Emerson Liebert NXL, Operation And Maintenance Manual

Page 1: ...AC Power For Business Critical Continuity Liebert NXL Operation and Maintenance Manual 250 400kVA 60Hz Three Phase Single Module ...

Page 2: ..._________ Serial Numbers _______________________________________________________________ kVA Rating __________________________________________________________________ Date Purchased _______________________________________________________________ Date Installed ________________________________________________________________ Location _________________________________________________________________...

Page 3: ...ing 19 2 2 9 Help 19 2 2 10 Reset 19 2 2 11 Silence 19 2 3 Modes of Operation 19 2 3 1 Load on Bypass 19 2 3 2 OK to Transfer 20 2 3 3 Input Power Failure Load on Battery 21 2 3 4 Off Battery 22 2 3 5 Emergency Module Off 22 2 3 6 Remote Emergency Power Off 23 2 4 Manual Procedures 23 2 4 1 Startup Procedure 24 2 4 2 Load Transfer Procedures 26 2 4 3 Maintenance Bypass Load Transfers 26 2 5 Shutdo...

Page 4: ... 34 3 4 Battery Maintenance 34 3 4 1 Battery Safety Precautions 35 3 4 2 Torque Requirements 37 3 5 Detecting Trouble 37 3 6 Reporting a Problem 38 3 7 Corrective Actions 38 3 8 Upstream Feeder Circuit Breaker Setting Inspections 38 4 0 SPECIFICATIONS 39 4 1 Battery Operation 39 4 2 Environmental Conditions 39 APPENDIX A UPS ALARM AND STATUS MESSAGES A43 ...

Page 5: ...8 Transfer retransfer commands 16 Figure 19 Time remaining display 17 Figure 20 Battery cycle monitor 18 Figure 21 Battery cycle monitor summary 18 Figure 22 Battery cycle monitor clear log 19 Figure 23 Load on bypass UPS not available 19 Figure 24 Load on bypass UPS available 20 Figure 25 Load on UPS bypass available 20 Figure 26 Input power fail load on battery 21 Figure 27 Load on UPS battery n...

Page 6: ...iv ...

Page 7: ...all battery safety precautions in 3 0 Maintenance when installing charging or servicing batteries In addition to the hazard of electric shock gas produced by batteries can be explosive and sulfuric acid can cause severe burns In case of fire involving electrical equipment use only carbon dioxide fire extinguishers or others approved for use in electrical fire fighting Extreme caution is required w...

Page 8: ... converts the AC utility into DC power The inverter converts that DC power from the utility or DC power from the batter ies into AC power for the load The batteries power the load through the inverter in the event of a power failure The utility source can also power the load through the static bypass If maintenance or repair of the UPS is necessary the load can be switched without interruption in ...

Page 9: ... variety of battery types provided the battery plant is designed for the UPS DC voltage range and the load requirements of your application This option is required to com plete the UPS system Battery Cabinets Valve regulated lead acid VRLA sealed batteries are available in match ing cabinets for convenient installation and maintenance in otherwise unprotected space Depending on the UPS module rati...

Page 10: ...llowing attributes can be programmed for each alarm latching audible event log and time delay 0 to 99 9 seconds Temperature Compensated Charging When the battery temperature exceeds a preset limit typically 77 F 25 C this optional circuit proportionally reduces float charging voltage to pre vent overcharging the battery Battery Load Testing When activated this option forces the battery string to a...

Page 11: ...mable parameters access limited by security access function Adjustment output voltage before performing a manual load transfer The touchscreen is a white background display with multicolor text The display turns on automati cally but after 15 minutes of inactivity the backlight will go out and the display will appear very dim Touching the screen will reactivate the backlight the backlight will aga...

Page 12: ...status is shown as open or closed DC Bus Displays the DC Bus voltage and the state of the battery charger Load Displays the output line voltage phase voltage current kVA kW power factor and fre quency The critical load current per phase is also displayed in this block During an overload the time remaining before transfer is displayed at the bottom of the load box After an overload transfer retrans...

