Emerson 7400 Series User Manual Download

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Single Phase UPS system

S i n g l e m o d u l e

a n d ‘1 + N’ ( e x p a n d a b l e )

U s e r M a n u a l

UNINTERRUPTIBLE POWER SYSTEM

EMERSON Network Power (India) Pvt. Ltd.

Summary of Contents for 7400 Series

Page 1: ...Single Phase UPS system S i n g l e m o d u l e a n d 1 N e x p a n d a b l e U s e r M a n u a l UNINTERRUPTIBLEPOWERSYSTEM EMERSON Network Power India Pvt Ltd ...

Page 2: ...on If you already own and use a Liebert we are doubly honoured by your decision of continuing this relationship It is our constant endeavour to partner you for the growth and success of your business This philosophy is reflected in our Mission statement To deliver value through Air Power Quality solutions to achieve customer delight Please do give us feedback to help us realize our Mission Emerson...

Page 3: ...se in any life support application If you encounter any problem with the procedures contained in this manual you should seek immediate assistance from Emerson Network Power India Pvt Ltd Sales Office from whom the equipment was purchased Alternatively contact the Emerson Network Power India Pvt Ltd Customer Service Support department at the address shown below EMERSON NETWORK POWER INDIA PRIVATE L...

Page 4: ...inema LBS Road Ghatkopar W MUMBAI 400 086 Tel 022 5002318 5002294 5002437 Fax 022 5002415 Pager 9623 988 000 Mobile 9820030917 9820030915 NEW DELHI 18 14 WEA Pusa Lane Karol Baug NEW DELHI 110 005 Tel 011 5724706 5781878 5781071 5744774 5766438 Fax 011 5757601 Pager 9632 100 300 KOLKOTA 77 A Raja Basant Roy Road KOLKOTA 700 029 Tel 033 4646387 4647197 Fax 033 4667172 BANGALORE 501 C Wing Mittal To...

Page 5: ...ar CHENNAI 600 017 Tel 044 8231742 8221063 8228996 Fax 044 8231742 NAGPUR 203 Ganga Apts 13 Giripeth NAGPUR 400 010 Phone Fax 0712 540423 548551 COCHIN Lakshmini No 36 2684 Veluthamma House Azad Road Kaloor COCHIN 682017 Tel 0484 341985 Fax 0484 341986 PUNE B 6 Shri Dwarka co op Society 467 C1 Hare Krishna Mandir Path Model Colony Off University Road PUNE 411006 Tel 020 5676975 5670709 Fax 020 400...

Page 6: ...NING HIGH EARTH LEAKAGE CURRENT EARTH CONNECTIONS IS ESSENTIAL BEFORE CONNECTING THE INPUT SUPPLY This equipment must be earthed in accordance with local electrical codes WARNING THIS UPS DOES NOT INCORPORATE AUTOMATIC BACKFEED PROTECTION A WARNING LABEL MUST BE FITTED TO ALL EXTERNAL PRIMARY POWER ISOLATIONS STATING INSULATE THE UNINTERRUPTIBLE POWER SYSTEM BEFORE WORKING ON THIS CIRCUIT ...

Page 7: ...ions concerning local environmental conditions and the provision of protective clothing first aid and fire fighting facilities TEST EQUIPMENT When the battery is under charge it is earth referenced about its mid point e g if the battery s being charged at 460V the battery extremities will be at 230V and 230V with respect to neutral earth When using mains powered test equipment such as oscilloscope...

Page 8: ...autions 14 1 3 1 General 14 1 3 2 Batteries 14 1 3 3 Test Equipment 14 1 3 4 Personnel 14 2 Operating Instructions 15 2 1 Introduction 15 2 1 1 Redundant Module System 15 2 1 2 Non Redundant Module System 15 2 1 3 General Notes 15 3 Installation Electrical 21 3 1 Introduction 21 3 1 1 Equipment Positioning and Environmental considerations 22 3 1 2 Raised floor installation 22 3 1 3 Battery Locatio...

