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A55-00033 Rev. E                                                                                                          December 2015 

UPS Unpacking Instructions 

     

The POWERVAR 3200 Series comes packed in heavy cardboard with foam 

dividers on a heavy wooden pallet. The unit is bolted to the skid with two metal brackets. A 
wooden ramp is stored vertically in front of the UPS. This ramp is used to move the UPS off of 
its shipping pallet. 

 

       

Note: POWERVAR encourages the end user to retain all shipping 

materials until the UPS has been inspected, installed and verified for proper operation. 

 

The POWERVAR 3200 Series UPS utilizes internal batteries which are pre-assembled in 
individual trays and shipped separately from the UPS. These trays come completely wired and 
ready for connection to the internal battery harness of the UPS. A quick visual inspection is 
requested to determine if any connections were unseated during the shipping process. 

 

Unpacking the UPS requires a 19mm wrench or socket. To remove the UPS from the packing 
materials:  

1.

 

Visually inspect the unit for any signs of transit damage (Fig. 2-1). Remove and retain all 
associated paperwork (packing list, user’s manual etc.) that is affixed to the top of the 
unit. Remove the cardboard lid from the top of the container. 

2.

 

Remove any fasteners from the lower edge of the cardboard container. 

3.

 

With the help of an assistant, carefully lift the heavy cardboard container straight up until 
it is clear of the UPS. (Fig. 2-2) 

4.

 

Remove the foam dividers. (Fig. 2-3) 

5.

 

Lift the ramp clear of the alignment pin, and place it sloping downward at the front of the 
UPS, using the pin to hold the back of the ramp in place. 

6.

 

Remove the protective plastic cover from the UPS. 

7.

 

The UPS is attached to the shipping pallet with two shipping brackets—one on each side 
of the UPS. Using an adjustable wrench or 19mm socket, remove the three bolts that 
attach the bracket to the UPS. If your location has a Seismic requirement, please contact 
factory for Seismic installation instructions. (Fig. 2-4) 

8.

 

The UPS has two leveling feet. Be sure to check that the levelers are up against the 
bottom of the UPS to ensure it rolls freely on the ramp.  

Summary of Contents for 3200 Series

Page 1: ...1 A55 00033 Rev E December 2015 3200 Series User s Manual ...

Page 2: ...2 A55 00033 Rev E December 2015 ...

Page 3: ... Specifications 3200 Series Product Specifications 21 22 4 Operation UPS Operational Overview 23 24 UPS Operation Normal Mode 24 UPS Operation Battery Mode 25 UPS Operation Bypass Mode 26 UPS Operation Emergency Bypass 27 UPS Operation Manual Maintenance Bypass Mode 28 Touch Screen Description Calibration Using the Touch Screen 29 Touch Screen Descriptions Monitoring 30 UPS Startup Sequence 31 35 ...

Page 4: ...8 Drawings UPS Outline Drawings 108 Block Diagram UPS External Battery Cabinet 109 Block Diagram UPS Input Transformer Cabinet 110 Block Diagram UPS Output Transformer Cabinet 111 Block Diagram UPS Input Output Transformer 112 Block Diagram UPS 3 Breaker MBS 113 Block Diagram UPS 3 Breaker MBS Input Step Down Transformer 114 Block Diagram UPS 3 Breaker MBS Output Isolation Transformer 115 Block Di...

Page 5: ...5 A55 00033 Rev E December 2015 1 Introduction and Safety ...

Page 6: ...AVE THIS MANUAL FOR FUTURE REFERENCE SPECIAL SYMBOLS The following are examples of symbols used on the UPS or within this manual to alert you to important information Please familiarize yourself with these symbols Risk of Electric Shock observe the warnings associated with the risk of electrical shock CAUTION HOT SURFACE Do not touch Risk of burn hazard CAUTION REFER TO OPERATOR S MANUAL refer to ...

Page 7: ...scard never discard Waste Electrical or Electronic Equipment WEEE in the trash For proper disposal contact your local recycling refuse or hazardous waste center Information of Special Note Specific handling or operational instructions may apply Phase This is the electrical symbol for the word phase Recycle equipment or components are made of recyclable material please contact your local recycling ...

Page 8: ...t 6 To prevent damage or a safety hazard keep the UPS away from open flame and any other devices that may cause sparks 7 Do not open or damage individual battery cases as spillage of caustic electrolyte may occur resulting in danger to life safety and the environment 8 The charging characteristics of UPS batteries vary by both brand and type For this reason replacement batteries should be of the s...

