Chloride SYNTHESIS User Manual Download

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PHONE: 1-800-239-2257 FAX: 1-800-833-6829 24HR SERVICE: 1-800-388-4234

28430 NORTH BALLARD DRIVE

LAKE FOREST, IL 60045

Summary of Contents for SYNTHESIS

Page 1: ... 67 06 8VHUV 0DQXDO DWH QVWDOOHG BBBBBBBBBB 6WDUW 8S DWH BBBBBBBBBB 0RGHO 1XPEHU BBBBBBBBBB 6HULDO 1XPEHU BBBBBBBBBB PHONE 1 800 239 2257 FAX 1 800 833 6829 24HR SERVICE 1 800 388 4234 28430 NORTH BALLARD DRIVE LAKE FOREST IL 60045 ...

Page 2: ...ther cables are connected the equipment grounding conductor shall be connected 2 An insulated grounding conductor that is at least the same size insulation material and thickness as the ungrounded branch circuit supply conductors except that it is green with or without one or more yellow stripes is to be installed as part of the branch circuit that supplies the unit or system 3 The grounding condu...

Page 3: ...BINET 8 12KVA 20 1 6 5 CONNECTION OF THE LOAD WIRING 21 1 6 6 LEVELING THE CABINETS 24 1 7 ELECTRICAL CONNECTIONS 14 18KVA 25 1 7 1 CONNECTING THE AC INPUT SUPPLY TO THE UPS 25 1 7 2 BATTERY CABINET CONNECTIONS 29 1 7 3 CONNECTION OF THE LOAD WIRING 14 18KVA 30 1 7 4 LEVELING THE CABINETS 30 2 0 CONTROLS AND OPERATION 31 2 1 INTRODUCTION 31 2 2 CONTROL PANEL 31 2 2 1 COMMANDS AND SIGNALS 31 2 2 2 ...

Page 4: ...2 5 LIFE2000 50 4 2 6 OPTIONS SUMMARY TABLES 51 5 0 SPECIFICATIONS 52 5 1 ELECTRICAL 52 5 1 1 SYNTHESIS 4 12kVA 52 5 1 2 SYNTHESIS 14 18kVA 53 5 2 MECHANICAL 53 5 2 1 SYNTHESIS 4 12kVA 53 5 2 2 SYNTHESIS 14 18kVA 54 6 0 SPARE PARTS LISTING 54 6 1 4 6 KVA SPARE PARTS LISTING 54 6 2 8 12 KVA SPARE PARTS LISTING 55 6 3 14 18KVA SPARE PARTS LISTING 56 7 0 WARRANTY 57 4 ...

Page 5: ... OR 240VAC INPUT AND 120 240VAC OUTPUT 26 FIGURE R SINGLE AC SOURCE 14 18KVA 208 OR 240VAC INPUT AND 208VAC OUTPUT 27 FIGURE S CONFIGURING THE DUAL FEED OPTION 14 18KVA 28 FIGURE T BATTERY INPUT CONNECTION DETAIL BACK OF ELECTRONICS MODULE 29 FIGURE U BATTERY CABINET CONNECTION DETAIL 29 FIGURE V UPS SWITCHES 4KVA TO 12KVA 33 FIGURE W BATTERY CABINET CONNECTIONS 33 FIGURE X UPS SWITCHES 14 18KVA 3...

Page 6: ... FSU was ordered contact your Chloride Power Electronics Sales Agent two weeks prior to the desired start up date CAUTION WEAR PROTECTIVE GOGGLES OR SAFETY GLASSES WHEN HANDLING BATTERIES LEAD ACID BATTERIES CONTAIN SULPHURIC ACID NICKEL CADMIUM BATTERIES CONTAIN POTASSIUM HYDROXIDE CAUSTIC POTASH CONTACT WITH THESE ELECTROLYTES IS DANGEROUS AND COULD RESULT IN BURNS IF EITHER OF THESE ELECTROLYTE...

