AEG PROTECT 1 Series, Operating Instructions Manual

Page 1: ...UPS OPERATING INSTRUCTIONS PROTECT 1 100 PROTECT 1 150 PROTECT 1 200 PROTECT 1 ...

Page 2: ...2 ...

Page 3: ...om AEG Power Supply Systems The following safety instructions are an important part of the operating instructions are will protect you against problems from operating errors and possible dangers Please read these instructions carefully prior to commissioning ...

Page 4: ...g instructions to all personnel transporting or starting the PROTECT 1 or performing maintenance or any other work on the unit Validity These operating instructions comply with the current technical specifications of PROTECT 1 at the time of publication The contents do not constitute a subject matter of the contract but serve for information purposes only Warranty and liability We reserve the righ...

Page 5: ...y be performed by trained and qualified personnel Illustrations are provided to clarify and facilitate certain steps If danger to personnel and the unit cannot be ruled out in the case of certain work it is highlighted accordingly by pictographs explained in the safety regulations of chapter 3 Hotline If you still have questions after having read these operating instructions please contact your de...

Page 6: ... Set Up 23 4 4 Overview Connections Operating Display Elements 25 4 4 1 Front view 25 4 4 2 Display 26 4 4 3 Rear view connections 27 5 Electrical connection 29 5 1 Safety of personnel 30 5 2 Mains connection general 30 5 2 1 Checklist for cable connections 30 5 2 2 Connection Cross Sections and Fuse Protection 31 5 3 Mains connection 32 5 3 1 Preparation for the three phase mains connection 32 5 ...

Page 7: ...nd troubleshooting 48 8 1 1 Signalling 48 8 1 2 Overview table of LED displays acoustic warning signals 50 8 2 Faults 52 8 2 1 Error Messages 52 9 Parallel Operation 54 9 1 Principle of Operation 54 9 2 Set up connection of parallel operation board 55 9 3 Operation of the UPS in a parallel system 57 9 3 1 Start Up 57 9 3 2 Changes to the parallel system 59 10 Maintenance 60 10 1 Charging the Batte...

Page 8: ...and mains energy backfeed protection Rectifier section with PFC logic power factor correction unit Separate battery charger with switch mode power supply technology IGBT inverter for continuous supply of connected loads with sinusoidal AC voltage Automatic electronic bypass SBS as additional passive redundancy SBS Static Bypass Switch Manual bypass for maintenance and service purposes with automat...

Page 9: ...filter Mains filter Last Load Netz Mains Filter Filter Gleichrichter Rectifier Wechselrichter Inverter DC DC Booster DC DC booster Ladegleichrichter Battery charger DSP Regelungslogik DSP control logic Komponentendarstellung Component diagram Batteriesystem extern Battery system external RS 232 SNMP RS 232 SNMP ...

Page 10: ...logy and extremely fast pulsating IGBT power semiconductors of the inverter a voltage system of the highest quality and availability on the secured busbar In the event of mains faults such as e g current failures the voltage continues to be supplied from the inverter to the load without any interruption From this point onwards the inverter draws its power from the battery instead of the rectifier ...

Page 11: ...edundancy The relationship between the available output power and the degree of active redundancy can be seen in the following overview Parallel system with PROTECT 1 100 Number of UPS units Available power 1 2 3 0 10 kVA 20 kVA 30 kVA 1 10 kVA 20 kVA Active redundancy degree 2 10 kVA Parallel system with PROTECT 1 150 Number of UPS units Available power 1 2 3 0 15 kVA 30 kVA 45 kVA 1 15 kVA 30 kV...

Page 12: ...61 VAC VAC 3 bypass Frequency 50 Hz 60 Hz autom detection Frequency tolerance range 4 Hz Current consumption at full load max PROTECT 1 100 13 A 3ph 46 A bypass PROTECT 1 150 19 A 3ph 68 A bypass PROTECT 1 200 25 A 3ph 91 A bypass System disturbance factor λ 0 95 UPS output Nominal voltage output 220 230 240 VAC 1 configuration via CompuWatch software Nominal frequency 50 Hz 60 Hz 0 1 dependent on...

Page 13: ...oad min Coupled battery cubicles PROTECT 1 100 PROTECT 1 150 PROTECT 1 200 Recharging time to 90 capacity 1 x PROTECT 1 100 BP 16 42 5h 2 x PROTECT 1 100 BP 42 97 7h 3 x PROTECT 1 100 BP 60 134 10h 1 x PROTECT 1 BP 20 19 47 10 29 6 19 5h 2 x PROTECT 1 BP 20 47 103 29 68 19 47 9h 3 x PROTECT 1 BP 20 78 77 47 103 34 62 13h 4 x PROTECT 1 BP 20 103 243 68 153 47 103 18h 5 x PROTECT 1 BP 20 138 312 85 ...