Page 9: ...horized distributor for any assistance with troubleshooting 11 The UPS should only be serviced or maintained by a factory authorized service technician 12 This UPS meets FCC Class A electromagnetic compatibility requirements 13 Depleted batteries must be disposed of in a proper manner Contact your local recycling or hazardous waste center or the UPS manufacturer for instructions concerning proper ...

Page 10: ...10 A55 00033 Rev E December 2015 2 Installation ...

Page 11: ...ials 1 Visually inspect the unit for any signs of transit damage Fig 2 1 Remove and retain all associated paperwork packing list user s manual etc that is affixed to the top of the unit Remove the cardboard lid from the top of the container 2 Remove any fasteners from the lower edge of the cardboard container 3 With the help of an assistant carefully lift the heavy cardboard container straight up ...

Page 12: ...r at your desired UPS location is uneven the levelers may be used to steady the UPS once it is in place Please do not install batteries in the UPS Batteries should be installed ONLY by factory authorized personnel once the UPS is in its final location and at the time of initial startup Fig 2 1 Fig 2 2 Fig 2 3 Fig 2 4 Shipping bracket bolts 3 per side UPS Leveler ...

Page 13: ...velers are not designed to support the weight of the entire unit they are to be used when the floor is not entirely level CAUTION Please confirm that the AC Input switch and the Battery Disconnect switch are in the Off position and the Manual Maintenance Bypass is in the Normal position before making any connections to this UPS The POWERVAR 3200 Series requires a 208V three phase four wire ground ...

Page 14: ...net 36 Front of Cabinet 36 Rear of Cabinet 12 Sides of Cabinet 6 Matching peripheral cabinets are considered to be part of the UPS system so the 6 spacing should be taken from the outside edge of the peripheral cabinet POWERVAR 3200 SERIES UPS 12 Inches 6 Inches 6 Inches 36 Inches Front of UPS Minimum Clearance Guidelines ...

Page 15: ...n Recommended Wire Size Terminal Wire Range Min Max Tightening Torque Min Max 10 35A 8 AWG 16 to 0 AWG 2 8 Nm min 3 0 Nm max 20 70A 4 AWG 16 to 0 AWG 2 8 Nm min 3 0 Nm max 30 110A 1 AWG 1 AWG to 350 kcmil 1 to 350 375 In lbs 40 150A 2 0 AWG 2 0 AWG to 350 kcmil 1 0 to 350 375 In lbs Gnd All models 6 AWG 6 2 0 AWG 120 In lbs To be provided by customer 75 C min rated CU conductors only The terminals...

Page 16: ... terminals can be accessed by removing the screws holding the terminal safety cover in place Fig 2 8 This cover is located just below the three rotating handles used for the operation of the UPS Their operation is described elsewhere in this manual Fig 2 8 UPS front view with door opened and terminal safety cover removed ...

Page 17: ... to the L R first four terminals This UPS will not operate without an incoming neutral conductor The required input phase rotation is ABC The output LOAD or T designated terminals conductors are connected to the L R next four terminals In all cases the conductors should enter the enclosure from the bottom and enter the lugs or terminals from the bottom All conductors entering this terminal area mu...

Page 18: ...VA Lug Care should be taken when installing these conductors so as to not confuse the input LINE and output LOAD phase conductors Keeping in mind this UPS requires an input neutral for proper operation Once all conductors are properly landed and sufficiently tightened to their respective torque specs the terminal safety cover may be reinstalled ...

Page 19: ...200 Series UPS to the critical load UPS Model kVA External Overcurrent Protection Recommended Wire Size Terminal Wire Range Min Max Tightening Torque Min Max 10 35A 8 AWG 16 to 0 AWG 2 8 Nm min 3 Nm max 20 70A 4 AWG 16 to 0 AWG 2 8 Nm min 3 Nm max 30 110A 2 AWG 4 AWG to 350 kcmil 1 to 350 375 In lbs 40 150A 1 0 AWG 1 AWG to 350 kcmil 1 0 to 350 375 In lbs Gnd All models 6 AWG 6 2 0 AWG 120 In lbs ...

Page 20: ...20 A55 00033 Rev E December 2015 3 Product Specifications ...

Page 21: ... 18 50 60Hz 3200 30 30 27 50 60Hz 3200 40 40 36 50 60Hz System Input Converter Operating Input Voltage 208VAC operating window 177to 239VAC Nominal 15 15 3 Phase 4 wire Frequency Range 5Hz Input Current THD 1 100 load 2 50 load Input Power Factor 99 100 load 98 minimum 50 load Battery Voltage 432VDC Nominal 36 batteries x 12V Converter Walk in Time 20 Seconds System Input Bypass Nominal Input Volt...