Page 13: ...gure 5 Monitor mimic display example Normal power flow Figure 6 Monitor mimic display example Utility fail Green Normal Orange Marginal Gray Absent Black Unknown Green Normal Orange Marginal Gray Absent Black Unknown ...

Page 14: ...tor mimic display example Load on bypass UPS On Figure 8 Monitor mimic display example Load on bypass UPS module off Green Normal Orange Marginal Gray Absent Black Unknown Green Normal Orange Marginal Gray Absent Black Unknown ...

Page 15: ...rt NXL Menu Help Menu Metering Silence Reset Configurations Status Reports Startup Shutdown Transfer Battery Management System Settings Adjustable Setpoints Battery Management Event Management Rating System Status Event Log Device Control Manual Start Open MBD Open Trap System UPS Bypass UPS Battery Cycle Monitoring Commissioning Manual Battery Equalize Manual Battery Test Time Remaining Graph Int...

Page 16: ...ameters Nominal Input Voltage Unit Model Nominal Bypass Voltage Unit Serial Nominal Output Voltage Maintenance Bypass Model Nominal Source Frequency Maintenance Bypass Serial Nominal Output Frequency Battery Cabinet Model Nominal Cell Count Battery Cabinet Serial Output kVA Order Number 1 Output KW Order Number 2 Configuration Type Service Telephone Number Rectifier Type Site ID Number Input Isola...

Page 17: ...Adjust Hour Minute or Seconds Date MM DD YYYY format Adjust Month Day or Year Password Reset the password 4 characters alphanumeric case sensitive Language English Chinese French Spanish German Italian Portuguese Audio level Range 1 to 10 default 5 Phase labeling Auto ABC RST XYZ RYB RWB UVW 123 L1L2L3 default Automatic Unit Locator Location ID Alphanumeric System Number Alphanumeric Unit Number N...

Page 18: ...High Limit 1 to 15 default 5 Inlet Air Temp Warning Inlet Air Temp Warning 30 C to 40 C default 35 C Figure 12 Adjustable setpoints parameters Battery Management These battery settings can be changed from the touchscreen Press the box to the left of each parame ter to bring a popup window that will allow the parameter to be changed Battery Equalize Equalize Voltage Vpc 2 30 to 2 40 default 2 3 Equ...

Page 19: ...VPC this is the minimum voltage the battery test will stop Low Battery Warning Time Low Battery Warning Time minutes 2 to 60 depending on configured batteries default 5 min utes Battery Temperature Battery Temp Warning 30 C to 50 C default 40 C Battery Temp Limit 35 C to 60 C default 50 C Disconnect Enable Disable default disabled Figure 13 Battery Management Parameters Cell Count Adjustment Cell ...

Page 20: ...ped events are captured in the log The oldest record will be overwritten with a new record once the buffer reaches 1024 events System Status Total Operating Hours Total number hours the UPS has been operational Battery Operating Time A running total of the battery discharge time for all events since the log was last cleared 2 2 4 Startup Menu This menu is used to start the UPS and individual devic...

Page 21: ...ilable Figure 16 UPS shutdown popup System Turns off inverter rectifier and trips all battery breakers Will shutdown UPS completely NOTICE Risk of equipment damage This command will result in the load being shut down The following popup window is displayed when the UPS is about to be shut down To shutdown the UPS an operator must press OK Figure 17 System shutdown popup NOTE The following popup wi...

Page 22: ...ass mode A graph in the multipurpose window shows if the UPS is in synch with the bypass If the UPS and bypass are in synch pressing Bypass will switch the UPS to Bypass mode Pressing UPS will switch back to Normal Inverter Mode see Figure 18 Figure 18 Transfer retransfer commands ...

Page 23: ...re 19 Figure 19 Time remaining display Manual Battery Test Start Stop Manual Battery Equalize For Service only Commissioning For Service only Battery Cycle Monitor Displays how many discharges have occurred for these time periods 0 30sec 31 90sec 91 240sec 4 15min 15 30min 30 60min 60 240min 4 8hrs 8hrs and up Each discharge record will include see Figure 20 Max KW Date AH Time Start Temp C Durati...