Page 9: ...Alarm Outputs 40 4 3 2 Remote control inputs 40 4 4 Remote Alarm Monitor RAM for Single Module and 1 1 UPS System 42 5 Maintenance 47 5 1 Introduction 47 5 2 Safety Precautions 47 5 3 Scheduled Maintenance 47 5 3 1 Daily checks 47 5 3 2 Weekly checks 48 5 3 3 Annual Service 48 5 3 4 Extended Service 49 5 3 5 Battery Maintenance 49 6 Troubleshooting 51 6 1 Troubleshooting UPS systems 51 6 1 1 Opera...

Page 10: ...ne system comprises two standard 7400 series UPS modules which are modified to allow their outputs to be connected in parallel These can then be used in a redundant or non redundant configuration as explained below In a non redundant module configuration the system is sized such that both UPS modules are required to feed the potential load and if one of the two modules develops a fault or is for s...

Page 11: ...ilure the rectifier becomes inoperative and the inverter is powered solely from the battery Critical load power is maintained under these conditions until the battery is fully discharged whereupon the UPS shuts down The end of battery discharge is assumed when the battery voltage falls to 320Vdc In case of 80 to 125 kVA 1 PH models the end of discharge is taken as 330Vdc The period for which the l...

Page 12: ...an acceptable frequency window of 1Hz A warning message INVERTER UNSYNCHRONIZED is displayed on the operator control panel when the inverter and bypass supplies are not synchronized A second manually controlled Maintenance bypass supply is also incorporated into the UPS design Its purpose it to enable the critical load to be powered from the mains bypass supply while the UPS is shut down for maint...

Page 13: ...ssified as a power the reset switch may be used as a part of the UPS operating procedure Fitted to the UPS Logic Board the reset switch is used by the operator to re transfer the load to the inverter following a detected overload or overtemperature fault The battery is connected to the DC Busbar through a circuit breaker fitted inside the battery Cabinet Rack or located adjacent to the batteries w...

Page 14: ...Isolator 830 830 I4 Output Isolator I3 Maintenance Bypass Isolator I2 Static Bypass Isolator I1 Input Isolator I4 Output Isolator I3 Maintenance Bypass Isolator I2 Static Bypass Isolator I1 Input Isolator 900 900 I4 Output Isolator I3 Maintenance Bypass Isolator I2 Static Bypass Isolator I1 Input Isolator 1400 1400 I4 Output Isolator I3 Maintenance Bypass Isolator I2 Static Bypass Isolator I1 Inpu...

Page 15: ...t Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 900 900 I4 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 1250 1250 I4 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 1400 1400 Figure 3B Power Isolator identification for 110V output system 10 40 kVA 50 kVA 60 70 kVA 105 kVA ...

Page 16: ...equency Current sharing The parallel control circuit compares the module s output current with that of its partner and is thereby able to effect current sharing between the modules by making fine adjustments of an individual module s output voltage Redundancy configuration A link in the parallel control logic determines whether the one plus one system operates in a redundant or non redundant confi...

Page 17: ...tion kit which allows the two modules in a one plus one system to share a common battery Such an installation is shown in figure 5 overleaf Figure 4 Parallel control in a one plus one system RECTIFIER STATIC SWITCH INVERTER Mains Supply BATTERY 1 1 PARALLEL CONTROL RECTIFIER STATIC SWITCH INVERTER Mains Supply BATTERY 1 1 PARALLEL CONTROL Bypass Supply Bypass Supply UPS Output Supply ...

Page 18: ...s a module to match its charge current to that of its partner by effecting fine voltage control over the rectifier section The components used by the Common Battery Option are contained in a separate cabinet known as the Common Battery Panel Figure 5 Common Battery configuration 1 2 7 Common Battery RECTIFIER STATIC SWITCH INVERTER Mains Supply UPS Output Supply BATTERY 1 1 PARALLEL CONTROL RECTIF...

Page 19: ... LS2 Battery volts OK This led illuminates when the battery circuit breaker is closed and the battery voltage is within the UPS operating range 320V 432V nominal 330V 445V nominal for the 80 to 125 kVA Models LS3 Bypass supply OK This led illuminates when the static bypass supply in within 10 of its nominal voltage and the static bypass isolator is closed LS4 Inverter output OK This led illuminate...

