procedure be followed in the sequence given 3 6 1 System Startup Procedure Before ini...

Page 43: ...r Not Available Retransfer Inhibited Battery Not Available and this screen which will be displayed for a short time then 2 When this instruction appears on the Message Screen close BYPASS CIRCUIT BREA...

Page 44: ...voltage does not equal output voltage this is a rotary switch This should light the following LED s Transferred to Bypass Retransfer Inhibited 6 On dual input UPS only when this instruction appears o...

Page 45: ...ng the or button going through the sequence of screens described in Paragraph 3 4 2 until this screen appears xx month yy day of the month zz year uu hour on the 24 hour clock vv minutes of the hour w...

Page 46: ...first entry shown on the screen is the latest entry on the list Pressing moves you toward the top of the list and pressing moves you toward the bottom of the list See an example below Table 3 1 Typica...

Page 47: ...high Input voltage too high Verify correct UPS inputvoltage Decrease if necessary inp vlt low Input voltage too low Verify correct UPS input voltage Increase if necessary inp vlt norm Input voltage no...

Page 48: ...mblies rct pwr norm Rectifier power normal No action required rct lock Rectifier phase locked No action required rct not lock Rectifier not phase locked Verify UPS input voltage and frequency rct cur...

Page 49: ...requency inv ovr tmpA Inverter over temperature phase A Verify cooling fans are operating on A1 power assembly inv ovr tmpB Inverter over temperature phase B Verify cooling fans are operating on A2 po...

Page 50: ...on required inverter off Inverter off Follow Startup procedure to restart UPS mv fan fail Inverter fan failure Verify all cooling fans are operating mv fan norm Inverter fan normal No action required...

Page 51: ...ass Switch power supply failure Phase B Test replace SBS drive board on A2 power assembly sbs pwr faIC Static Bypass Switch power supply failure Phase C Test replace SBS drive board on A3 power assemb...

Page 52: ...c Bypass Switch by pass frequency low Verify SBS input frequency byp f req nml Static Bypass Switch by pass frequency normal No action required rct summary Rectifier summary alarm Review other rectifi...

Page 53: ...processor initialized No action required EPO btn pshd EPO pushbutton pressed Complete UPS restart procedure_is_required EPO btn rlsd EPO pushbutton released Complete UPS restart procedure_is_required...

Page 54: ...ass input switch or circuit breaker closed No action required sbs out open Static bypass output switch is open Follow Startup procedure to close switch sbs out clsd Static bypass output switch is clos...

Page 55: ...current is too high Perform bypass shutdown and call Customer Service inp 5 th norm The 5 th harmonic content of the input current is at an acceptable level No action required unused Unused alarm app...

Page 56: ...enu 3 6 3 2 Inverter Maintenance Menu 3 6 3 3 SBS Maintenance Menu 3 6 3 4 System Maintenance Menu 3 6 3 5 Password Maintenance Menu 1 To bring the UPS Maintenance Menu to the screen depress the pushb...

Page 57: ...to obtain 7 Depress to bring up the first of the secondary menus Depress to bring up the other four Maintenance Menus in turn Some times it will be faster to depress to obtain the desired menu 3 6 3...

Page 58: ...ll appear on the screen To confirm the previous action press again returning the screen to 3 Press to obtain this screen 4 Press to return to the Rectifier Maintenance Menu 3 6 3 2 Inverter Maintenanc...

Page 59: ...justments can be made 3 Press to obtain this screen Steps 4 5 and 6 should only be per formed when advised by qualified service personnel 4 Press to reset the inverter faults 5 This screen will ask yo...

Page 60: ...his screen Press to begin the Bypass Shutdown Procedure Retransfers are disabled by this procedure To Skip Bypass Shutdown procedure and go directly to Manual Transfer to Bypass Step 12 press instead...

Page 61: ...put transformer T2 is energized in Maintenance Bypass mode 6 When this message appears open the BATTERY CIRCUIT BREAKER 7 On dual input UPS only when this message appears open SBS INPUT CIRCUIT BREAKE...

Page 62: ...This message appears briefly Manual Transfer to Bypass 12 Press and to obtain this screen 13 Press to obtain this screen 14 Press to manually transfer input to reserve power source This will inhibit...

Page 63: ...e system will be left so that transfer and retransfer are enabled Following Step 11 of this subsection press once or twice to obtain this screen with either transfers or retransfers on the top line Pr...

Page 64: ...erformed only from the front panel display 4 Press to obtain this message This is the beginning of a procedure to change the language on the monitor panel if desired To leave it in English press This...

Page 65: ...en This is the start of the procedure if it is necessary to change the date setting 9 Press The screen will ask you to confirm that you want to reset the date If you do not wish to reset the date pres...

Page 66: ...ill display the new time you have set 16 This sequence is only for those units with LCD display screens The screen may be tilted up and down to give persons of different height a better view of the me...

Page 67: ...the Alarm History records 3 6 3 4 2 Latching Alarms Menu The purpose of this procedure is to allow the user to set the various alarms as latching or non latching Pressing successively through this se...

Page 68: ...If you wish to change the latching instructions on any of the screens from Step 26 through Step 32 press change the latching instructions confirm and press To go from step 26 to step 27 without makin...

Page 69: ...ss to obtain this screen 35 Press to obtain this screen 36 Press to obtain this screen Pressing at this point will reset the optional COM1 serial port See NOTE 1 NOTE 1 The last display line shows the...

Page 70: ...on or equivalent P Rec Proto allows computer to computer communications with user developed software per the protocol provided in section VII or optional Windows based UPS Manager Plus software BCM Pr...

Page 71: ...creens Press or to obtain another of these three screens as desired Pressing will display the Save Changes screen User Interface enables the UPS to communicate in a standard ANSI terminal format VT100...