Page 24: ...monitor Display summary see Figure 21 Battery Commission Date Time Last Battery Discharge Date Time Active Battery Discharge Time Active Battery Amp Hours Active Battery KW Total Number of Discharges Figure 21 Battery cycle monitor summary ...

Page 25: ...arious modes of operation The same modes of operation apply to all configurations of the Lie bert NXL Highlighted thick lines in the diagrams indicate power flow and power availability These illustrations do not show an alternate power source generator and automatic transfer switch external to the UPS that might be present at your installation 2 3 1 Load on Bypass Load on Bypass with the UPS not a...

Page 26: ...e load can be manually retransferred from the bypass to the UPS To perform a manual transfer Use the Load Transfer Procedures screen Refer to 2 4 2 Load Transfer Procedures The UPS control logic will initiate an automatic transfer to bypass if an overload condition exceeds the system current versus time window or if a UPS fault is detected The control logic may initiate an automatic retransfer to ...

Page 27: ...tery can sustain the load depends on the size of the load and the size and condition of the battery plant Alarm messages that indicate battery status are Battery Discharge Low Battery and Battery Shut down The voltage limits for these alarms are displayed on the UPS module Alarm Limit Settings screen These limits were selected for your installation by Liebert Services during initial startup The ba...

Page 28: ...move power from all UPS module components except the controls bypass circuit breaker and the static switch The Emergency Module Off control is a guarded pad next to the display touchscreen Figure 2 Lift the cover and press the pad The load will be transferred to bypass and the battery MBD input and output circuit breakers will be opened tripped Refer to 2 5 Shutdown Procedures Figure 28 Emergency ...

Page 29: ...ol logic as explained in 2 6 Automatic Opera tions Other procedures must be performed manually Manual procedures available to the operator include Startup Load Transfers and Shutdowns These procedures are performed by using the touchscreen and some manually operated circuit breakers and switches The touchscreen lists all steps required for each manual procedure This section lists step by step con ...

Page 30: ...aintenance shutdown 3 If the bypass line is not supplying the load energize the bypass line by a Closing the Bypass Input Breaker BIB external to the UPS This breaker may be in the Maintenance Bypass Cabinet The display touchscreen should start up b Pressing the Start Up then Manual Start menu buttons see Figure 30 c The Close BFB message appears in the multipurpose window Close the BFB breaker se...

Page 31: ...us voltage is at 100 you can manually close the module battery disconnect MBD circuit breaker external to the UPS The Battery block in the Monitor Mimic Display indicates the battery voltage and charge current Figure 30 Startup commands NOTE The battery charge current may increase quickly but then should slowly decrease If the system is recovering from a battery shutdown or an input power failure ...

Page 32: ...multipurpose window see Figure 18 3 If the UPS output is with synchronization with the bypass press the UPS button This will transfer the load from Bypass to UPS 2 4 3 Maintenance Bypass Load Transfers To manually transfer the load between Maintenance Bypass and the UPS bypass line carefully follow these instructions Do not transfer the load between Maintenance Bypass and the UPS module inverter o...

Page 33: ...pass Input Breaker BIB Maintenance Bypass Load Transfers If Load is on Maintenance Bypass 1 Close the Bypass Input Breaker BIB or verify BIB is closed Note that UPS Bypass circuit breaker motorized must also be closed Refer to 2 4 1 Startup Procedure 2 If the maintenance bypass cabinet or switchboard has an optional two key interlock system press the button on the maintenance bypass cabinet to rem...

Page 34: ...hat overload conditions can be sustained without a transfer to bypass Initiates an automatic transfer to bypass to sustain an overload or when selected UPS faults occur Can initiate an automatic retransfer to the UPS after an overload has been cleared Initiates an automatic transfer to bypass and emergency module shutdown when specified UPS faults occur 2 6 1 Overloads Without Transfer The UPS sys...