Page 22: ...than 1 linear load0 Less than 2 with a crest factor of 2 5 to 1 Output Overload Capacity 125 for 10min OR 150 for 60 seconds Voltage Transient Response 2 for a 100 step load Environmental Efficiency 100 load Operating Ambient Temperature DC to AC 94 AC to AC 92 Storage Temp non operating 0 to 40 C no derating required Relative Humidity non condensing 20 to 60 C without batteries Recommended 30 to ...

Page 23: ...23 A55 00033 Rev E December 2015 4 Operation ...

Page 24: ...onditions The basic system consists of a rectifier battery and inverter which are complemented by static bypass and manual maintenance bypass switches UPS Operation Normal Mode With the AC supply present the rectifier transforms the AC input into DC raising the DC to a suitable level to supply the inverter and to charge the batteries The inverter transforms the DC bus voltage into AC providing a s...

Page 25: ...teries provide the power necessary to supply the inverter The inverter continues functioning as in normal mode supplying AC power to the critical load CRITICAL LOAD CUSTOMER SUPPLY Rectifier Inverter Static Bypass Switch UPS Cabinet Battery Static Switch Battery Breaker Manual Maint Bypass AC Disconnect ...

Page 26: ...but if a power outage occurs while in this mode the critical load will not be maintained This bypass circuit can be enacted in two ways Normal Bypass This circuit may be enacted manually by use of the stop button Note The rectifier will continue to charge the batteries when in this state CRITICAL LOAD CUSTOMER SUPPLY Rectifier Inverter Static Bypass Switch UPS Cabinet Battery Static Switch Battery...

Page 27: ...rs the output to the critical load will be automatically transferred to bypass mode through the use of the static bypass switch CRITICAL LOAD CUSTOMER SUPPLY Rectifier Inverter Static Bypass Switch UPS Cabinet Battery Static Switch Battery Breaker Manual Maint Bypass AC Disconnect ...

Page 28: ...eans of a make before break manual maintenance bypass switch This same switch simultaneously isolates the output of the UPS which will allow the rectifier and inverter to be energized for troubleshooting and repair purposes without affecting the critical load CRITICAL LOAD CUSTOMER SUPPLY Rectifier Inverter Static Bypass Switch UPS Cabinet Battery AC Disconnect Static Switch Battery Breaker Manual...

Page 29: ...however slight will affect the accuracy of the display and subsequently the overall functionality of the UPS itself This process may be manually initiated at any time by touching anywhere on the display continuously for 10 seconds Using the UPS display The main user interface for this UPS is the touch screen display The Home symbol in the upper left corner returns the user to the home screen from ...

Page 30: ...5 User information text area 6 Power flow diagram 7 User information text 8 External Battery cabinet optional icon appears only when UPS is programmed for the External Battery Cabinet option 9 Action buttons 10 Scroll for hidden action buttons 11 State of UPS 12 User information alert when touched takes user to the relevant informational screen 13 Date and Time 1 3 4 5 6 7 10 11 12 9 13 8 2 ...

Page 31: ...THORIZED PERSONNEL WILL VOID YOUR WARRANTY UPS User s Start up Sequence The POWERVAR 3200 Series UPS utilizes a hinged front door to access its three primary switches These switches are described as L R AC Input which will disconnect the UPS from the AC source the Manual Maintenance Bypass which will seamlessly transfer the critical load to an alternative current path allowing the UPS to be servic...

Page 32: ...o UPS startup and MUST NOT be closed until instructed to do so Step 1 Close the AC Input Switch This will supply power to the UPS and cause the initializing screen to become illuminated Fig 4 7 This screen should be visible for approximately 15 20 seconds and should transition into the start up bypass screen Fig 4 8 4 9 AC Input Switch Manual Maint Bypass Switch Battery Disconnect Battery Chamber ...

Page 33: ...Fig 4 7 Fig 4 8 Fig 4 9 Fig 4 10 Fig 4 11 Step 2 The UPS will pre charge the rectifier and start to energize the DC bus Once the bus is fully charged the unit will alarm to let the user know that the batteries are disconnected and the ...

Page 34: ... The UPS may now be started by pressing the start button at the bottom of this screen Fig 4 12 Step 4 The START STOP screen Fig 4 13 will now appear To actually execute the start sequence the start action button must be pressed AND dragged to the larger gray square to the right Fig 4 14 The UPS will initialize and execute the start function to turn on the inverter Fig 4 14 ...

Page 35: ...has now changed from green to gray and the main power path is now green The battery section is now green and input output and battery charge information has appeared in columns above the power path Also the words normal operation will appear below the power path To return to the Home screen from any other screen simply press the home icon in the upper left corner Pressing the back button on the bo...

