Gamatronic B60US-IB, Installation Manual

Page 1: ...GAMATRONIC THREE PHASE MODULAR UPS FOR THE 208V GRID B60US IB INSTALLATION GUIDE Revision 3 0 January 2020 Doc 2MUM B60I This installation guide is for product 101SW463 1...

Page 2: ...UPS for 208 Vac Grid Installation Guide doc rel 3 0 ii Remember to register your product at http www gamatronic com product warranty in order to activate your warranty...

Page 3: ...pecific system in any particular environment Operation and control of the UPS is accomplished through a touch sensitive LCD display screen In this manual when explaining how to navigate the control so...

Page 4: ......

Page 5: ...d connecting external batteries 38 3 3 5 Powering up the system 41 3 3 5 1 Before starting up the UPS 41 3 3 6 Initial Configuration 41 3 3 6 1 System Startup Wizard 42 3 3 6 2 Continuing First Time U...

Page 6: ...nance bypass for parallel systems 87 7 MAINTENANCE BYPASS MODE PROCEDURE 88 7 1 CIRCUIT BREAKER LAYOUT 89 7 2 TRANSFERRING THE UPS TO MAINTENANCE BYPASS MODE FROM NORMAL MODE 89 7 3 TRANSFERRING THE U...

Page 7: ...6 Figure 19 One of the internal battery banks 37 Figure 20 Connecting a Single Battery Set 39 Figure 21 Connecting multiple battery sets using CBs 40 Figure 22 Initial configuration wizard Start scree...

Page 8: ...for a single module 84 Figure 86 Connection diagram for 2 parallel units 85 Figure 87 Connection diagram for 4 Units in Parallel 86 Figure 88 Electrical setup 89 Figure 89 UPS On Normal Mode 90 Figure...

Page 9: ...mage 2 Inspect the ShockWatch and TiltWatch devices which are adhered to the outside of the wooden packing crate Verify that their indicators are not red A red indicator is a sign of rough handling Sh...

Page 10: ...was subject to shock or tip over 4 Using a forklift move the shipping crate close to the place in which the UPS will be installed 5 Cut and remove any straps on the shipping crate 6 Stand on a secure...

Page 11: ...remove the walls themselves leaving the UPS standing on its wooden shipping pallet Figure 4 Remove the walls of the crate 8 Cut and remove any straps that are securing the UPS to the shipping pallet...

Page 12: ...pment injury to personnel or even death Ensure all power is disconnected before performing installation or maintenance See Table 1 and Figure 7 for recommended clearances The UPS must be well grounded...

Page 13: ...be used between the battery and the UPS for example the Ferraz Shawmut A70QS fuse WARNING RISK OF LETHAL ELECTRIC SHOCK WARNING HIGH TOUCH CURRENT EARTH CONNECTION ESSENTIAL BEFORE CONNECTING POWER SU...

Page 14: ...the battery circuit and AC circuit breakers are turned OFF Do not turn ON the battery circuit breaker when the battery cabinet is disconnected from the UPS Do not install the UPS next to gas or elect...

Page 15: ...de doc rel 3 0 11 3 System Structure and Installation The UPS is composed of Up to 3 power modules each provides 20 kVA 18 KW Static switch module System controller Up to 3 internal battery banks Maxi...

Page 16: ...UPS for 208 Vac Grid Installation Guide doc rel 3 0 12 Figure 5 Major components of the UPS system Figure 6 Main terminals viewed from the UPS rear...

Page 17: ...BE CONNECTED TO THE AC MAINS AND OPERATED WITH NO LOAD FOR A PERIOD OF FOUR HOURS BEFORE APPLYING A LOAD 3 1 Important Installation Information The Gamatronic UPS must be connected in a 4 wire Ground...

Page 18: ...When the checklist is complete e mail it to your vendor and to Gamatronic at Support gamatronic com INSTALLATION CHECKLIST FOR THE GAMATRONIC MODULAR UPS Customer Address Site Phone E mail Serial numb...