Page 35: ... the UPS system Refer to 2 6 3 Automatic Transfers to Bypass UPS System Faults In an automatic transfer to bypass the output and bypass circuit breakers do not overlap as they do in a manual transfer The static bypass switch is fired closed the output circuit breaker is opened and the bypass circuit breaker is closed Bypass power is supplied to the critical load through the static bypass switch du...

Page 36: ...transfer of the critical load from the bypass source to the UPS inverter 1 Critical load was initially transferred to the bypass source due to a system overload only A manual retransfer from bypass is required if the transfer to bypass was caused by any condition other than output overload 2 Overload has since dropped below 100 of the rated load 3 Both the Input and the Battery MBD circuit breaker...

Page 37: ...ltage will remain on the bypass and output circuit breakers and the static bypass switch unless associated external circuit breakers are opened Check for voltage with both AC and DC voltmeters prior to making contact When the UPS system is under power both the operator and any test equipment must be isolated from direct contact with earth ground and the UPS chassis frame by using rubber mats Some ...

Page 38: ...e for each installation Mission critical sites can have the standard parts and labor around the clock coverage for their UPS with or without scheduled preventive maintenance visits Other sites can benefit from a variety of money saving options Liebert recommends two preventive maintenance visits per year for the UPS The first can be con ducted with the UPS operational and includes an infrared scan...

Page 39: ...quipment so that abnormal condi tions may be more quickly recognized Know what typical meter readings are and where adjust able settings should be 3 3 1 Record Log Set up a maintenance log to record scheduled checks and any abnormal conditions The log should have space for all metered parameter indications including phase readings alarm messages UPS mode of operation air filter replacement date an...

Page 40: ...stance with your specific component specifications replacement component selection and sourcing call 1 800 LIEBERT For customers using Liebert Services preventive maintenance ser vices periodic inspection of these components is part of this service as well as recommending compo nent replacement intervals to customers to avoid unanticipated interruptions in critical load operations 3 4 Battery Main...

Page 41: ...s is not required visual inspections and checks of battery voltage and connec tion resistance should be made NOTICE Risk of equipment damage Batteries should be cleaned with a dry cloth or a cloth lightly moistened with water Do not use cleaners on the batteries Solvents can make the battery cases brittle WARNING Risk of electric shock explosive reaction hazardous chemicals and fire Can cause equi...

Page 42: ...n corrosion and connection integrity Clean and tighten if necessary Note that when installing a new battery the initial torque value is 5 lb in more than the retorque value Table 8 shows battery retorque values If you have a different model battery contact Liebert Services for the required torque value To access battery cell terminals disconnect the inter tier cable and two shelf retaining screws ...

Page 43: ...ge current Input current on each phase should be within 10 of the average input current Alarm messages indicate malfunction or impending malfunction A daily check of the Display Screen will help to provide an early detection of problems Refer to Table 7 for information about interpreting alarm messages Tracing a problem to a particular section is facilitated by alarm messages and the metered param...

Page 44: ...ult Coordination Study must be done by a registered professional engineer experienced in this activity and familiar with local codes and related requirements Liebert strongly recommends periodic inspections of the bypass feeder breaker instantaneous trip set tings as well as the module input rectifier feeder breaker trip settings to ensure that they are cor rect For a variety of reasons although t...

Page 45: ...ntaminants 2 The UPS system is designed to operate continuously at 104 F 40 C However design equipment life expectancy will be extended with lower temperatures 25 C is recommended 3 Ambient temperature is the maximum ambient temperature during any 24 hour period For operation at higher temperatures consult your Liebert sales representative or call Liebert Services at 1 800 LIEBERT 4 Exercise care ...

Page 46: ...e IGBT based Sine Sine PWM Controlled Output Power kW 225 270 360 Output Voltage 480VAC 3 ph 4 w Output Voltage Regulation 1 3 phase RMS average Output Voltage Regulation 100 Unb Load 2 3 phase RMS average Output Frequency Hz 60 Output Frequency Regulation 0 1 Output THDu at Nominal Voltage Linear Load 2 Output THDu at nominal voltage Including a 100kVA Non Linear Load per EN 62040 3 2 5 max Capac...