Page 36: ...erform a sequential shutdown of your applied load Once there is no critical load the UPS may be transferred to its static bypass state by pressing the stop button at the bottom of the Home screen Fig 4 16 Fig 4 17 Step 2 Drag and drop the red stop action square to the larger gray square to the right The UPS will transfer to static Bypass mode Fig 4 17 ...

Page 37: ... 19 Fig 4 20 Step 3 Open the battery disconnect switch Fig 4 18 which is behind the hinged front door at the lower right side An audible alarm will sound when the breaker is open This alerts the user to the state of the battery breaker Fig 4 19 4 20 AC Input OFF ON Fig 4 21 ...

Page 38: ...gized Maintenance Bypass Mode The POWERVAR 3200 Series UPS is supplied with a make before break maintenance bypass switch as a standard feature This switch allows the user to transfer the UPS to an alternate current path for service or troubleshooting without affecting the applied load If it becomes necessary to utilize this function please follow these steps Fig 4 22 Fig 4 23 Fig 4 24 ...

Page 39: ...e Home screen Fig 4 22 Drag and drop the red stop action square to the gray square at the right Fig 4 23 The inverter will now be offline An alarm will alert the user to the fact the UPS is now in bypass mode and the critical load is no longer battery protected Fig 4 24 4 25 Fig 4 25 Battery Disconnect OFF ON Fig 4 26 Fig 4 27 ...

Page 40: ...26 An audible warning will sound but during this operation the warning may be disregarded Fig 4 27 4 28 Fig 4 28 Maintenance Bypass NORMAL BYPASS Fig 4 29 Fig 4 30 Step 3 Rotate the Maintenance Bypass Switch to the bypass position Fig 4 29 The maintenance bypass path will now appear Fig 4 30 An Alarm will appear to indicate this state Fig 4 31 ...

Page 41: ...e technician without affecting the applied critical load Note opening the AC Input breaker will remove power to the touch screen display and cause it to go completely dark Live voltages are still present at the Input Output terminals of the UPS Once necessary repairs or maintenance is completed the unit may be re transferred back to inverter for normal operation by following these steps ...

Page 42: ...tep 5 Close the AC Input breaker Fig 4 33 This will supply power to the UPS and cause the initializing screen to become illuminated Fig 4 34 This screen should be visible for approximately 15 20 seconds and should transition into the start up bypass screen Fig 4 35 then Fig 4 36 ...

Page 43: ...3 Rev E December 2015 Fig 4 36 Battery Disconnect OFF ON Fig 4 37 Fig 4 38 Step 6 When prompted close the battery breaker Fig 4 37 The display will confirm this operation Fig 4 38 Maintenance Bypass NORMAL BYPASS ...

Page 44: ...ion Fig 4 39 Fig 4 40 Step 8 The UPS may now be started by pressing the start button at the bottom of this screen Fig 4 40 Fig 4 41 Step 9 The start stop screen will appear To actually execute the start sequence the start action button must be pressed AND dragged to the larger gray square to the right Fig 4 41 ...

Page 45: ...ion of the internal control checks Fig 4 42 the inverter will turn on and the Normal Operation screen will appear Fig 4 43 Note The bypass path has now changed from green to gray The main power path is now green the critical load will once again be battery protected Fig 4 43 ...

Page 46: ... frequency and total real apparent power OUTPUT L N voltage and current frequency total effective apparent power and power factor BATTERY with AC present Battery voltage charge current of times on batteries and of battery charge BATTERY when on batteries of times on batteries battery voltage discharge current and estimated runtime at current load BYPASS L L voltage RMS phase current and frequency ...

Page 47: ...tails of last 100 alarm events BATTERY OPERATION HISTORY shows time stamp and date of power fail history DATA LOG shows summary of Input voltage kVA and output current The sample rate for these values is set up in the control menu RELAY STATUS shows configuration of relay contacts ...

Page 48: ...must be utilized to bring them into view START STOP Used to initiate the START STOP funcitons of the UPS Complete functional description of the these sequences is previously described within the User s Startup Sequence portion of this section SETUP This action button will take the user to another set of menu options to set the Date Time configure I O ports and contacts and set the default language...

Page 49: ...49 A55 00033 Rev E December 2015 Fig 4 46 Setting the Date and time The following screens Figs 4 47 to 4 53 take the user step by step through this self explanatory process Fig 4 47 Fig 4 48 ...

Page 50: ...50 A55 00033 Rev E December 2015 Fig 4 49 Fig 4 50 Fig 4 51 Fig 4 52 Fig 4 53 ...

Page 51: ...d to input this new information into the UPS internal clock Setting the COMM Ports Choosing the Comm Ports option Fig 4 54 from the SETUP MENU allows the user the ability to program the communication speed between the UPS and LCD and RS 232 Fig 4 54 Choosing the LCD COMM Fig 4 55 controls the communication between the UPS and the touch screen display This allows the user to manually modify the set...