Page 14: ...ed transformer technology Full load efficiency 90 88 AC AC DC AC Inherent noise 1m distance PROTECT 1 100 55 dB A PROTECT 1 150 60 dB A PROTECT 1 200 60 dB A Cooling type Forced air cooling through variable speed fans Operating temperature range 0 C to 40 C Recommended 15 C to 25 C due to battery system Storage temperature range 0 C to 40 C Relative humidity 95 without condensation Site altitude U...

Page 15: ...with the EC outline directives for 73 23 EEC Low voltage and for 89 336 EEC Electromagnetic compatibility if the installation instructions described in the operating instructions are observed For 73 23 EEC low voltage directive reference number EN 62040 1 1 2003 For 89 336 EMC directive reference number EN 50091 2 1995 EN 61000 3 2 1995 EN 61000 3 3 1995 i Warning This is a product for industrial ...

Page 16: ...n Attention Note and indented text Caution This symbol identifies all working and operational procedures requiring absolute compliance to avoid any danger to persons Attention This symbol identifies all working and operational procedures requiring absolute compliance to prevent any damage irreparable or otherwise to the unit and its components i Note This symbol identifies technical requirements a...

Page 17: ...nel having completed training and gained experience in the respective field familiar with the pertinent standards rules and regulations and accident prevention regulations having received instruction on the mode of operation and operating conditions of the PROTECT 1 capable of recognising and preventing dangers Regulations and definitions for qualified personnel can be found in DIN 57105 VDE 0105 ...

Page 18: ...th the UPS and the battery modules special accessories Do not dismantle the UPS The UPS does not contain any parts that require regular maintenance Bear in mind that the warranty will be invalidated if the unit is opened Do not install the unit in direct sunshine or in close proximity of heaters The unit is designed to be installed inside in heated rooms Never install the housing in the vicinity o...

Page 19: ... out maintenance work this must be done by or under the supervision of a specialist familiar with batteries and the necessary safety precautions Only authorized persons are allowed in the vicinity of the batteries When replacing the batteries the following must be observed Only ever use identical maintenance free sealed lead batteries with the same data as the original batteries Danger Explosive N...

Page 20: ...end to use it for some time PROTECT 1 must be switched off every evening if the electricity supply in your company is switched off every night Otherwise the battery will be discharged Frequent and exhaustive discharging of the battery leads to a shorter service life of the battery and should therefore be avoided For personal safety reasons never switch on the main switch when the mains connector o...

Page 21: ...21 3 5 CE Certificate ...

Page 22: ...t the damage to the AEG representative or dealer within eight days of delivery Check that the delivery is complete PROTECT 1 with 10000 15000 or 20000 VA Cable clamping unit Special battery connection cable PROTECT 1 100 25 pin parallel operation cable RS232 communication cable Management software CompuWatch on CD Operating instructions Delivery of external battery modules includes External batter...

Page 23: ...gard the connection cables should be long enough to move the UPS to open the UPS if necessary without having to switch it off The use of an external manual bypass is recommended The UPS is protected against external atmospheric influences The humidity and the ambient temperature are within the limits The fire protection standards are observed The battery service life strongly depends on the ambien...

Page 24: ...system To ensure the greatest possible mechanical stability do not place the external battery unit s above or below the UPS system Avoid extreme temperatures We recommend an ambient temperature from 15 C to 25 C in order to maximize the service life of the batteries Do not expose the units to direct sunlight or operate them close to other heat sources such as radiators Protect the units against ex...

Page 25: ...25 4 4 Overview Connections Operating Display Elements 4 4 1 Front view PROTECT 1 100 PROTECT 1 150 PROTECT 1 200 PROTECT 1 100BP PROTECT 1 BP20 ...

Page 26: ...n 11 orange coloured for UPS capacity utilisation or remaining battery capacity 7 LED load 0 35 battery capacity 96 100 8 LED load 36 55 battery capacity 76 95 9 LED load 56 75 battery capacity 51 75 10 LED load 76 95 battery capacity 26 50 11 LED load 96 105 battery capacity 0 25 12 Red Fault LED A detailed explanation of the displays is found on page 48ff 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 27: ...27 4 4 3 Rear view connections PROTECT 1 100 PROTECT 1 150 1 200 1 2 3 4 5 6 7 8 N L1 L2 L3 JP1 JP2 L N 1 1 1 2 1 3 11 13 9 10 11 4 1 2 3 5 6 6 8 7 N L1 L2 L3 L N JP1 JP2 1 1 1 3 1 2 11 13 9 10 11 12 ...