Page 19: ...Check ambient temperature Between 59 F 77 F 15 C 25 C Min max 14 F 104 F 10 C 40 C 3 3 2 5 Check humidity and condensation No condensation dampness 3 3 2 6 Check ventilation Proper airflow to batterie...

Page 20: ...correct torque values 3 3 3 15 Remove all battery trays from the system only then begin assembly Assemble all battery trays and only connect the batteries to the battery cabinet once you have populat...

Page 21: ...W4 open OFF Verify polarity in each battery set 19 3 Switch ON SW1 and SW2 and measure the voltage across SW3 and SW4 If the voltage difference across SW3 or SW4 is greater than 10V charge the battery...

Page 22: ...ltiple battery sets add the Ah value of the of sets 24 Enter your local time zone 25 Press the Finish button The controller restarts with the new configuration 26 From the System Menu screen choose Pr...

Page 23: ...d select only this module and turn it on main operation on off modules on 5 Once fully operational fully shut it down and insert the next power module 6 Repeat this process for each additional power m...

Page 24: ...d be no greater than 2 Vac OK Not OK record value ____________ V 33 Go to Main Status STSW Detail1 Verify that Bypass phase sequence field says Correct 34 For each BYPASS phase use the mesurments take...

Page 25: ...fference between the bypass line and the ac output line L1 L1 L2 L2 L3 L3 The difference should not exceed 60 V OK Not OK record phase and value ____________ V 43 Manually transfer the load to bypass...

Page 26: ...test Verify that the system is running in normal mode the output is supplied from the inverter then disconnect AC input and see that inverters remain ON and output of the system is on inverter Return...

Page 27: ...he visual inspection explained in this section immediately after unpacking UPS To perform UPS visual inspection 1 Inspect the UPS from all angles and ensure that there is no visible damage to any part...

Page 28: ...or forced ventilation is present at the location of the unit and battery cabinets 5 Verify that the foundation and access routes are adequate for the dimensions and weight of the UPS and battery cabin...

Page 29: ...nd service Rear 100 cm 39 in Minimum adequate clearance for cable connections Sides No minimum clearance provided that the UPS is not placed next to heat emitting or electronic equipment If the UPS is...

Page 30: ...s and Gamatronic system specifications 3 Verify that the input and output power cable connections ground and neutral lines comply with local and national codes and are appropriate for the circuit brea...

Page 31: ...onnected to the UPS and must be available Confirm the battery is connected to the UPS and is available 3 3 4 Cable Site Preparation This section explains UPS cabling and connection requirements Warnin...

Page 32: ...t the neutral line Warning If you have a four pole mains to generator switching system you are in danger of having the neutral line disconnected when the four pole switch is operated This can result i...

Page 33: ...UPS for 208 Vac Grid B60US IB Installation Guide doc rel 3 0 29 Figure 9 Recommended system connections Note For recommended circuit breaker and fuse ratings see Table 2...

Page 34: ...UPS for 208 Vac Grid Installation Guide doc rel 3 0 30 Figure 10 Recommended connections with input isolation transformer Note For recommended circuit breaker and fuse ratings see Table 2...

Page 35: ...essage following warning WARNING There is a UPS attached to this electrical panel To avoid electric shock DO NOT DISCONNECT THE UPS s NEUTRAL LINE WHEN THE UPS IS OPERATING 3 3 4 4 Connecting the UPS...

Page 36: ...Figure 10 the Neutral line must be shared following warning WARNING The recommended cable and breaker sizes are based on optimal installation conditions Local code must be followed to coincide with t...

Page 37: ...e all battery trays externally from the system Next verify polarity on each tray Only then can you insert the populated trays into the system For an explanation of what populated batteries mean refer...

Page 38: ...UPS for 208 Vac Grid Installation Guide doc rel 3 0 34 Figure 12 Internal battery bank layout Figure 13 Battery wire terminals Figure 14 Single battery tray 1 2 3...