Page 52: ...ommunication speed Fig 4 58 and contacts of the port on the Communication Interface PCB BM505 of the UPS Fig 4 57 Fig 4 58 To access BM505 open the front access door of the UPS by pulling on its left hand side The Communication Interface board is at the top right side of the UPS just to the right of the two intake fans in the center of the unit Fig 4 58 ...

Page 53: ...400 Interface and RS232 The micro terminals are used to connect an optional external EPO switch and come with a factory installed jumper as the default configuration If used the external EPO switch should have a rating of 12V 3A be a latching type N C contact connected with 18AWG at a maximum length of 25 The DB15 connectors are used exclusively for the parallel operation of two or more UPS EPO Co...

Page 54: ... The pin assignments for the above connectors are as follows Pin No AS 400 Interface RS 232 Serial Comm Port 1 Shutdown No Connection 2 Shutdown RXD 3 No Connection TXD 4 Battery Discharge NO No Connection 5 Common No Connection 6 Bypass No Connection 7 Low Battery No Connection 8 Summary Alarm No Connection 9 Battery Discharge NC No Connection ...

Page 55: ... 60 Setting the I O Contacts When choosing the I O contact option from the setup menu it is important to remember that there are three options Digital Inputs Fig 4 61 Output Contacts Fig 4 62 and AS 400 Interface Fig 4 63 Fig 4 61 Fig 4 62 ...

Page 56: ...4 AWG 2mm 2 to 2 5mm2 with a torque spec of 3 5 to 4 4 inch pounds NC1 NO1 C1 NO2 NC2 C2 C3 C4 NO4 NO5 NO3 NO6 NC3 NC4 NC5 NC6 C5 C6 IN1 IN1 IN2 IN2 IN3 IN3 IN4 IN4 IN5 IN5 IN6 IN6 These terminals are configured as follows INPUT INx and INx OUTPUT NOx NCx and Cx The INPUT terminals are designed to accept an external digital 5V signal The available programmable options for the INPUT contacts are as...

Page 57: ...t Fig 4 64 Fig 4 65 Fig 4 66 Fig 4 67 To program Digital Inputs select one from the list Fig 4 64 by touching the screen The selected input will be highlighted and the Set UP Contact screen will appear Fig 4 65 The location type and number should correspond to the selected input Press the Select Action button and choose from the list of eight options on the Contact Options screen Fig 4 66 Once sel...

Page 58: ... Overload 8 Inverter Voltage Out of Margins 9 Maintenance Bypass Inverter Not Available 10 High Temperature 11 Asynchronous Operation 12 End of Battery Life 13 Battery Temp Too High 14 Battery Test Fail 15 Battery Disconnection Shutdown Restart 16 Inverter Overload 17 Inverter Stopped Due to Shutdown 18 Maintenance Bypass Inverter Stop 19 Parallel System Disconnection 20 Low Battery 21 Emergency P...

Page 59: ...inded to save your contact choice before proceeding Fig 4 70 DATALOG This function allows the user to customize the datalog feature of the UPS This feature will track and record the input voltage load and output currents over a user specified time and sampling rate This log will record 100 events during this time period The circular function allows for a continuous recording of the most recent 100...

Page 60: ...Fig 4 73 After the hours and minutes have been programmed you will need to input the desired sample rate in the example shown above the unit will sample every 20 seconds When finished programming the desired parameters hit SAVE If you want the DATALOG to program to commence you must hit ENABLE As with the I O contacts if you attempt to leave the screen without saving your program you will be remin...

Page 61: ...N When the Enable PIN Security box is checked the Start Stop function will not be available unless this PIN is entered Fig 4 74 Fig 4 74 BATTERY TEST This function allows the user to immediately test the internal batteries Once this test is completed another test may not be executed for at least one hour Fig 4 75a b c Fig 4 75a Fig 4 75b ...

Page 62: ...55 00033 Rev E December 2015 Fig 4 75c TOUCH SCREEN MENUS The following diagrams depict the structure of the available menus for this UPS For ease of understanding the menus are separated into the following ...

Page 63: ... OUTPUT BATTERY BYPASS BYPASS 1 6 MONITOR MENU 1 0 CONTROL MENU 2 0 INPUT 1 1 OPERATE HISTORY ALARM HISTORY BATTERY HISTORY CURR VOLT Depends on mode ALARM CALL ALARM DETAIL DATALOG HISTORY 1 8 DATALOG HISTORY I O CONTACTS I O CONTACTS 1 17 ALARM or Click on red screen title START STOP 3 SILENCE ALARM CONDITONAL PIN INPUT 3 1 START STOP 3 2 START STOP CANCEL BACK See MAIN B BATTERY STATUS 1 41 BAT...

