Xtreme Power Conversion 20kVA Model, User And Installation Manual

Page 1: ...R91 Online UPS 20kVA Model User Installation Manual www xpcc com 2016 Xtreme Power Conversion Corporation All rights reserved Rev 7 21 16 ...

Page 2: ...n 10 UPS Multi Module Installation 12 CYCLON Battery Pack Connection 15 BP XR4U480A Battery Pack Connection 16 Assembly 17 4 Post Rail Mounting 20 Multiple Battery Pack Connections 20 Installation and Setup 21 BP XR2U480A Battery Pack Connection 22 Assembly 23 4 Post Rail Mounting 26 Multiple Battery Pack Connections 26 Installation and Setup 27 Operation 28 OperationModes 28 Turn On Off the UPS 2...

Page 3: ...Xtreme Power Conversion Corporation R91 User s Manual Page 3 Uninterruptible Power Supply Specifications 46 Shipping List 46 Obtaining Service 47 Xtreme Power Conversion Limited Warranty 48 ...

Page 4: ...ation that should be followed during installation and maintenance of the UPS and batteries allowing you to correctly set up your system for the maximum safety and performance Included is information on customer support and service if it is required If you experience a problem with the UPS please refer to the Troubleshooting section in this manual to correct the problem If the problem is not correc...

Page 5: ...dispose of batteries in a fire the battery may explode CAUTION Do not open or mutilate the battery released electrolyte is harmful to the skin and eyes CAUTION A battery can present a risk of electric shock and high short circuit current The following precaution should be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles To reduce the r...

Page 6: ... accessible Except for replacing the batteries all servicing on this equipment must be carried out by qualified ser vice personnel Before conducting any maintenance repair or shipment first ensure that everything is turned off com pletely and disconnected For additional safety instructions please use the Safety Manual as a reference Special Symbols The following symbols used on the UPS warn you of...

Page 7: ...tage conditions slow voltage fluctuations frequency variations differential and common mode noise transients etc To prevent power line problems from reaching critical systems causing damage to software hardware and equip ment malfunctions the UPS maintains constant voltage isolating critical load output and cleaning the utility AC power Main Features This is a three phase input three phase output ...

Page 8: ...ess than the UPS nominal power rating then actual backup time is longer The following options are available o Connectivity Options SNMP WEB card o Extended Battery Packs minimum 1 required See the Specification section of this manual for additional model information Unpacking the UPS 1 Do not lean the UPS against anything when moving it out of the packaging 2 Check the physical appearance of the U...

Page 9: ...data is quoted for an operating temperature between 20 C and 25 C Operating above this range will reduce the battery life while operation below this range will reduce the battery capacity If the equipment is not to be installed immediately it must be stored in a room so as to protect it against excessive heat and humidity sources CAUTION An unused battery must be recharged every 6 months Temporari...

Page 10: ...OCATION AND OPERATION OF THE EXTERNAL ISOLATORS WHICH ARE CONNECTED TO THE UPS INPUT BYPASS SUPPLY OF THE UTILITY DISTRIBUTION PANEL CHECK TO SEE IF THESE SUPPLIES ARE ELECTRICALLY ISOLATED AND POST ANY NECESSARY WARNING SIGNS TO PREVENT ANY INADVERTENT OPERATION Cable Sizes UPS MODEL CABLE SIZES THHW wiring at 75 C AC INPUT AC OUTPUT DC INPUT GROUNDING R91 20K 8 awg 8 awg 6 awg 8 awg CAUTION Prot...

Page 11: ...age 11 Uninterruptible Power Supply Power cable connection diagram Select the appropriate power cable size paying attention to the diameter of the connection terminal of the cable which should be greater than or equal to the connection posts Wiring diagram ...

Page 12: ...l system consisting of two or more R91 20KVA modules is that same as that of a single module The following provides installation procedures related to a parallel system Cabinet Installation Connect all R91 20KVA UPS required in the parallel system as shown in the diagram below WARNING MAKE SURE THE N A L1 B L2 AND C L3 WIRING IS CORRECT AND THAT GROUND IS CONNECTED Parallel Cable Installation The ...

Page 13: ...Xtreme Power Conversion Corporation R91 User s Manual Page 13 Uninterruptible Power Supply Parallel connection of UPS ...