Page 47: ...2 Color Charcoal ZP 0420 Front Door Opening for serviceability More than 180 Degree of Protection for UPS Enclosure IP 20 with and without front door open Standards Conformities UL 1778 CSA 22 2 107 3 FCC Part 15 Class A IEC62040 2 Level 4 Criteria A EN61000 4 3 Level 3 Criteria A EN61000 4 6 Level 4 Criteria A EN61000 2 2 Criteria A EN61000 4 4 Level 4 Criteria A ANSI C62 41 Category A3 B3 ISTA P...

Page 48: ...SPECIFICATIONS 42 ...

Page 49: ... Auto Restart Fail is the only alarm present attempt a manual start of the unit by pressing Startup Manual Start then following the prompts to attempt to place the unit back online If the manual start fails or if there are other alarms present that won t clear contact your factory authorized service provider Auto Rexfer Failed The condition that caused an automatic transfer to bypass failed to cle...

Page 50: ...lizing The batteries are being equalized Battery equalization stops automatically based on the Equalize Time Setting This status message is self clearing When the condition is no longer present the message and any control activity tied to the status event reverts to normal In normal operation no user response is required Equalize charge can be terminated at any time by pressing Battery Management ...

Page 51: ...o the alarm reverts to normal Press SILENCE to silence the audible alarm Observe the One Line Display To identify which battery cabinet is reporting the temperature condition press the Battery Box on the One Line Display to cycle through each battery compartment or string The temperature display is located under the voltage reading in the Battery Box Press User Settings Battery Management Battery ...

Page 52: ...rify all battery strings show at least 90 charged and all battery breakers are closed If the issue cannot be resolved contact your factory authorized service provider Batt Test Passed The Battery Test passed None BFB Open The Backfeed Breaker is open The Backfeed Breaker feeds the Static Bypass Switch BPSS The physical location of the breaker depends on unit configuration It may be located in the ...

Page 53: ...ce the audible alarm Observe the calculated load percentage on A phase displayed on the Module Output Meter If the A phase steady state load percentage exceeds 110 perform the following If Maintenance Bypass is available follow Standard Operating Procedures to transfer the load to Maintenance Bypass If Maintenance Bypass is not available but the system has an Internal Bypass Breaker CB3 on the One...

Page 54: ...e condition is no longer present the alarm and any control activity tied to the alarm reverts to normal Press SILENCE to silence the audible alarm Observe the One Line Display The bypass power line feeding the static switch is green when bypass power is within normal operating range If the line feeding the static switch is orange gray or black bypass voltage is out of tolerance Also check the bypa...

Page 55: ... each connected battery string Once the location is identified or if the battery string tests are inconclusive contact your factory authorized service provider DC Link Gnd Fault The positive DC Bus has a ground fault The UPS controls monitor the DC Bus positive half for a voltage imbalance caused by current flow to ground This fault means excessive ground current is detected In normal operation wi...

Page 56: ...porting the high temperature the UPS may do one of three things once the limit is reached shut down transfer to bypass or transfer to battery operation This is a potentially serious event Investigate possible causes for a rising temperature condition such as loss of air conditioning airflow obstructions etc If the ambient temperature is high due to loss of air conditioning and cannot be addressed ...

Page 57: ...ce provider immediately and prepare to shut down the load b If external Maintenance Bypass is available close the Maintenance Bypass Breaker MBB to place the load on Maintenance Bypass Do not attempt to re transfer to UPS without first contacting your factory authorized service provider c If external Maintenance Bypass is not available but the CB3 option is visible on the One Line Display close CB...

Page 58: ...are inhibited Press SILENCE to silence the audible alarm Check the Module Output Meter and verify the output currents are normal the kVA kW percentages are less than 100 and the Rexfer Timeout is 00 00 Verify the Inverter box on the One Line Display is green Investigate any other active alarms or faults before attempting to clear this fault Press RESET to clear the fault If the Event Window is cle...