Page 64: ... COMM 2 8 MONITOR MENU 1 0 See MAIN A START STOP 3 0 See tree in MAIN A DATE TIME COMM PORTS I O CONTACTS LANGUAGE I O CONTACTS 2 3 ADD EDIT DIGITAL INPUT OR OUTPUT CONTACT 2 4 SET LANGUAGE 2 15 BATTERY TEST CHANGE DATE TIME CHANGE TIME ZONE 1 50 DIGITAL INPUTS OUTPUT CONTACTS AS 400 INTERFACE SELECT PIN PIN INPUT 3 1 SELECT PIN 2 12 PIN SECURITY DISABLED BATTERY TEST 2 13 Please note This symbol ...

Page 65: ... E December 2015 Home Screen 000 Fig 4 76 The HOME screen and its self explanatory start up variations Fig 4 77 Fig 4 78 The UPS will initialize then automatically go to static bypass Press Start button to activate UPS ...

Page 66: ... Fig 4 79 Fig 4 80 Once START is initiated the rectifier will start after system checks the inverter will come on line Fig 4 81 Fig 4 82 HOME screen during normal and battery operations once BATTERY breaker is closed Fig 4 83 Fig 4 84 ...

Page 67: ... will alarm and transfer to bypass Fig 4 86 When the MAINTENANCE BYPASS switch is placed in the bypass position the maintenance bypass path will appear on the HOME screen Fig 4 86 Please see procedural instructions on pg 38 in this manual to perform this operation This is the only time this path will be seen The UPS may not be started by the user when in this state ...

Page 68: ... at the bottom of this screen can be pushed and scrolled or the individual sections of the power path may be touched to gain access to the following informational screens Fig 4 89 INPUT L L and L N voltage and current frequency and total real and apparent power OUTPUT VOLTAGE L N voltage frequency total effective apparent power and power factor Pressing the blue CURRENT button at the bottom will b...

Page 69: ... RMS and percentage of total available current Fig 4 91 Fig 4 92 BATTERY With AC Present Battery voltage and charge current of times on batteries and of battery charge BATTERY When on batteries of times on batteries battery voltage discharge current and estimated runtime at current load level ...

Page 70: ...ion type time of alarm and code of the alarm Pressing ACK acknowledge will silence the audible alarm Pressing CALL SERVICE will display the phone of local service provider or POWERVAR Fig 4 94 Fig 4 95 OPERATION SUMMARY of times on batteries inverter rectifier run times in hours ALARM HISTORY Time stamp and date PLUS details of the last 100 alarm events ...

Page 71: ...ATTERY HISTORY shows time stamp and date of power fail history Fig 4 98 Fig 4 99 DATA LOG shows summary of input voltage kVA and output current The sample rate for these values is set up in the control menu I O CONTACTS shows configuration of the digital inputs the output contacts and the AS 400 interface ...

Page 72: ...e CONTROL button at the bottom of the HOME screen Once accessed the blue buttons at the bottom of this screen can be pushed or scrolled to gain access to the following interactive screens Fig 4 101 SETUP MENU This screen allows the user access to set the date time configure communication ports the I O contacts and set the default language ...

Page 73: ...33 Rev E December 2015 Fig 4 102 Fig 4 103 Fig 4 104 Fig 4 105 Fig 106 Fig 4 106 These screens guide the user through the process required to set the year date time and time zone on the internal clock in the UPS ...

Page 74: ...to the RS 232 and LCD COMM ports available on this unit Fig 4 108 Fig 4 109 These two screens allow the user to configure the available COMM ports I O CONTACTS Choosing this option will allow the user to custom configure the DIGITAL INPUTS the OUTPUT CONTACTS and the AS 400 INTERFACE ...

Page 75: ...75 A55 00033 Rev E December 2015 Fig 4 110 Fig 4 111 Fig 4 112 Fig 4 113 DIGITAL INPUT press the numbered contact to configure it from the pre determined SELECT ACTION menu Fig 4 114 Fig 4 115 ...

Page 76: ...oe exiting this screen There are a total of eight options for the digital inputs OUTPUT CONTACTS press to highlight the desired output contact then choose from the predetermined SELECT ACTION menu Press NEXT to scroll froward through the menu PREV to scroll back There are thirty different available otions for the output contacts Fig 4 118 Fig 4 119 ...