Page 14: ...ll switch must be voltage free and normally open EPO connections for parallel systems Requirements for a Parallel System A group of parallel UPS modules behave as one large UPS system with the advantage of presenting higher reli ability In order to assure that all modules are equally utilized and comply with relevant wiring regulations please follow the requirements below 1 All UPS modules must be...

Page 15: ...e diagrams respectively display battery pack internal connections internal cell connections in each individual tray and battery pack external connections to UPS and another battery pack R91 BPSYS battery pack wiring diagram R91 BPSYS battery module connection CAUTION Ensure correct polarity of the battery string series connection DO NOT mix batteries with different capacity or dif ferent brands or...

Page 16: ...tion The BP XR4U480A battery pack dimension is 443W x 861 5D x 175H mm 17 4 x 33 9 x 7 0 in and unit weight is 127 kgs 280 lbs It includes battery connection cables breaker fuse terminal etc with a maximum capacity of 40 pcs CSB UPS12580 batteries inside The battery connection could be configured to output 240V two groups batteries connect in series as BAT N BAT ...

Page 17: ...ower Supply Complete BP XR4U480A cabinet Assembly Dismount the Cabinet Shell Put the battery pack on a level pull of bolts at the right side battery tray than pull out the battery tray remove the battery tray top covers for easier battery installation and connection as shown below ...

Page 18: ...allation and Connection Users need 40 pcs batteries divide into 2 groups Each group has 20 pcs batteries in series as BAT N BAT shown below 40 pcs batteries installation and connection Each battery tray fit 10pcs batteries then connect the batteries as shown in below pictures 40pcs batteries installation ...

Page 19: ...correct with multi meter or other equipment Install the cover if the voltages are correct Note Battery poles cannot be reversed also cannot short the battery poles otherwise batteries would be damaged or other accidents would happen Don t touch the battery poles at the same time It s better only single man make the operation Fuse in Battery Pack The battery pack has 2 x fuses inside as shown in be...

Page 20: ... batteries with different capacity or dif ferent brands or new or old batteries WARNING ENSURE CORRECT POLARITY OF STRING END CONNECTIONS TO THE BATTERY CIRCUIT BREAKER AND FROM THE BATTERY CIRCUIT BREAKER TO THE UPS TERMINALS I E TO TO N TO N DISCONNECT ONE OR MORE BATTERY CELL LINKS IN EACH TIER DO NOT RECONNECT THESE LINKS AND DO NOT CLOSE THE BATTERY CIRCUIT BREAKER UNLESS ALL CONNECTIONS ARE ...

Page 21: ...ackaging Note The battery modules are very heavy be cautious when unpacking and lifting the unit to avoid injury Selecting Installation Position It is necessary to select a proper environment to install the unit in order to minimize the possibility of damage to the battery system and extend the life of the batteries Please follow the instructions below 1 Do not block the air flow to the ventilatio...

Page 22: ...enclosure into the shelf kit and rack with screws at front and rear Battery Module Installation 1 Remove front cover from the battery enclosure 2 Slide in battery modules 3 Secure front cover in place 4 Remove UPS connection cover from battery pack and connect the Anderson connector to UPS BP XR2U480A Battery Pack Connection The BP XR2U480A battery pack dimension is 442W x 1086D x 86H mm 17 4 x 42...

Page 23: ...23 Uninterruptible Power Supply Assembly Dismount the Cabinet Shell Put the battery pack on a level remove the battery pack top covers pull out the battery tray and remove the bat tery tray layering for easier battery installation and connection as shown below ...

Page 24: ...allation and Connection Users need 40 pcs batteries divide into 2 groups Each group has 20 pcs batteries in series as BAT N BAT shown below 40 pcs batteries installation and connection Each battery tray fit 10pcs batteries then connect the batteries as shown in below pictures 40pcs batteries installation ...

Page 25: ...correct with multi meter or other equipment Install the cover if the voltages are correct Note Battery poles cannot be reversed also cannot short the battery poles otherwise batteries would be damaged or other accidents would happen Don t touch the battery poles at the same time It s better only single man make the operation Fuse in Battery Pack The battery pack has 2 x fuses inside as shown in be...