Page 59: ...ndition If the display shows Case 4 the controls force the Rectifier into Reduced Input Current Limit operation this limits the amount of current available to charge the battery typically during generator operation This alarm message is self clearing When the condition is no longer present the message and any control activity tied to the alarm will revert to normal Check the wires landed on Input ...

Page 60: ...r If the unit is running normally when this event occurs the UPS goes to battery This alarm is self clearing When the condition is no longer present the alarm and any control activity tied to the alarm reverts to normal Press SILENCE to silence the audible alarm Examine the One Line Display The Rectifier input line feeding the Input Breaker should be green If not investigate source power to the UP...

Page 61: ...tude of the overload When the timer reaches zero the UPS transfers to bypass and populates the Active Event Window with this alarm This fault is non latching When the underlying condition is no longer present this fault and any control activity tied directly to this fault reverts to normal Press SILENCE to silence the audible alarm Observe the load percentages for each phase on the Module Output M...

Page 62: ...and the load is greater than 80 reduce the load or investigate Contact your factory authorized service representative Load on Bypass The load is being supplied by bypass None Load on Maint Byp The load is on Maintenance Bypass None Low Batt Capacity One or more battery circuit breakers are open This alarm applies if the system includes more than one battery circuit breaker and at least one is clos...

Page 63: ...ine Display will be restored however Liebert does not recommend attempting to return the load to inverter until a service visit has been made and action taken to determine why the fault occurred Action will involve resetting the UPS controls by removing and then reapplying control power Therefore it will be necessary to utilize maintenance bypass either by closing the optional CB3 internal bypass ...

Page 64: ...s setpoint The setting allows the user to monitor the load status of the UPS For example if the current load on Phase B is 50 the user can set this setpoint to 80 and an alarm is received if the added load exceeds 80 The alarm may also be configured with a delay to prevent nuisance alarms due to cycling loads The alarm is self clearing Once the load level decreases to less than 95 of the level set...

Page 65: ... warmer than normal If the room temperature is warmer than normal investigate and resolve the issue If the room temperature is normal and the Inlet Air Temp reading on the One Line Display is higher than normal contact your factory authorized service provider Output Fault This summary event occurs when the detected system output exceeds acceptable limits in either voltage or frequency If the UPS w...

Page 66: ...rns as soon as a Rectifier restart is attempted contact your factory authorized service provider Redundant Fan Fail This alarm indicates a fan has failed Press SILENCE to silence the audible alarm Contact your factory authorized service provider Regen Active Regeneration Mode is a service mode that is normally controlled by the service technician Regeneration Mode Status or Alarm messages are gene...

Page 67: ...wires are present contact your factory authorized service provider Remote Off Rect The Rectifier was turned off by an external signal This indicates an external signal forcing the Rectifier to remain off is active This type of signal is wired into an Input Contact Isolator and the specific channel is assigned as Remote Off Rectifier This status message is self clearing When the condition is no lon...

Page 68: ... condition returns contact your factory authorized service provider Xfer to Byp Failed An event such as an Inverter fault caused an attempted automatic transfer to bypass and the transfer failed The controls detect the Static Bypass Switch BPSS failed to assume the load and the Inverter was off Press SILENCE to silence the audible alarm Check the Event Log by pressing Status Reports Event Log to i...

Page 69: ...UPS Alarm and Status Messages 63 NOTES ...

Page 70: ...UPS Alarm and Status Messages 64 ...

Page 71: ......

Page 72: ...oration All names referred to are trademarks or registered trademarks of their respective owners Technical Support Service Web Site www liebert com Monitoring 800 222 5877 monitoring emersonnetworkpower com Outside the US 614 841 6755 Single Phase UPS 800 222 5877 upstech emersonnetworkpower com Outside the US 614 841 6755 Three Phase UPS 800 543 2378 powertech emersonnetworkpower com Environmenta...