Page 7: ...upper compartment of the Output Cabinet of 4 12kVA only Check each package for shipping damage and for proper marking The Installation Kit is enclosed in the Output Cabinet The necessary hardware flexible conduit and interconnect cables are included in the Installation Kit All external wire and fittings are supplied by the customer in compliance with local code requirements The Electronics Module ...

Page 8: ...a well ventilated area The ambient temperature in the installation area must not exceed 90 F for Lead Battery Systems The site foundation must be capable of supporting 300 pounds per square inch Wall mounting of this equipment is not recommended NOTE Consider cabinet diagram Figures A and B before final system placement Allow at least three 3 feet in front of and four 4 inches behind the cabinets ...

Page 9: ...TPUT CAB FRONT Figure A Recommended placement Standard configuration 4 12kVA overhead view BATT CAB OUTPUT CAB UPS FRONT CABLE ENTRY BOTTOM FRONT Figure B Recommended placement Extended Run configuration 4 12kVA overhead view 9 ...

Page 10: ...it weights 1 5 2 SPECIFICATIONS FOR UTILITY INPUT LINE AND RATINGS This system must be connected to a properly rated 60Hz 5 line Voltage tolerance must be 10 of nominal Refer to Table B for the proper input current rating 1 5 3 INSTALLATION DATA Ambient temperature 0 C to 40 C 32 F to 104 F Relative humidity w o condensing at 20 C 90 Maximum altitude without derating 1000 m 3300 ft Cable entrance ...

Page 11: ...ORAGE DATA Temperature limits batteries 0 C to 35 C 32 F to 88 F Temperature limits electronics 20 C to 70 C 0 F to 144 F Relative humidity from 0 to 90 1 5 5 EXTERNAL PROTECTION DEVICES AND WIRE SIZES The Synthesis UPS does not contain branch overcurrent protection devices on either its input or output It is the responsibility of the installer to provide this protection Read the following section...

Page 12: ...ated UPS output current UPS Rating kVA Nominal UPS Output Voltage s 4 5 6 8 10 12 14 16 18 120 only 33 42 50 67 83 100 N A N A N A 208 only 19 24 29 38 48 58 67 77 87 240 only 17 21 25 33 42 50 58 67 75 120 208 33 19 42 24 50 29 67 38 83 48 100 58 117 67 133 77 150 87 120 240 17 21 25 33 42 50 58 67 75 120 208 configuration is NOT a 3 wire system Total not to exceed rating of the unit 120 240 rati...

Page 13: ...closure and all packing material from the Output Cabinet Attach the ramp to the front of the pallet and roll the unit down the ramp 1 6 ELECTRICAL CONNECTIONS 4 12kVA NOTE Save shipping materials of all cabinets until final testing is complete NOTES Connections to the building electrical system should utilize flexible raceway to allow movement of the cabinet for service access All cabinets should ...

Page 14: ...tection panel situated on the rear of the UPS Ensure that the UPS is electrically isolated before removing this panel NOTE Once installation has been completed the leveling feet on the UPS should be lowered so that the casters are off the floor Input and Battery Connections Conduit Entry Points Figure D UPS connections back of UPS 4 12kVA 14 ...

Page 15: ... Battery Cabinets Extended Run Battery Connection if present To Output Cabinet Utility Input Figure E Single AC Source The configuration shown in Figure E details the connections when the UPS is fed by a single AC source In this configuration the rectifier bypass and maintenance bypass lines are all fed by the same source Connect your utility input wires to the Utility Input terminals marked L1 an...

Page 16: ... are between L1 and third terminal from the left and L2 and fourth terminal from the left The configuration shown in Figure F shows the terminal connections necessary when a second source is brought to the UPS Bypass line supplies the static bypass line and the maintenance bypass line while Utility input supplies the rectifier and inverter of the UPS After removing the jumpers shown in Figure F co...

Page 17: ... Figures G or H Ensure that the battery disconnect switch QS5 is in the OFF 0 position before completing the interconnect wiring Attach the other end of the conduit to the knockout hole in the bottom rear of the battery cabinet Note the cover panel on the back of the battery cabinet must be removed to gain access to the conduit holes and terminal blocks Connect the battery cables to the battery ca...