Page 20: ...his switch is pressed the lower line of the LCD Display shows the output frequency Switch S3 Io Output current When this switch is pressed the lower line of the LCD Display shows the output current Switch S4 B Battery When this switch is pressed the lower line of the LCD Display shows the battery voltage and current Note that a discharging current is symbolised by a preceding minus sign plus auton...

Page 21: ...ot remove UPS input power since this is applied through a manually controller isolator however if the UPS input supply is connected via a circuit breaker having an electrical trip facility the emergency stop signal can be used to drive the external circuit breaker s trip circuit There are two LEDs contained within the switch panel area LS7 Alarm This led accompanies the audible alarm warning when ...

Page 22: ...ctive simultaneously the appropriate messages are displayed in a cyclic fashion with each message appearing on the display for approximately for 10 seconds For all kVA Models battery circuit breaker can be provided either in auxiliary cubicle or in a separate box This box is designed to be wall mounted and is connected between the UPS and battery bank The batteries associated with the UPS are gene...

Page 23: ...oncerning local environmental conditions and the provision of protective clothing first aid and fire fighting facilities When the battery is charge it is earth referenced about it is mid point e g if the battery is being charged at 432V the battery extremities will be at 216V and 216V with respect to neutral earth When using mains powered test equipment such as oscilloscopes in the UPS high voltag...

Page 24: ... bypass lines of both modules will be turned on as soon as its inverter is stopped That is both modules will provide load power through their paralleled bypass lines Starting In a Non Redundant module system both modules must be running before the load is transferred to their paralleled inverters Therefore when the first module is started the load will remain connected to its static bypass line St...

Page 25: ...located adjacent to the battery racks 4 Press the battery metering selector switch B Mimic panel LEDs LS1 LS3 and LS5 should illuminate immediately to indicate that the load is being supplied through the static bypass line Note In a Redundant Module system LS5 will not illuminate on the second module to be started as its static bypass line is inhibited The inverter should start automatically once ...

Page 26: ...if either modules Maintenance Bypass Isolator is closed Mimic panel LEDs LS1 and LS3 should illuminate immediately to indicate that the input and bypass supplies are healthy Inverter will not turn ON unless output isolator is closed Inverter will not turn ON for 1 1 configuration at this stage Inverter will not turn ON at this stage with output isolator open if modules are in 1 1 configuration Mim...

Page 27: ...h Static Bypass Isolator Switch if fitted UPS output terminals How to turn OFF the System but continue to provide Load power through the Maintenance Bypass This procedure should be followed if one plus one is to be powered down while continuing to supply load through the maintenance bypass line Note that during this procedure the load will be unprotected against mains supply disturbances once the ...

Page 28: ...emergency stop pushbutton is fitted in the mains supply line How to totally Power down the System This procedure should be followed only if the one plus one AND LOAD are to be completely powered down Step Action Response 1 Press the Inverter OFF switch S6 on both modules 2 Open the battery circuit breaker 3 Open the input isolator and static bypass isolator also For 110V systems Static bypass isol...

Page 29: ...20 Series 7400 Single Phase 1 N UPS ...

Page 30: ...tection should be worn to prevent injury from accidental electrical arcs Ø If a sealed battery leaks electrolyte or is otherwise physically damaged it should be placed in a container resistant to sulphuric acid and disposed of in accordance with local regulations Ø If electrolyte comes into contact with the skin the affected area should be washed immediately This chapter contains information regar...

Page 31: ...he front back and side panels and the door in the case of the 50 60 80 105 120 kVA models and exhausted through grills located in the equipment roof When the equipment is located on a raised floor and bottom cable entry is used additional cooling air also enters the UPS via the floor void Clearances To allow adequate cooling air flow you should position the equipment with the following space aroun...

Page 32: ...ate recommendations The batteries are connected to the UPS through a circuit breaker which is manually closed and electronically tripped via the UPS control circuitry If the batteries are cabinet mounted this circuit breaker is fitted within the cabinet however if the batteries are rack mounted or otherwise located remote to the main UPS cabinet then the battery circuit breaker must be mounted as ...