Page 26: ... batteries with different capacity or dif ferent brands or new or old batteries WARNING ENSURE CORRECT POLARITY OF STRING END CONNECTIONS TO THE BATTERY CIRCUIT BREAKER AND FROM THE BATTERY CIRCUIT BREAKER TO THE UPS TERMINALS I E TO TO N TO N DISCONNECT ONE OR MORE BATTERY CELL LINKS IN EACH TIER DO NOT RECONNECT THESE LINKS AND DO NOT CLOSE THE BATTERY CIRCUIT BREAKER UNLESS ALL CONNECTIONS ARE ...

Page 27: ...w 1 Do not block the air flow to the ventilation openings of the unit 2 Please ensure the installation site environmental conditions are in accordance with the unit s working specifications to avoid overheat and excessive moisture 3 Do not place the unit in a dusty or corrosive environment or near any flammable objects 4 This unit is not designed for outdoor use Enclosure Installation Note Shelf k...

Page 28: ...pass supply without interruption to the critical load In the event that the inverter output is not synchronized with the bypass AC source the static switch will perform a transfer of the load from the inverter to the bypass with power interruption to the critical AC loads This is to avoid paralleling of unsynchronized AC sources This interruption is programmable but typically set to be less than o...

Page 29: ...lied power by the inverter Cold Start Procedure CAUTION Follow these procedures when there is an input AC Utility Failure but the batteries are normal Turn on the battery switch The battery will feed the Auxiliary power board Trigger the Cold Start Buttons of the modules respectively using the ON BUTTON shown in the above dia gram When battery is normal the rectifier starts operation 30 seconds la...

Page 30: ...tops spinning in 60 seconds If there are external battery packs connected turn the Battery breakers on each battery pack to the OFF Open position WARNING Wait about 5 minutes for the internal DC bus bar capacitors to be completely discharged Computer Access Connect one end of the RS232 communications cable to a computer and the other end to the RS232 port on the UPS Open the software Muser4000 and...

Page 31: ...ting and set selections as shown below and then save settings o COM COM1 o Baud Rate 9600 o Protocol HIP On the main page of Muser4000 choose the Append button place the UPS name into Equipment Name and UPS ID address into Equipment address Choose the Append button then the connection between UPS and computer is complete ...

Page 32: ...eme Power Conversion Corporation R91 User s Manual Page 32 Uninterruptible Power Supply Parallel Setting Connect the UPS with a computer Power ON the UPS Open Muser4000 software and choose System User Set ...

Page 33: ...dow CAUTION When powered by inverter it is necessary to turn off the inverter before setting the voltage and frequency level in PC Once Set is selected you will be prompted to enter a password corresponding with which battery pack is being used with the UPS Reference the battery pack manual for corresponding password ...

Page 34: ...ode with Parallel for the Value then select Set as shown in the figure below If the UPS beeps it means the setting is correct At the window of Data Set select UPS ID enter the Value for the parallel UPS ID at the right side then select Set as shown in the figure below If the UPS beeps it means the setting is correct 1 1 3 3 2 2 4 ...

Page 35: ...led power OFF all the UPS s Connect all the UPS s according to parallel cable installation and then power ON the UPS s Communication Port Definitions RS232 RS485 Definition of the Port Connection between PC RS232 port and UPS RS232 port PC RS232 port UPS RS232 port Description Pin 2 Pin 2 UPS send PC receive Pin 3 Pin 3 PC send UPS receive Pin 5 Pin 5 Ground Connection between the computer RS485 p...

Page 36: ...wer Conversion Corporation R91 User s Manual Page 36 Uninterruptible Power Supply RS 232 communication data format Baud rate 9600bps Byte length 8bit End bit 2bit Parity check none LCD Display System LCD Diagram ...

Page 37: ...ent Charge State UPS ID Parallel ID Scroll Button System Time UPS State UPS Working Mode Page Menu Options Current State Fault of the UPS Enter Button On Button CAUTION The display provides more functions than those described in this manual Data Press Scroll Button the UPS goes to the next screen as shown below Displays Phases A B and C L1 L2 and L3 Input Output Voltage Current and Frequency and O...