Page 28: ...als for external battery PROTECT 1 150 1 200 5 Connectors for parallel operation 6 Fan attention Leave at least 10 cm clearance behind fan for unobstructed airflow out 7 Communication slot for optional expansion boards SNMP AS 400 USB 8 Communication interface RS232 Sub D9 9 Cable clamping unit is mounted instead of the cover from no 1 10 Strain relief clamps 11 PE earthing terminals 12 Macrolon p...

Page 29: ...sible metal parts The PROTECT 1 is earthed by the provided earthing bolts PE Prior to start up it must be ensured that the PROTECT 1 is earthed in accordance with valid regulations e g VDE 0100 Before the connection work is carried out check that The values of the nominal voltage input voltage and frequency match those on the nameplate of the UPS The earth connection matches the prescribed IEC sta...

Page 30: ... structured in a similar way The cables are connected as follows Remove terminal cover retain the four screws Insert the cables to be connected into the terminal space of the PROTECT 1 from the rear Connect the wires of the supply lines to the corresponding terminal block Connect the PE to the terminal block of the PROTECT 1 100 or to the strain relief unit of the PROTECT 1 150 or 1 200 Fasten the...

Page 31: ... mm Max 35 mm per terminal Battery connection cable is included with the battery unit Observe earth fault and short circuit proof routing Mains fuse UPS input 50A gl 80A gl 100A gl When using line safety switches observe trigger characteristic D Line safety switch B characteristic Load fuse recommended max 16A 20A 25A To ensure a reliable strain relief individual wires must be laid especially for ...

Page 32: ...h a minimum cross section acc to chapter 5 2 2 Connection Cross Sections and Fuse Protection The UPS can be live and the voltage can be dangerous The unit may only be installed and if necessary opened by trained and qualified personnel Repairs may only be carried out by qualified customer service staff 5 3 2 Connection of the Three Phase Input Mains Voltage In order to ensure the safety of personn...

Page 33: ...e you connect the loads to the UPS the nominal output listed on the nameplate must be greater than or equal to the sum of the load power outputs The output of the PROTECT 1 should supply further separate circuits in a subdistribution Make sure that the fuse protection is selectively designed see also chapter 5 2 2 For the connection between the PROTECT 1 and the subdistribution cable cross section...

Page 34: ...to the OFF position Connect the loads as follows terminals 1 3 p 27 28 Connect the UPS terminals PE ground N neutral conductor L phase that are marked with OUTPUT with the corresponding terminals of your UPS subdistribution 5 4 Connection of External Battery Modules The PROTECT 1 requires the use of at least one external battery module Two preconfigured battery cubicle types are available Both ver...

Page 35: ... the supplied battery connection cable PROTECT 1 100 with 1 battery unit PROTECT 1 100 BP i PROTECT 1 100 BP is only intended for connection to the UPS type PROTECT 1 100 Connect further battery cubicles of identical design to the second battery connection socket of the neighbouring battery cubicle Insert the battery connection plugs quickly and firmly into the battery connectors ...

Page 36: ...first remove the rear cover Now create the electrical connections with the enclosed connectors see also circuit diagram X1 X2 X3 and The PROTECT 1 100 is connected to the UPS at the socket using the special battery connection cable enclosed with the UPS and in the case of the PROTECT 1 150 or PROTECT 1 200 with the battery connection cables enclosed with the battery cubicle at the terminals Make s...

Page 37: ... cable make sure that the plugs are inserted quickly and firmly in the battery connectors Prepare further PROTECT 1 BP20 battery cubicles as described above and then connect them to the terminals X2 and X3 of the previously installed battery cubicle with the enclosed battery connection cables Observe the correct polarity and as well as an earth fault and short circuit proof routing during connecti...

Page 38: ... system is connected to the mains on the input side or switch on the corresponding line protection switch there 18 Next actuate the mains input miniature circuit breakers on the UPS no 2 p 27 28 Move this to the ON position i Factory presetting The loads are supplied via the integrated bypass which connects the phase L1 with the UPS output Do not switch on your loads yet however 19 Now switch on t...

Page 39: ...e distinguished Operation with mains supply 6 1 1 Operation with faulty mains supply 6 1 2 Operation with faulty inverter 6 1 3 Manual bypass 6 1 4 6 1 1 Normal Operation Batterie Lade GR GR WR Hand umgehung Handumgehungspfad EUE Netzeingangs sicherungs automat Netz Schematische Darstellung Gesicherte Schiene Verbraucher Energiefluss bei vorhandenem Netz Energiefluss bei vorhandenem Netz Power cir...