Page 33: ...ng bar fitted to the output transformer T1 and input choke L1 during shipment This should be removed when the UPS has been placed in its final position Also PCB door is fixed with z type clamps which should be removed CAUTION Ensure the stabilising bar fitted to the output transformer T1 is removed before proceeding with the installation Ensure removal of z type clamps used for fixing PCB door ...

Page 34: ...enching and also allows cables to pass from one module to the other when positioned side by side When connected as a one plus one Non Redundant system the UPS modules input and output cables must be rated to suit the supported load rather than the individual module s power rating This is due to the possibility of connecting the full load to the mains via the Maintenance Bypass line of one module I...

Page 35: ...diagram relevant to your equipment before commencing cabling 1 Verify that the UPS equipment is totally isolated from its external power source and all the UPS isolators are open 2 On each module connect the input supply cables between the mains distribution panel and the UPS input mains terminals ENSURE CORRECT PHASE ROTATION 3 Connect the UPS bypass supply cables between the bypass distribution ...

Page 36: ...connected to a pair of normally closed contacts on the UPS emergency stop button and will go open circuit when the emergency stop pushbutton is pressed These terminals can be used to control an external circuit breaker connected in the UPS input mains supply line to isolate the UPS input power when the emergency stop button is pressed 9 Connect one plus one parallel control ribbon cables between t...

Page 37: ...28 Series 7400 Single Phase 1 N UPS Figure 11 Cable connection 25 40kVA 230V 1 Ph Figure 12 Cable connection 50kVA 230V 1 Ph NU RU I1 I2 I3 I4 NS RS RI SI TI NU RU NI RI SI TI NS RS I1 I4 I3 I2 ...

Page 38: ...29 Series 7400 Single Phase 1 N UPS Figure 14 Cable connections for 105 kVA 230V 1 Ph Figure 13 Cable connection 60 80 kVA 230V 1 Ph U2 N2 I4 I3 I2 I1 U3 N3 NI UI VI WI RU NU RS NS RI SI TI I1 I2 I3 I4 ...

Page 39: ...30 Series 7400 Single Phase 1 N UPS I1 I1 I3 I2 NS NU RU RS RI SI TI Figure 15 Cable connection 25 40kVA 110V 1 Ph Figure 16 Cable connection 50kVA 110V 1 Ph RU NU I1 I1 I3 I2 NS1 RS1 NS2 RS2 RI SI TI ...

Page 40: ...31 Series 7400 Single Phase 1 N UPS Figure 18 Cable connections for 105 kVA 230V 1 Ph Figure 17 Cable connection 60 70 kVA 110V 1 Ph RU I1 NU NS RS RI SI TI I2 I3 I1 RI SI TI N2 N3 N2 U3 U2 I2 I3 ...

Page 41: ...f various current ratings are available and are similar in their design and content These are listed below 100 Amp C B 0120206014 for use with 25 40 kva models 160 Amp C B 0120206014 for use with 50 60 kva models 250 Amp C B 0120206014 for use with 80 kva models 400 Amp C B 0120206014 for use with 90 125 kva models Figure 19 Battery C B box connections for 25 40kVA 1Ph UPS NU RU NI RI SI TI NS RS ...

Page 42: ...escribed As a safety precaution remove the battery fuse in the UPS before making the battery circuit breaker power connections Note The polarity of the battery connections in the 25 40 kVA UPS cabinets are reversed for 50 125kVA UPS modules Figure 20 Battery C B box connections for a typical 105 kVA 230V 1 PH UPS B A T T E R Y C A B I N E T U P S C A B I N E T BatteryCB Interface Bd 100202120003 1...

Page 43: ...34 Series 7400 Single Phase 1 N UPS ...

Page 44: ...ired These options are o IBM AS400 Interface o IBM AS400 Interface with 4 way output o Output Interface Board o Remote Alarms Board o Input filter In addition to these options it is possible for the customer to use an RS232 extension of the operator control panel fitted as standard for external indications C h C h a p t e r 4 a p t e r 4 Optional Equipment ...