Page 39: ...the terminal insulator Figure 15 Connect the eighth battery on each tray The eighth battery on each tray is to be connected to the black negative cable plug attached to the connector at the back of e...

Page 40: ...eries There are 2 wires with cable plugs on one end and Anderson plugs on the other to connect the 4th and 5th battery on each tray They allow for a safe disconnect of every 48V Be sure to use the ter...

Page 41: ...UPS for 208 Vac Grid B60US IB Installation Guide doc rel 3 0 37 Figure 19 One of the internal battery banks...

Page 42: ...extended backup time multiple battery sets can be attached to the UPS 1 Ideally the external battery cabinet s should be located as close to the UPS as is practical 2 Assemble the batteries within th...

Page 43: ...tings for semiconductor fuses and circuit breakers 7 The fuses between the battery cabinets and The UPS F1 F2 F3 and F4 in Figure 20 must be FAST FUSES SEMICONDUCTOR FUSES for example the Ferraz Shawm...

Page 44: ...F1 through F4 depends on the number of battery sets The greater the number of battery sets the lower the rating required for fuses F1 through F4 Fuses F5 and F6 and DC SW 1 and 2 must be rated accord...

Page 45: ...meter on external battery box terminals 2 Leave all battery and output circuit breakers in the OFF in position 3 Check to see if the bypass and rectifier input are linked If they are linked then you h...

Page 46: ...D display panel You will be prompted to provide the UPS with basic system configuration information in order to enable initial operation of the UPS To perform first time UPS configuration 1 Activate t...

Page 47: ...the Technician password you received from Gamatronic in the Password text input field and press OK Without a password you cannot continue The Battery Capacity screen appears Figure 24 Initial configur...

Page 48: ...attery banks the Ah value of each battery bank must be added i e for 2 battery banks of 20Ah each you would enter a value of 40Ah 4 Indicate the capacity of the connected batteries in ampere hours Ah...

Page 49: ...B60US IB Installation Guide doc rel 3 0 45 The Finish screen appears Figure 26 Finish configuration wizard 6 Press Finish The System Menu wizard exits 7 Continue the first time installation process S...

Page 50: ...n in the battery manufacturer s data sheet Verify that the parameter values are appropriate for the batteries you have chosen 2 Turn off the bypass and rectifier input circuit breaker Figure 27 Flat c...

Page 51: ...turn on the module System Menu Operation On off Modules on The Modules on screen appears Press Confirm 6 In the Operation section you will select and shut down the module Navigate to Main Operation T...

Page 52: ...Confirm 13 The selected power module is switched on Notice that the active power module is highlighted in blue and is active module 2 while the primary power module is in Standby State module 1 becau...

Page 53: ...2 Confirm Switch on All Modules 22 Confirm OK 23 The system will transfer to bypass then once all inverters are fully operational the system will transfer the output to the inverter i e Normal Mode 24...

Page 54: ...s Next perform a brief battery test to verify that The UPS is ready and it is able to operate in battery mode when needed 28 Perform a brief battery test to verify that the UPS is ready and able to op...

Page 55: ...otation over all CBs 31 On the Status screen verify that the bypass and the inverters are synchronized This is the recommended stage at which to perform load testing before transferring the customers...

Page 56: ...bypass circuit breaker to move the load to the UPS 36 Transfer the load to inverter Do not transfer the load to the inverter if the maintenance bypass circuit breaker is still in the ON position Opera...

Page 57: ...date using the sliders This will set a system maintenance reminder alarm one year from this date 40 Press Confirm Finally you must save the settings you have defined 41 To save the settings you define...

Page 58: ...process at that time The UPS supports use of a fixed IP address and also supports dynamic assignment of IP addresses DHCP Consult your IT systems administrator and determine if your IP network suppor...

Page 59: ...ystem Menu select Setup Connectivity IP Address Configuration 47 Select Use static IP address The IP address configuration screen appears Figure 41 IP address configuration You should have previously...

Page 60: ...ection explains how to perform the following tests on the UPS unit 1 Self loading PQ mode test 2 Under load test 3 Battery mode blackout test 4 ATS test 5 ECO Mode test 6 Check IP communication with C...