Page 40: ...protection in particular when there are mains fluctuations and mains failures because the loads are continuously supplied with reliable and clean voltage with no interruptions in this operating mode The bar graph LED LED chain above the pictograph indicates the current capacity utilisation of the UPS in this operating mode see chapter 8 p 48 ff 6 1 2 Battery Operation Autonomous Operation Batterie...

Page 41: ...is discharged This status is signalled by the battery symbol lighting up Battery LED as well as an intermittent acoustic signal at first every 4 seconds and then every second shortly before switching off The initial alarm can be suppressed by pressing the Alarm off button The alarm is automatically reactivated when the battery capacity decreases Depending on the expansion level age and condition o...

Page 42: ...iefluss bei gestörtem WR Energiefluss bei gestörtem WR Power circuit with faulty INV Handumgehungspfad Manual bypass path Netz Mains GR REC EUE SBS WR INV Netzeingangssicherungsautomat Mains input miniature circuit breaker Lade GR Load REC Handumgehung Manual bypass Gesicherte Schiene Secured busbar Schematische Darstellung Schematic diagram Batterie Battery Verbraucher Load If the inverter is ove...

Page 43: ...e overload or overtemperature goes away The bypass consists of an inverse parallel thyristor stack and functions as an extremely rapidly switching link between a load and the mains The synchronization unit ensures that the frequency and phase of the inverter voltage is synchronized with the mains and can therefore be switched over without interruption within the tolerance limits i The bar graph LE...

Page 44: ...ndumgehung Manual bypass Gesicherte Schiene Secured busbar Schematische Darstellung Schematic diagram Batterie Battery Verbraucher Load The manual bypass enables maintenance and service personnel to perform work on the PROTECT 1 without having to switch off the load circuit If the current supply fails while the manual bypass is active a total failure of the load supply results For this reason it s...

Page 45: ...verload condition may cause the total loss of all UPS functions Also avoid short term unit overloads which may for example occur when connecting a laser printer or laser fax machine Do not connect any household appliances or machine tools to the UPS Never connect or switch on any additional loads to the UPS if there is a mains failure i e if the UPS is working in emergency power mode As a rule if ...

Page 46: ...7 2828 no 7 When this is removed additional optionally available communication components can be installed there e g AS 400 board Slot board with status messages realised via potential free relay contacts USB board Slot board for communication via USB SNMP board Slot board for direct connection of the UPS to the Ethernet network with RJ 45 TCP IP Details can be found in the description enclosed wi...

Page 47: ...indows NT 2000 XP Windows Vista Linux SUSE Linux RedHat Novell Netware IBM AIX HP UX SUN Solaris Mac OS and others Example of a CompuWatch screen Refer to the manual on the CD for details about installing the software on the various operating systems Download of updates at www aegpss de Download ...

Page 48: ...e alarm for approx 2 seconds to switch off the alarm UPS test Press this button during normal mode for approx 2 seconds to carry out a UPS self test 24 Bypass LED The orange coloured LED lights up when voltage is supplied via the integrated bypass of the UPS 25 Inverter LED The green LED lights up when voltage is supplied via the inverter of the UPS system 26 Battery LED The orange coloured LED li...

Page 49: ...LED as the measure of the UPS capacity utilisation or the remaining battery capacity These LED s show the current UPS capacity utilisation when mains voltage is present normal mode 11 Orange LED 96 105 10 Green LED 76 95 9 Green LED 56 75 8 Green LED 36 55 7 Green LED 0 35 In battery mode the LED s indicate the capacity of the batteries 11 Orange LED 0 25 10 Green LED 26 50 9 Green LED 51 75 8 Gre...

Page 50: ...ic signal every 4 seconds 10 B a t t e r y m o d e 81 100 capacity 1 acoustic signal every 4 seconds 11 Load supply via bypass of the UPS 1 acoustic signal every 2 minutes 12 Unit overload UPS in INV mode 2 acoustic signals per sec 13 Unit overload UPS in bypass mode 2 acoustic signals per sec 14 Mains abnormal 15 Overload in battery mode early warning 2 acoustic signals per sec 16 Overload in bat...