Page 45: ...ontacts provide a duplicate set of volt free alarm outputs that are connected to terminal block M1 as shown in figure 21 These outputs can be used to drive an external alarms monitoring device Note When using the above contacts for remote alarm annunciation the power supply for the remote indicators must be provided from an external power source Under no circumstances should the UPS internal low v...

Page 46: ...on Maintenance Bypass Control Inputs RL1 2 RL2 2 RL3 2 RL4 2 RL5 2 A S 4 0 0 I N T E R F A C E B O A R D P a r t N o 1 0 0 2 1 5 1 2 0 0 0 3 CN1 CN2 1 2 3 SH1 CN1 9 CN2 9 Mains or Rectifier Failure Load on Inverter Low Battery Load on Mains Common 0V RL1 1 RL2 1 RL3 1 RL4 1 RL5 1 CN1 8 CN2 2 CN1 7 CN2 10 CN1 6 CN2 3 CN1 5 CN2 11 A S 4 0 0 O u t p u t s Figure 21 AS400 Interface Board Outputs ...

Page 47: ...rface Board is also positioned in the UPS cabinet below the power isolators and connected to the UPS control electronics by a ribbon cable FC17 in 25 40 kVA modules and FC13 in 50 125k VA single phase modules connected to CN1 The Interface Board has facilities to accept two remote control inputs as shown in figure 22 One remote input allows the inverter to be shut down transferring the load to the...

Page 48: ...f TB M1 Control Inputs RL7 RL9 RL6 RL8 RL10 1 Common 2 3 4 5 6 7 Mains or Rectifier Failure UPS On Low Battery Load on Mains Load on Maintenance Bypass Load on Inverter RL2 RL4 RL1 RL3 RL5 1 Common 2 3 4 5 6 7 Mains or Rectifier Failure UPS On Low Battery Load on Mains Load on Maintenance Bypass Load on Inverter Outputs from M2 M5 to Remote Alarm or AS400 Figure 22 Four output AS400 Interface Boar...

Page 49: ...n transferring the load to the bypass supply and the other enables the inverter synchronisation feature to be inhibited This facility is valid only for single module The inverter synchronisation inhibit feature is most often used if the UPS is powered from a standby generator when the input mains supply fails and the generator frequency is unstable The external control signals 12V 24V should be co...

Page 50: ...1 12 13 14 15 M3 RELAY RELAY MAINS VOLTAGE OK RECTIFIER ACTIVE BATTERY OK PRE ALARM END OF DISCHARGE INVERTER OK SYNCHRO OK LOAD ON UPS LOAD ON BYASS OVER TEMPERATURE OVERLOAD MAINT BYPASS ENABLED STATIC BYPASS ISOLATOR CLOSED SPLIT BYPASS OUTPUT SWITCH CLOSED SYNCHRO INHIBIT INVERTER ON OFF Figure 24 Output Interface Board 10021512002 ...

Page 51: ...ven power supply Power is applied through a standard two pin mains connector located at the backside of the RAM This 2 pin male female type connector is marked as N L The supply is rated to approximately 10 watts and hence can be tapped from any suitable source This generates required DC power supply for functional requirement of the RAM Once AC power is available to RAM POWER indicating LED on RA...

Page 52: ...43 Series 7400 Single Phase 1 N UPS Figure 25 Remote alarm monitors for single module and 1 1 configuration ...

Page 53: ...OK ALARM SIGNAL LED OVERLOAD ALARM SIGNAL LED OVER TEMPERATURE ALARM SIGNAL LED INVERTER NOT OK ALARM SIGNAL LED RECTIFIER NOT ACTIVE ALARM SIGNAL LED BATTERY NOT OK ALARM SIGNAL LED MAINS VOLTAGE NOT OK ALARM SIGNAL LED LOAD ON MAINT BYPASS 24 VOLT SUPPLY OUTPUT INTERFACE PCB MOUNTED IN UPS SYSTEM REMOTE ALARM MONITOR LOCATED AT REMOTE PLACE 230V AC Supply M2 M1 M2 M1 M1 M1 RM1 M2 M2 M2 M2 M1 M1 ...