Page 18: ...QS5 B B GND QS4 QS3 QS1 BLK FROM BATTERY CABINET RED Figure H Battery Input Connection Detail 8 12kVA Models Back of Electronics Module GND NEG POS Figure I Battery Cabinet Connection Detail 18 ...

Page 19: ...d lifting the panel off Remove the knock out from the conduit panel located in the bottom front of the cabinet Route the wires through the knockout hole Secure the conduit to the access panel Connect the black cables to terminals A and B in the output cabinet and the green and yellow wire to the ground stud as shown in Figure J The leveling feet of the output cabinet should be lowered after instal...

Page 20: ...ing the panel off Remove one of the knock outs from the conduit entry panel located at the bottom front of the cabinet Route the wires through the knockout hole Secure the conduit to the access panel Connect the black cables to terminals A and B in the output cabinet and the green and yellow wire to the ground stud as shown in Figure K The leveling feet of the output cabinet should be lowered afte...

Page 21: ...ions NOTE This equipment is manufactured as a separately derived system The output neutral shall be grounded in accordance with NEC Art 250 5 1 6 5 1 HARDWIRE CONNECTIONS STANDARD The UPS in its standard configuration has hardwire connections configured according to the following drawings Customer terminal connections Conduit knockouts Ground bond electrode connection point Figure L Customer conne...

Page 22: ...cted using terminals L2 and L4 Use L1 and N and or L3 and N for 120VAC loads Refer to Figure N below The total kW drawn from these three connections cannot exceed the kW rating of the UPS Note Balance 120V loads evenly between L1 N and L3 N Labels Terminals 208 V 120 V 120 V 240 V L4 L2 GND L3 N L1 Figure M 120 208 240 Output connections 4 12kVA 22 ...

Page 23: ...A or 16 8 12kVA 1 breakers inside the Output Cabinet The PDP comes configured for 120 240 volts only In 120 208 240 applications the 208 volt connection is a hardwire only Ground bond electrode Conduit knockouts Ground bus Breaker pole positions Neutral bus Figure N Output Cabinet with PDP configuration Note The 8 12kVA units contain 2 PDPs 23 ...

Page 24: ...LING THE CABINETS After all connections have been completed adjust leveling feet to lift casters off of the floor and immobilize the cabinets See Figure O LEVELING FEET 4 PLACES Figure O Leveling the cabinets 24 ...

Page 25: ...f the Electronics Cabinet and at the rear of the Battery Cabinet 1 7 1 CONNECTING THE AC INPUT SUPPLY TO THE UPS In order to gain access to the external electrical connections it is necessary to remove the protection panel situated on the rear of the UPS Ensure that the UPS is isolated before removing this panel NOTE Once installation has been completed the leveling feet on the UPS should be lower...

Page 26: ...s fed by a single 208 or 240VAC source and a 120 240VAC output is required Connect the utility supply cables to L7 and L8 and connect the grounding cable to one of the ground studs on either side of the terminal blocks Connect the load lines to L3 N and L4 N for 120VAC loads Ensure that the loads are evenly balanced between L3 and N and L4 and N For 240VAC loads connect the load lines to terminals...

Page 27: ... connections when the UPS is fed by a single 208 or 240VAC source and a 208VAC output is required Connect the utility supply cables to L7 and L8 and connect the grounding cable to one of the ground studs on either side of the terminal blocks Connect the load lines to terminals L5 and L6 The load grounding cable should be connected to one of the ground studs The external battery cabinet connection ...

Page 28: ...IES Figure S Configuring the dual feed option 14 18kVA Removing the two jumpers shown in Figure S allows the UPS bypass line to be fed by a separate source Connect the source that is to supply the Bypass and the Maintenance Bypass to L1 and L2 The source that is to supply the rectifier the main input is to be connected to L7 and L8 Refer to Figure S above for these connection locations 28 ...