Page 77: ... 2 Mains Failure Battery Discharging 3 Load on Bypass 4 Battery Low Level Alarm 5 Summary Alarm 6 Rectifier Overload 7 Inverter Overload 8 Inverter Voltage Out of Margins 9 Maintenance Bypass Inverter Not Available 10 High Temperature 11 Asynchronous Operation 12 End of Battery Life 13 Battery Temp Too High 14 Battery Test Fail 15 Battery Disconnection Shutdown Restart 16 Inverter Overload 17 Inve...

Page 78: ...ffect until the SAVE button is pressed The user will be reminded before leaving the set up screen LANGUAGE Allows user to set default language of all screens Factory default is English Fig 4 122 DATALOG SETUP accessed from the CONTROL screen this allows the user to sample and log INPUT voltage and load or OUTPUT phase currents at the rate of their choosing Fig 4 123 Fig 4 124 ...

Page 79: ...s user to enable password security to start stop unit and configure the time date stamp Not checking the enable box will leave unit with no password protection Fig 4 126 BATTERY TEST allows user to immediately test batteries or set up a recurring test schedule ...

Page 80: ...80 A55 00033 Rev E December 2015 Fig 4 127 ...

Page 81: ...81 A55 00033 Rev E December 2015 5 Maintenance ...

Page 82: ...access to the unit Ventilation holes in the UPS are not blocked The operating environment of the system is within POWERVAR specifications Annual maintenance should be performed by factory authorized personnel DANGER This UPS contains lethal voltages Do not operate this UPS with side panels removed or safety shields not in place DC capacitors remain charged after UPS is de energized Wait 5 minutes ...

Page 83: ... dispose of the batteries in a fire Do not attempt to open or mutilate batteries The sealed electrolyte is harmful skin and eyes and may be toxic The charging characteristics of UPS batteries vary by both brand and type For this reason replacement batteries should be of the same brand and type as those specified by the manufacturer Using batteries other than the brand and type specified by the man...

Page 84: ...d during installation of the batteries in the POWERVAR 3200 Series UPS 10 40kVA Please read all instructions before installing or operating the described equipment and PLEASE SAVE THIS MANUAL FOR FUTURE REFERENCE The servicing and installation of batteries should be performed by factory authorized personnel See Battery Installation insert for specific instructions ...

Page 85: ... 1251W FR 20kVA 12v 51W 250 Fast ON GP 12260B1 FR 30 40kVA 12v 26 AH Recessed tab with M5 hole ALTERNATE HR 12120W FR 30 40kVA 12v 120W Recessed insert to accept cccccc M5 bolt ALTERNATE Manufacturer YUASA NP24 12 30 40 kVA 12v 24 AH Recessed tab with M5 hole Manufacturer ENERSYS NP 24 12 30 40kVA 12v 24AH Recessed tab with M5 hole Trays per Model 10 20kVA 6 30 40kVA 12 Use type FR Flame Retardant...

Page 86: ...connect charging source prior to connecting or disconnecting battery terminals Determine if a battery is inadvertently grounded If inadvertently grounded remove source from ground Contact with any part of a grounded battery can result in electrical shock The likelihood of such shock can be reduced if such grounds are removed during installation and maintenance These trays weigh 35 and 60 lbs respe...

Page 87: ...y that you have received the six trays for each unit required for installation Verify that the trays that were sent are correct for the model of UPS that is to be installed the trays for a 10kVA utilize six 12v 34W cell CSB model HR 1234 FR batteries and the trays for the 20kVA utilize six 12v 51W cell CSB model HR 1251 FR batteries The trays used in the 10kVA model utilize a spacer insert at the ...

Page 88: ...tery Tray Spacer Insert 10kVA Only Fig 5 1 Fig 5 2 Verify that all connections between the batteries within the tray are secure if not using the small pliers secure these connections to the battery tabs Fig 5 3 If any interconnection cables are missing from the harness please contact POWERVAR immediately Fig 5 3 ...

Page 89: ...ess connector The range of DC voltage present should be 72 81 vDC Top view Side View End View Typical battery tray connectors 1 Open front door of the UPS by pulling slightly on the left hand side Fig 5 4 2 Uninstall battery chamber cover by removing perimeter cover screws eight total Fig 5 4 Fig 5 5 3 Uninstall battery tray keepers by removing screws 3 each at the front of the individual shelves ...

Page 90: ...ide battery trays one at a time onto the shelves of the UPS The connector should face the front of the UPS Make sure the trays are installed so that they are in contact with the tray stops located at the rear of each shelf Fig 5 6 10 20 kVA Units 3 Battery trays per shelf 6 batteries per tray Total 6 trays 36 batteries Fig 5 6 ...

Page 91: ... per Shelf Secure with 3 screws Fig 5 7 6 The individual battery trays may now be connected to the UPS internal battery harness CAUTION Once a single battery tray connection has been made dangerous DC voltages will be present at the cable connectors Please proceed with great caution The connections are made to the fixed connectors at the right hand side of the battery chamber ...