Page 54: ...DULE 1 MODULE 2 M2 M1 M2 M1 M1 M1 M1 M2 M2 M3 M1 M1 M1 M1 M1 M1 8 2 5 14 5 8 11 1 14 2 4 4 13 13 7 7 MODULE 1 MODULE 2 MODULE 1 MODULE 2 MODULE 1 MODULE 2 TERMINAL CONNECTION ARE GOING TO TEST RESET 24 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NOTES 1 Short terminal with the help of suitable wire 2 Note that if this supply is not availa...

Page 55: ...46 Series 7400 Single Phase 1 N UPS ...

Page 56: ...s supply bypass supply and batteries It is essential that the safety and precautionary notes contained throughout this manual are read and FULLY UNDERSTOOD before touching any UPS internal component part 5 3 Scheduled Maintenance The UPS utilises solid state components which are not subject to wear with the only moving parts being the cooling fans Scheduled maintenance requirements beyond ensuring...

Page 57: ... This entails working inside the equipment in regions containing hazardous voltages A manufacturer trained engineer is fully aware of the hazards concerned and will carry out this procedure with the load connected to the maintenance bypass supply however if the customer decides to carry out this service procedure himself it is imperative that the UPS be totally shut down and isolated from the inpu...

Page 58: ...ter following the appropriate operating procedure 1 If possible check the battery autonomy time by opening the input isolator I1 with the UPS on load Close the input isolator immediately the DC busbar voltage falls to 325V note that at 320V the battery circuit breaker will trip and the load will transfer to bypass Ensure that the available battery autonomy time meets the installation specification...

Page 59: ...50 Series 7400 Single Phase 1 N UPS ...

Page 60: ...pplicable However it is important to maintain a regular record of the UPS meter indications as suggested in the maintenance instructions in order that any change in the system or load characteristics are readily identified In general the output voltage should be within 2 of nominal If the UPS has not operated on battery power within the previous ten hours the battery charge current should be typic...

Page 61: ...ether fault rectification is successful or not report the fault occurrence to the nearest service agent who will then forward the details to the manufacturer This type of customer feedback is an important factor in maintaining high product reliability and also provides important data concerning the equipment field performance CAUTION The following diagnostic charts are designed for first aid troub...

Page 62: ...it signifies that either the battery circuit breaker is open or that the dc busbar voltage is below 320V dc For 80kVA to 125kVA models this voltage is 330V dc The battery circuit breaker will open automatically if the dc voltage falls below this level Check the following a Battery circuit breaker is closed b DC busbar voltage if not above 320V then carry out checks as per LS1 mains failure above I...

Page 63: ...switch on the UPS Logic Board b Press the Inverter ON pushbutton c If the dc busbar is below 320V 330V for 80 125 kVA then do checks as per LS1 above d Check that slide switch I3 is closed on the UPS Logic Board is closed e If the inverter works OK when mains is available but not when mains is unavailable then check the dc power supply fuses If the above checks prove unsatisfactory then seek quali...

Page 64: ...D LOAD ON BYPASS Overtemperature is sensed by a normally closed thermostat 90º C operating fitted to each inverter heatsink If an overtemperature condition arises the audible alarm will accompany this message the inverter stops and load transfers to bypass after 3 minutes The inverter overload has an inverse load time characteristic i e it will accept 125 overload for 10 minutes and 150 for 60 sec...

Page 65: ... supply This warns that the inverter is not synchronised with the bypass supply which is normally due to a problem with the bypass supply being outside an acceptable frequency window Do not switch OFF the inverter when this alarm is active or the load will experience a 20 millisecond power break This is a status warning that the battery is discharging It normally accompanies a MAINS FAILURE BYPASS...

Page 66: ... based on this line up we will provide all interconnection cables The interconnecting cables are supplied only if auxiliaries are in ENP s scope ENP is not responsible for supply of these interconnection cables in case the recommended Line up is altered It is presumed that a All the panels are in single line up b All the panels are placed in such a way that side covers are touching to each other c...

Page 67: ...58 Series 7400 Single Phase 1 N UPS ...

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