Page 29: ...d Cable connects to Battery Positive The green and yellow wire connects to the ground stud L1 L2 L7 L8 L3 N L4 L5 L6 _ EXTERNAL BATTERIES Figure T Battery Input Connection Detail Back of Electronics Module Next attach the other end of the conduit to the battery cabinet and connect the black cable to Battery Negative and the red cable connects to Battery Positive The green and yellow wire connects ...

Page 30: ...18kVA Connections for 240VAC loads are available between L3 and L4 Figure Q Loads that utilize 208V can be connected using terminals L5 and L6 Figure R Use L3 and N and or L4 and N for 120VAC loads Figure Q Ensure that the loads are evenly balanced between L3 and N and L4 and N The total kW drawn from these connections cannot exceed the kW rating of the UPS All reference figures are located in sec...

Page 31: ...PS which provides visual LED and audible indications of the current condition of the supply to the load 2 2 2 VISUAL INDICATIONS The visual indications are in three different colors that are associated with a set of easy to understand symbols LED 1 LED 2 LED 3 Red Yellow Green NOTE For a description of the significance of the visual indications see Table D 2 2 3 COMMAND BUTTONS These buttons allow...

Page 32: ...n 24 hours call the Customer Service Center Off ON Off Active WARNING UPS supplying load with INVERTER OFF UPS supplying load in pre alarm condition e g high ambient temperature or mains interruption Start INVERTER by pressing appropriate button If the condition persists for more than 24 hours contact the Customer Service Center ON ON Off Active FAILURE UPS supplying load with battery switch OPEN ...

Page 33: ...ITS QS1 QS3 QS4 QS5 Figure V UPS Switches 4kVA to 12kVA A A BATTERY CONNECTOR C C BATTERY CONNECTOR Figure W Battery Cabinet Connections Step 1 Join battery inter shelf connectors A A and C C Step 2 Turn on the battery switch QS5 Step 3 Turn on the input switch QS1 Step 4 Wait approximately 3 seconds then close output switch QS4 Step 5 Close all output circuit breakers at the output distribution m...

Page 34: ...ry switch QS5 Step 2 Turn on the input switch QS1 Note This switch controls both the utility and the bypass paths in dual input machines Step 3 Wait approximately 3 seconds then close output switch QS4 Step 4 Press the inverter start button on the front panel The green LED should illuminate 34 ...

Page 35: ...inimum of 24 hours in order to recharge the batteries 2 5 MANUAL BYPASS PROCEDURE 4 18kVA Step 1 Press the inverter stop button for at least 2 seconds Step 2 Turn on QS3 manual bypass Step 3 Turn output switch QS4 off Step 4 Turn the input switch QS1 off Note This switch controls both the utility and the bypass paths in dual input machines Step 5 All LEDs shall be extinguished Step 6 Turn the batt...

Page 36: ...the reserve static switch In the event of a power event the load is transferred to the inverter for a time period determined by the duration and severity of the power disturbance and then transfers back to the reserve line In Double Conversion mode The AC input power is rectified to DC to power the inverter and charger The inverter converts this to AC to power the load through the inverter static ...

Page 37: ...BATTERY CABINET OPTIONAL 4 12kVA LOAD OUTPUT CABINET QS3 QS4 QS1 UPS CABINET INTERNAL BATTERIES QS5 INPUT POWER SUPPLY Figure Y UPS Block Diagram 37 ...

Page 38: ...les or safety glasses when handling batteries All battery connections should be checked annually to make sure they are tight and free of contamination Re torque according to instructions printed on battery case Tops of cases should be kept free of dust 3 4 TROUBLESHOOTING PROCEDURES If the installation and operating instructions are followed carefully you should encounter no difficulty with the pe...

Page 39: ...SW2 SW1 F7 F8 8 12 kVA Port RS232 ALAR M SUMMAR Y RS232 Used by front panel display COMPUTE R INTERFA CE TM Figure Z UPS Module Interface Connector Locations 4 12kVA Back of Unit RS 232 INTERFACE REMOTE EPO TERMINAL RS 232 USED BY FRONT PANEL DISPLAY SUMMARY ALARM AS 400 TM INTERFACE DIP SWITCHES MODEM POWER SUPPLY Figure AA UPS Module Interface Connector Locations 14 18kVA Back of Unit 4 1 INTERF...