Page 38: ...hown below Displays Main Voltage Current and Frequency Bypass Voltage and Frequency Data Output Press Scroll Button the UPS goes to the next screen as shown below Displays Output Voltage Current and Frequency Data Battery Press Scroll Button the UPS goes to the next screen as shown below Displays Battery Voltage Current Battery Run Time and Battery Capacity ...

Page 39: ...splays Phases A B and C L1 L2 and L3 Load Percentage kW and kVA Data Inside Press Scroll Button the UPS goes to the next screen as shown below Displays V Bus T1 T2 V INV and Frequency Information Hold Scroll Button for 3 seconds to exit Data sub pages Press Scroll Button the UPS goes to the next screen as shown below Displays LCD PFC INV Versions and Rated Power for UPS ...

Page 40: ...creen as shown below Displays User Settings Language Date Time Backlight Buzzer and Battery Test options View User Settings and System Parameter Settings section for instructions on making selections Record Press Scroll Button the UPS goes to the next screen as shown below Displays Latest Recorded Event and Fault with time stamp and description ...

Page 41: ...ttings The setting function is controlled by 2 buttons Scroll and Enter Scroll Moves through parameters and adjust values Enter Goes into setting pages and confirms selections Enter System Parameter Setting Mode Hold Scroll and Enter simultaneously for 3 seconds See below for Maintenance password page Maintenance password 1121 Exit Setting Mode Sub Pages Parameter fields and Cancel Selection Hold ...

Page 42: ...t Grade 220V 230V 240V 240V F Output Grade 50Hz 60Hz 60Hz F Mode non CVCF CVCF non CVCF Test Type OFF 10s 10min EOD OFF Test Cycle 1 60 Day 30 Day Equipment ID 1 16 1 Temperature Compensation Enable Disable Enable Need to be in Bypass If not in Bypass Output will drop load Setting Bypass Displays Bypass Parameter Settings Page The following parameters can be adjusted Bypass Setting Range Default U...

Page 43: ... Capacity Battery Rating AH 7 200 7 Boost Charge Enable Disable Enable Group Battery Strings Qty 1 to 8 1 V Boost Boost Upper Limit Voltage V cell 2 41 2 50 2 45 V Float Float Base Voltage V cell 2 20 2 29 2 27 V EOD EOD Voltage V Cell 1 55 1 75 1 67 I MaxCharge Max Charging Current 1 6 2 Setting Parallel Displays Parallel Parameter Settings Page The following parameters can be adjusted Parallel S...

Page 44: ...rate user manual Network Management Card with Environmental Monitor which is shipped with the SNMP card SNMP Card external SNMP optional Connect the external SNMP adapter to the SNMP port indicated Tighten the screws The slot called SNMP supports the Megatec protocol We advise SNMP R90 as a tool to remotely monitor and manage any UPS system SNMP R90 External Snmp Card ...

Page 45: ...age and current Battery breaker does not switch on or batteries are damaged or battery is re verse connected Switch on the battery breaker If batteries are damaged replace the entire set of batteries Connect the battery cables correctly Battery number and capacity are not set correctly Go to the LCD display setting of the battery number and capacity and set with correct data 5 Audible beep every 0...

Page 46: ... to 99 UPS PHYSICAL Dimensions W x D x H 443 x 580 x 131 mm 17 4 x 22 8 x 5 2 in Unit shipping weight 31 kg 68 4 lbs 42 kg 92 lbs ENVIRONMENT Operating temperature 0 40 C 32 104 F Altitude 11 500 ft above sea level Humidity 0 95 non condensing Storage temperature 25 55 C 13 131 F non condensing UPS APPROVALS UL 1778 FCC A pending WARRANTY 3 years electronics USA and Canada COMMUNICATIONS INTERFACE...

Page 47: ...ask you for the above information and if possible help solve your problem over the phone In the event that the unit requires factory service the technician will issue you a Return Mate rial Authorization number RMA If you are returning the UPS to Xtreme Power for service please follow these procedures 1 Pack the UPS in its original packaging If the original packaging is no longer available ask the...

Page 48: ...poration personnel or authorized agents This warranty shall be void if a the equipment is repaired or modified by anyone other than XPC Corporation or a XPC Corporation approved third party b the equipment is damaged by the customer is improperly used or stored is subjected to an adverse operating environment or is operated outside the limits of its electrical specifi cations or c the equipment ha...