Page 61: ...F mode to PQ mode in 10 kW active load increments 3 From the System Menu select Operation PQ Setup 4 The PQ Mode Setup screen appears Figure 43 PQ Mode setup 5 Select PQ Mode 6 Begin with 2kW active p...

Page 62: ...in 10 increments After each time you raise the active load level and you press the Confirm button wait 1 minute The load level can be incrementally raised to 95 98 kW of maximum system output power 12...

Page 63: ...ceptance testing lower the active and reactive load levels in 10 increments back down to 0 using the Active power slider and Reactive power sliders Transfer the system back to VF mode in order to retu...

Page 64: ...4 Check and record the total system load output current and make sure that the UPS is not overloaded with respect to system specifications 5 Verify that the UPS is operating normally and that no alarm...

Page 65: ...nsfer the load from the battery to the generator An auxiliary contact can be set to limit battery charging during the use of the generator Select an auxiliary contact that can be wired to the N O norm...

Page 66: ...r normally closed depending on your ATS or Generator s auxiliary output 3 Select Confirm Generator mode setting is setup now To perform the ATS test 1 Switch on the generator or secondary power source...

Page 67: ...that the load is directly affected by grid fluctuations To put the system in ECO mode 1 From the System Menu go to Setup System System Type The following screen appears Figure 49 ECO Mode 2 Select EC...

Page 68: ...creen select the Enabled checkbox and then select Confirm 4 Navigate to Operation Main Operation The following screen appears Figure 51 Turning on ECO mode 5 Select Eco mode off click for change Notic...

Page 69: ...N and ECO mode The system will run on ECO mode until either there is a variant in the grid power supply or manually transferred back to inverter 3 4 6 Test IP Communication with Controller This test i...

Page 70: ...is in the same domain as the UPS that is so that the first three nodes of the computer s IP address match the first three nodes of the UPS s IP address For example if the UPS s IP address is 192 212 1...

Page 71: ...tions They are grouped together on the front panel of the UPS in what is referred to as connector group 1 and connector group 2 See Figure 54 Figure 54 Location of Connector Groups 1 and 2 on the fron...

Page 72: ...the UPS immediately goes into bypass mode These contacts are intended to be used in conjunction with the Maintenance Bypass function They should be closed by the user s maintenance bypass switch to e...

Page 73: ...6 PLUG NAME PIN CONNECTION NAME COMMENT P1 1 Digital output 1 Low Battery 2 3 Digital output 2 AC fail 4 P2 1 Digital output 3 LVD this works in tandem with P13 pins 1 and 3 Do NOT remove P2 or P13 2...

Page 74: ...1 Digital input 1 2 Common 3 Digital input 2 Optional Generator mode 4 Common P9 1 Digital input 3 Surge protector fault 2 Common 3 Digital input 4 Optional Maintenance bypass 4 Common P10 1 Digital...

Page 75: ...emove 2 Battery current 1 3 Gnd 4 12 V P14 1 12 V N A 2 Battery current 1 3 Gnd 4 12 V P15 1 12 V Negative Battery Current 2 Battery current 1 3 Gnd 4 12 V P16 3 Digital output 2 4 Common 5 Digital ou...

Page 76: ...l Emergency Power Off EPO switch should be installed on the UPS by the customer The EPO switch cuts all output power to the load in emergency situations The connection point for the EPO switch is in c...

Page 77: ...ector makes use of one of the input dry contacts to transmit the alarm to the UPS This relay is normally open and closes when the surge arrestor detects a malfunction 4 4 LVD battery protector The LVD...

Page 78: ...roblem that can arise in such a situation is how to prevent the main circuit breaker from tripping before the downstream circuit breaker closest to the load is tripped As an example Figure 59 shows a...

Page 79: ...ent values and maximum bypass current values and recommended circuit breaker ratings In order to protect the UPS s bypass contactor and also the main input of the UPS for all scenarios including short...