Page 40: ...wer factor of UPS output Number and duration of mains interruptions Time on direct line Time on conditioned line 4 1 1 1 MESSAGES AND ALARMS The diagnostic procedure is divided into BLOCKS each of which represents a functional part of the UPS SYSTEM INPUT BATTERY INVERTER DIRECT LINE LOAD Four levels of information are available for each block BLOCK STATUS MEASUREMENT and ALARM PAGES BLOCK PAGE Th...

Page 41: ...ANY MESSAGES 5 SECONDS DELAY LIST OF LANGUAGE SELECT LANGUAGE BATTERY TEST START STOP INVERTER EXIT FUNCTION MENU c b a FUNCTION MENU Note If an attempt is made to send a remote command BATTERY TEST INVERTER START STOP to a UPS which is not in the normal operating condition e g battery recharging overload alarm active a message to this effect will be displayed for 5 seconds followed by the CONFIRM...

Page 42: ...ormation LOAD DIRECT LINE INVERTER BATTERY FUNCTION MENU SEE DIAGRAM C TO SYSTEM BLOCK PAGE INPUT SYSTEM STATUS PAGE MEASUREMENT PAGE ALARM PAGE BLOCK PAGE If no alarms are active this part will not be displayed and the system will return to the relevant block page upon exit from the Measurements page 42 ...

Page 43: ...OCK PAGE If active 4 1 2 RS 232 INTERFACE The UPS is equipped with a 9 pin D type connector which makes it possible to connect a computer to the microprocessor inside the UPS Note that the proper port to connect to is the one on the far right The center port is tied up with the internal display in the standard product Figure BB Installation of RS 232 computer interface 4 12kVA 43 ...

Page 44: ... LIFE remote monitoring system more details in Section 4 2 OPTIONS The pin out of the connector is as follows Table E Functions of RS232 connector N PIN DESCRIPTION FUNCTION 1 Data Carrier Detect DCD 2 Received data RXD 3 Transmitted data TXD 4 Data Terminal Ready DTR 5 Common GND 4 1 3 STATUS CONTACTS In addition to the RS 232 interface the Synthesis has a contact closure status port as shown bel...

Page 45: ...F Description of communication signals N PIN DESCRIPTION FUNCTION 1 4 Not Used Not used 5 Common Reference ground for all the status contacts but not the REPO contact 6 ABNORMAL operation Operation condition NOT in accordance with the assigned priority 7 Low battery The battery is nearly exhausted and in a short time the UPS will switch OFF and the load will be transferred automatically to the dir...

Page 46: ...ing load AC 2000VA Max switching load DC 8A for VDC 35V 50 watts for 300V VDC 35V 4 1 4 REMOTE UPS POWER OFF The UPS is provided with terminals allowing the installation of an external Emergency Power Off EPO switch in addition to the switch on the front panel A normally closed switch must be used The EPO becomes active when this switch opens normally closed contact To install the Remote EPO switc...

Page 47: ...pped with a remote indication that provides a summary of the alarm status 1 2 3 Figure II SUMMARY ALARM terminals 4 12kVA The summary alarm is simply a form C relay that changes state when there is a problem with the UPS The rating of these contacts is 1A 220 VAC VDC terminal 1 connected to terminal 2 UPS OK terminal 2 connected to terminal 3 UPS IN ALARM 47 ...

Page 48: ...ation from the UPS module The Remote Display requires the Optional RS232 Serial Port The Remote Display cable connects to the Optional RS232 port and low voltage power supply terminals on the rear of the Electronics Module Detailed instructions are provided in Figure KK 1 1 DISPLAY DISPLAY 2 RS232 SW1 SW2 1 3 4 5 7 8 1 8 2 6 2 3 4 5 6 7 OFF ON 2 3 Connections Inside Remote Display 4 5 48 ...

Page 49: ...6 7 8 XT1 RS232 Figure KK Remote Display Connection Detail 4 12kVA 49 ...