Page 72: ...o change the Com 2 baud rate press to increase baud rate from 2400 to 9600 or press to decrease from 9600 to 2400 Pressing will display the Save Changes screen 47 Pressing will select the desired baud...

Page 73: ...ge the character under the cursor originally a space You can move through the available characters faster by holding down the ALARM SILENCE button while pressing or To move the cursor to the right pre...

Page 74: ...faster by holding down the ALARM SILENCE button while pressing or To move the cursor to the right press to move to the left press 58 Press to save the changes 59 If Phone Home feature is being used th...

Page 75: ...s have been entered the screen will look like this Press 63 Press to save the changes 64 This sequence is for entering a 24 hour telephone number which can be called by Factory Field Service personnel...

Page 76: ...aster by holding down the ALARM SILENCE button while pressing or To move the cursor to the right press to move to the left press 67 When all characters have been entered the screen will look like this...

Page 77: ...en you start 3 Press The system will ask you to confirm the password level 4 Press as requested in the previous message You are now ready to modify the password Follow the procedure you used in steps...

Page 78: ...Previous Menu 11 Depress to leave UPS Maintenance Menu 3 6 4 System Shutdown 1 Perform the Bypass Shutdown procedure Paragraph 3 6 3 3 NOTE This leaves the critical load powered by the utility power s...

Page 79: ...see that lights are operating and no alarm conditions exist The Alarm History should be checked at this time see Paragraph 3 6 2 to determine if any recent alarms have gone un noticed If any unusual c...

Page 80: ...crease the reliability and efficiency of the UPS system operations 4 3 1 Air Filters Filters installed in the bottom of the cabinet eliminate particles from the air which is used to cool the UPS In ti...

Page 81: ...ing Then check for the presence of power with a voltmeter across the input and output terminals 4 4 Remedial Maintenance Troubleshooting Remember the International Power Machines 24 Hour Hot Line Phon...

Page 82: ...otline for assistance In general the BalancedPower Plus UPS is designed so that the operator should not find it necessary to have access to any area of the equipment except the Digital Monitor Panel a...

Page 83: ...or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries When replacing batteries use the same number and the following type...

Page 84: ...tery Pack This procedure is for shutting down the IPM battery pack It does not require that the protected load be removed from the UPS Perform the following steps in the order presented 1 Verify that...

Page 85: ...Remove the bolts from one tray at a time and very carefully pull the tray forward Care should be taken that the tray doesn t come all the way out The tray is heavy weighing as much as 200 pounds 91 k...

Page 86: ...described in Paragraph 2 8 Activating the Battery Pack Close the battery pack door 4 6 4 Battery Test Batteries should be tested whenever a battery related problem is suspected or at annual intervals...

Page 87: ...ry tester cable to the positive battery pole attach the black cable to the negative battery pole 6 Press the LOAD switch If using a brand of tester other than the Balkamp follow the tester s operating...

Page 88: ...nector bolts to battery manufacturer s specifications 6 Using a digital voltmeter which can be read to 0 01 vdc check voltage across the poles of the new battery Voltage should be at least 12 40 vdc 7...

Page 89: ...N IV Maintenance Page 4 11 BP 2 9X 11 95 4 6 Battery Maintenance continued 4 6 6 Reactivating the Battery Pack continued 6 battery trays Figure 4 1 10 battery trays Figure 4 2 Polarity of Batteries in...

Page 90: ...40FR 1 4 7 16 40 lb in 30 lb in UPS 12 170FR 1 4 7 16 40 lb in 30 lb in UPS 12 270FR 1 4 7 16 40 lb in 30 lb in UPS 12 310FR 1 4 7 16 65 lb in 50 lb in UPS 12 370FR 1 4 7 16 65 lb in 50 lb in UPS 12 4...

Page 91: ...differing requirements The desired Mean Time To Repair and the travel time from IPM s nearest Service Center would normally determine the approximate level of spares to be stocked This section lists...

Page 92: ...01 Spring Forest Road Raleigh NC 27604 Phone 919 871 1812 Fax 919 871 1822 5 3 Continuing Maintenance Program We consider regular maintenance of your UPS to be insurance for your equipment investment...

Page 93: ...e the UPS back on line without manual intervention CIRCUIT BREAKER PANEL That portion of the cabinet behind the right hand door containing the UPS Input Circuit Breaker Static Bypass Circuit Breaker B...

Page 94: ...is to change DC to AC LED Light emitting diode A semiconductor that give off light when it is energized LOGIC CIRCUIT A network of electronic components that performs a specific function OUTAGE Loss...

Page 95: ...nals which are easily accessible to the customer They provide the ability to remotely sense an alarm condition STATIC BYPASS SWITCH SBS A major component of the UPS Connects the UPS Input to the load...

Page 96: ...y Voltage Battery Not Available UPS Overloaded Retransfer Inhibited UPS Maintenance Input Van 121 1 Link Voltage 400 1 Menu Input Vbn 121 8 Battery Amps 7 2 Input Vcn 121 0 Max Out CF 1 86 UPS Input I...

Page 97: ...lue of modifiable elements D own Displays previous alarm entry in Alarm History when Alarm History is active Decrement displayed value of modifiable elements E nter Select the menu displayed in active...

Page 98: ...1 14 59 27 07 0 inv fan normal 09 20 91 14 59 27 08 0 input frequency normal 09 20 91 14 59 27 08 0 sbs bypass frequency normal 09 20 91 14 59 27 10 0 sbs bypass voltage low 09 20 91 14 59 28 41 0 rct...

Page 99: ...sers who need to query the UPS periodically for information as to its status or develop custom monitoring software It is used also when the phone home capability is enabled For additional information...

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