Page 92: ...92 A55 00033 Rev E December 2015 Expanded view Single shelf 10 20kVA 7 Once all of the tray connections have been made the battery chamber cover may be re installed 8 Once secured the UPS may be started ...

Page 93: ... CSB model GP 12260B1 FR batteries Verify that all connections between the batteries within the tray are secure secure these connections to the battery terminals If any interconnection cables are missing from the harness please contact POWERVAR immediately CAUTION Potentially dangerous DC voltages will be present at the cable connectors Please proceed with great caution Using the voltmeter verify ...

Page 94: ...front of the individual shelves The shelves should now be clear for battery tray installation Fig 5 9 These trays weigh 60 lbs It is recommended that assistance be sought if necessary 4 With any necessary required assistance slide each battery with the connector at the front of the tray onto the shelves of the UPS In the 30 40kVA units great care should be taken to avoid internal battery cable har...

Page 95: ...in contact with the tray stops located at the rear of each shelf Fig 5 10 30 40kVA units 4 battery trays per shelf 3 batteries per tray Total 12 trays 36 batteries Fig 5 10 5 Once all trays on any shelf are in place the tray keepers may be re installed Fig 5 11 ...

Page 96: ...ttery trays may now be connected to the UPS internal battery harness CAUTION Once a single battery tray connection has been made dangerous DC voltages will be present at the cable connectors Please proceed with great caution On the 30 40kVA units the connections are made to the corresponding fixed connectors above the shelf in the battery chamber ...

Page 97: ...97 A55 00033 Rev E December 2015 Expanded view Single shelf 30 40kVA 7 Once all of the tray connections have been made the battery chamber cover may be re installed 8 Start UPS per start up procedure ...

Page 98: ...98 A55 00033 Rev E December 2015 6 Warranty ...

Page 99: ... Additionally any costs related to installation or de installation of the Product for the purpose of replacement or servicing will be the Customers sole responsibility POWERVAR makes no warranties expressed or implied of merchantability fitness for a particular purpose performance condition capacity or otherwise POWERVAR is not liable for incidental or consequential damages monetary loss loss of s...

Page 100: ...ut notice Life Critical Applications While POWERVAR believes it designs and manufactures very reliable Products many of the vendors that POWERVAR sources components from do not recommend or endorse the use of their Products in life critical applications By extension POWERVAR must adhere to the same business policy and does not recommend the use of our Products in life critical applications Disclai...

Page 101: ...101 A55 00033 Rev E December 2015 7 Service and Troubleshooting ...

Page 102: ...nformational in nature alerts the user to an operating anomaly which may require action by the user to resolve It is recommended that the user take the appropriate follow up action indicated Warning A warning indicates a condition which if left unattended may result in the critical load not being protected by the UPS Upon receipt of this indication it is recommended that the user take the appropri...

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Page 107: ...107 A55 00033 Rev E December 2015 8 Drawings ...

Page 108: ...108 A55 00033 Rev E December 2015 POWERVAR 3200 Series 10 20kVA Dimensions ...

Page 109: ...109 A55 00033 Rev E December 2015 POWERVAR 3200 Series 30 40kVA Dimensions ...

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Page 118: ...mensions Model kVA UPS Crate Battery Pallet 10 24 W x 41 D x 56 H 441 lbs 40 W x 48 D x 32 H 479 lbs 20 24 W x 41 D x 56 H 449 lbs 40 W x 48 D x 32 H 581 lbs 30 29 5 W x 40 D x 66 5 H 650 lbs 40 W x 48 D x 30 H 840 lbs 40 29 5 W x 40 D x 66 5 H 715 lbs 40 W x 48 D x 30 H 840 lbs ...

Page 119: ...n UPS rated output it is recommended that AC input battery and AC output wiring and overcurrent protection be sized to UPS full load rating to accommodate possible Additional Notes future expansion A Ratings of cables and overcurrent devices supplied for information only User to consult with 5 Nominal battery voltage lead technology 2 0 volts cell cutoff 1 7 volts cell it s engineering services be...

Page 120: ...9 7179 Inside Illinois 847 596 7000 FAX 847 596 7100 POWERVAR Mexico Camino a la Montana No 178 101 PB4 Fracc Industrial La Perla 53340 Naucalpan Edo De Mexico Phone 52 55 5363 5448 FAX 52 55 5540 4430 International address POWERVAR Ltd Unit 5 Birch Kembrey Park Swindon Wilts SN2 8UU UK Phone 44 1793 553980 FAX 44 1793 535350 ...

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