Page 50: ...description of the UPS working status along with suggestions for possible remedial actions when necessary After having inserted a password EASY PLUS allows the operator to select working priorities Line Interactive or Double Conversion 4 2 4 EASY PLUS 1000 With an interface kit using an RS422 485 protocol it is possible to transfer UPS diagnostic information to a non dedicated PC up to 1000m away ...

Page 51: ...sequent analysis permit the service engineer to compile a detailed report that will be forwarded to the Customer periodically with the aim of informing her him of the condition of the UPS and of preventing potentially critical situations Please note that LIFE2000 is not a power quality monitoring system but a UPS monitoring system Chloride Power Electronics will not notify the customer in case of ...

Page 52: ...ase Factory Wired NOT AVAILABLE ON 6kVA or 12kVA SYSTEMS Output Voltage 120 208 240V Single Phase Factory Wired Output Frequency 60 Hz 0 05 Output Voltage Regulation 6 Static Dynamic Output Voltage 5 0 100 AND 100 0 Load Regulation Variation Over Static Regulation Charging Current 1A 4 6kVA 2A 8 12kVA Efficiency Measured at Rated Load 0 7 pf Line Interactive Mode 93 Double Conversion Mode 87 4 6kV...

Page 53: ...tatic Regulation Charging Current 3A Efficiency Measured at Rated Load 0 7 pf Line Interactive Mode 95 Double Conversion Mode 82 5 2 MECHANICAL 5 2 1 SYNTHESIS 4 12kVA Operating Temperature Range 0 40 C 32 104 F Temperatures above 25 C 77 F shorten battery life and affect system warranty Cooling Forced Air Unit Size kVA 4 0 5 0 6 0 8 0 10 0 12 0 Heat Rejection BTU Hr 1430 1790 2140 2600 3250 3900 ...

Page 54: ... 5 10B46347P001 FU7 FU8 Fuse 1A 250V Delayed 5 10B46209P05R FU9 Fuse 2A 500V Delayed 5 10B46209P11R FU3 FU6 AP1 Fuse 8A 500V Delayed 2 00B46030PF05T FU1 AP2 1 A Fuse Delayed 4 6 kVA Level 2 KIT P N SPK6KL2 Qty Part number CIRCUIT DESIGNATION Description 1 10B44112P0506 V5 IGBT 2 x 50A 600 V 1 10B44112P0512 V7 IGBT 2 x 50A 1200 V 1 10B44114P01 V4 SCR 40A 1200V 1 10B44087P2 V6 Diode ultra fast 2 x 3...

Page 55: ... 8 12 kVA Level 2 KIT P N SPK12KL2 Qty Part number Description 1 10B44112P1006 V5 IGBT 2 x 100A 600V 1 10B44112P1012 V7 IGBT 2 x 100A 1200V 1 10B44087P3 V6 Diode ultra fast 2 x 60A 600V 2 00B44074PT312 V3 V8 V9 SCR 55A 1 10B44114P02 V4 SCR 90A 1200V 1 10B48270P1 EV1 EV3 Fan EDP 50 8 12 kVA Level 3 KIT P N SPK12KL3 Qty Part number CIRCUIT DESIGNATION Description 1 15B10722G1 AP4 Micro board 1 15B10...

Page 56: ...EVEL 2 KIT P N SPK18KL2 Qty Part number CIRCUIT DESIGNATION Description 1 10B44112P2006 V5 IGBT 2 x 200A 600V 1 10B44112P2012 V7 IGBT 2 x 200A 1200V 1 10B44114P02 V4 SCR 90A 1200V 1 10B44087P3 V6 Diode 2 x 60A 600V 2 00B44074PT512 V3 V8 V9 SCR 90A 1200V 1 UPFAN011 EV1 EV7 Fan EDP 50 18K LEVEL 3 KIT P N SPK18KL3 Qty Part number CIRCUIT DESIGNATION Description 1 15B10722G1 AP4 Micro Board 1 15B10703...

Page 57: ...7 0 WARRANTY INSERT MARKETING LITERATURE DOCUMENT Warranty Statement 57 ...

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