Page 51: ... DC circuit faulty poss battery fault 1 acoustic signal per sec 22 Battery charger faulty Continuous warning signal 23 Fan fault 1 acoustic signal per sec 24 Fault in inverter output relay Continuous warning signal 25 Communication faulty Continuous warning signal 26 Parallel operation fault Continuous warning signal Note LED lights up LED flashes Display acoustic signal state undetermined unimpor...

Page 52: ...ition Switch mains input miniature circuit breaker to ON Line LED flashes and Battery LED lights up Mains voltage and or mains frequency are outside of tolerance Check the mains voltage frequency Inverter LED and Battery LED light up The acoustic signal sounds every 4 seconds operating states 7 10 Inverter LED and Battery LED light up The acoustic signal sounds every second operating state no 6 Ma...

Page 53: ...o 19 Switch off due to short circuit in UPS output Correct short circuit Switch UPS on again connect loads one after the other again Fault LED lights up Battery LED flashes warning signal sounds once per second error description 21 Fault in DC circuit or battery system faulty Notify dealer Fault LED lights up continuous warning signal Fault in the UPS Notify dealer Further diagnoses can also be fo...

Page 54: ...its required for load supply x for the degree of redundancy Up to 3 units of the same type can be connected in parallel here to increase the output power and or achieve higher availability NS Hauptverteilung MI main distribution USV Einspeisung UPS feed Parallelfeld Handumgehung plus USV Unterverteilung Parallel field manual bypass plus UPS subdistribution ...

Page 55: ...creases again when the power consumption decreases The connection normally takes place in the low voltage main distribution which also contains the external manual bypass and the following subdistribution of connected load circuits Such a parallel board can be purchased in a wall housing incl external HU as well as feeder and load distribution board from AEG Power Supply Systems via your specialis...

Page 56: ...lements are correctly labelled in order to prevent operating errors later as well The communication of the units switched in parallel takes place via the 25 pin parallel operation cable s included in the scope of delivery For this purpose first remove the parallel port covers no 5 p 27 28 and connect the UPS units with each other with one parallel operation cable each Use one parallel operation ca...

Page 57: ...nd all mains input miniature circuit breakers no 2 p 27 28 on the back of each UPS are in the OFF position 16 Check the position of the central external manual bypass This must be in the Bypass position i e supply of the load busbar by the supplying mains 17 Now close all isolators in the output of each UPS i e connect the output of each UPS with the parallel operation busbar 18 Now insert the bac...

Page 58: ...llel operation busbar i This is done using a manual bypass switch with overlapping switching contacts without any interruption in the load voltage i e completely interruption free 22 Now switch on the inverters of the UPS systems To do this press the ON pushbutton of each UPS for approx 2 seconds one after the other i After switching on each UPS carries out a self test and synchronizes itself with...

Page 59: ...on Check the operating state on the operating panels Next active the integrated manual bypasses no 3 p 27 28 on the back of each UPS To do this first remove the 4 screws of the covers on the back Put the mains input miniature circuit breakers of each UPS no 2 p 27 28 to OFF position Use your central external manual bypass to bypass the loads i e activate the bypass operation and remove the load su...

Page 60: ...he operating mode This is signalled by the Load LED s lighting up see also chapter 4 4 2 The complete charging time of the battery after a long discharge time depends especially on the number of additional external battery units see chapter 2 3 10 2 Checks The following maintenance work should be performed Task Interval Described in Visual check 6 months Chapter 10 2 1 Battery fan check 6 months C...

Page 61: ...gressive ageing of the battery system can be detected by regular capacity checks Every 6 months perform measurements to compare the achievable standby times e g by simulating a mains failure In this case the load should always have approximately the same capacity demand Please contact our hotline if the time drops drastically compared to the previous measurement see p 5 10 2 3 Fan Check Regularly ...

Page 62: ...oom temperature should be recharged every six months to maintain their full capacity and service life i Connect PROTECT 1 to the mains before putting it into storage in order to make sure that the battery is fully charged The charging time should at least match the time specified in chapter 10 1 11 2 Dismantling The system is dismantled in reverse order of the installation instructions 11 3 Dispos...

Page 63: ...n LED used for optic signalling PFC Power Factor Correction Circuit technology for minimising system disturbances particularly important when connecting non linear loads PWM Pulse Width Modulation Here circuit technology for generating a sinusoidal voltage of the highest quality from an existing DC voltage SNMP Simple Network Management Protocol A protocol encountered frequently in networks for ma...

Page 64: ...e Type Unit number Date of purchase Dealer stamp signature Errors and changes excepted AEG Power Supply Systems GmbH Emil Siepmann Straße 32 D 59581 Warstein Belecke Germany Operating Instructions BAL 8000019452 EN AEG0707DE ...