Page 80: ...h UPS to provide optimal load sharing between the units One of the parallel UPS systems assumes the role of Master This unit is synchronized to the mains power The other units operate as Slaves and ar...

Page 81: ...will also transfer to bypass mode simultaneously 6 1 2 Parallel communication When two or more UPS units are operated in parallel parallel communication must take place between them in a ring configu...

Page 82: ...le 7 Figure 62 Location of the parallel comm connections at inside rear of the system Connections for the two parallel communication cables when two or more UPS s are being operated in parallel config...

Page 83: ...ommon battery Is a single battery connection that is shared between all the UPS systems that are running in parallel 2 Decentralized battery Is a separate battery bank per UPS Clearly state when order...

Page 84: ...parallel communication between UPSs DESCRIPTION QUANTITY PER UNIT GAMATRONIC CATALOG NO PARALLEL KIT B SERIES DECENTRALIZED DC Black 1 101 B PARA ED PARALLEL KIT B SERIES COMMON DC Grey 1 101 B PARA...

Page 85: ...mmunication cable 4 Verify that each UPS s output circuit breaker is in the OFF position CB5 in the connection diagrams see Figure 69 5 Turn on one of the systems This system will become the master sy...

Page 86: ...in the necessary access codes 7 Now turn on the other parallel system or systems These will be the slave systems You can have up to four systems in a parallel configuration 8 Once the Master System ha...

Page 87: ...ter Power Module Figure 67 Modules screen 9 Put the slave systems in multisystem mode System Menu Setup System Type Multisystem mode 10 For each slave system compare the output voltage of each phase t...

Page 88: ...e 14 When you have verified that all of the slave systems have output voltages of 1 of the master system put each system in bypass mode From the System Menu go to Operation Transfer Transfer load to b...

Page 89: ...UPS for 208 Vac Grid B60US IB Installation Guide doc rel 3 0 85 Figure 69 Connection diagram for 2 parallel units...

Page 90: ...UPS for 208 Vac Grid Installation Guide doc rel 3 0 86 Figure 70 Connection diagram for 4 Units in Parallel...

Page 91: ...power to the loads The maintenance bypass switch routes the current around the UPSs for the safety of the technician The optional maintenance bypass switch is shown in the connection schematics for pa...

Page 92: ...is enables a technician after turning off ALL the input output and battery circuit breakers to work safely on the UPS The technician can perform full maintenance procedures load testing and even repla...

Page 93: ...c rel 3 0 89 7 1 Circuit breaker layout Figure 71 Electrical setup 7 2 Transferring the UPS to maintenance bypass mode from normal mode In normal operation the UPS s ac circuit breakers are positioned...

Page 94: ...nd output of each phase If there is there is a bad phase rotation either on the input of the system or on the maintenance bypass CBs 4 and or 6 This will have to be corrected before the system can be...

Page 95: ...er load to bypass screen appears Figure 73 Transfer load to bypass confirm dialog 5 Select OK The transfer load to bypass is confirmed 6 From the System Menu go to Main Status The UPS On Bypass mode s...

Page 96: ...s mode and can now be safely serviced 7 3 Transferring the UPS back to normal mode from maintenance bypass mode In maintenance bypass operation the UPS s ac circuit breakers are positioned as shown in...

Page 97: ...e MAINTENANCE BYPASS circuit breaker 9 On the system controller LCD screen select Operations transfer load to inverter 10 Verify that the load is being supported by the inverters on the Status screen...

Page 98: ...ing between the two sources the mains and the generator is performed by an Automatic Transfer Switch ATS Because these two sources are not usually synchronized switching between them requires an inter...

Page 99: ...ns the normal source is available R is the reserve source The timing variables T1 through T5 are described in Figure 75 The knob at the bottom of the control panel controls the actions of the ATS The...

Page 100: ...America Modifications could entail adding or removing modules as well as performing service or maintenance 2 A UPS kVA rating is a maximum rating the actual UPS can have fewer power modules and there...