Xtreme 20kVA, User And Installation Manual

Page 1: ...www xpcc com 2013 Xtreme Power Conversion Corporation All rights reserved UNINTERRUPTIBLE POWER SUPPLY UPS R90 Online UPS 20kVA Model USER INSTALLATION MANUAL ...

Page 2: ...tective Devices 14 External Battery 14 UPS Output 14 Over Current Protection 14 Power Cables 15 Cable Sizes 15 Power Cables Connection 16 Battery Connection 18 UPS Multi Module Installation 20 Cabinet Installation 20 Parallel Cable Installation 21 Remote Emergency Power Off EPO for Parallel Systems 22 Requirements for a Parallel System 23 OPERATION 23 Operation Modes 23 Normal Mode 23 Battery Mode...

Page 3: ... RS232 RS485 33 The Display 34 System LCD Display 34 Parameters setting 44 Mode setting 44 Output voltage setting 45 Frequency setting 46 Battery capacity setting 47 Battery quantity setting 48 Bypass voltage upper limit setting 49 Bypass voltage lower limit setting 50 Parallel ID setting 51 Parallel quantity setting 52 Parallel redundancy quantity setting 53 Display Messages 54 Operational Status...

Page 4: ...INTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 4 SPECIFICATIONS 59 BATTERY RUN TIMES USING EBP32 60 SHIPPING LIST 60 OBTAINING SERVICE 61 XTREME POWER CONVERSION CORPORATION LIMITED WARRANTY 62 ...

Page 5: ...tant information 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...

Page 6: ...ION Do not 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 r...

Page 7: ...where easily accessible Except for replacing the batteries all servicing on this equipment must be carried out by qualified service personnel Before conducting any maintenance repair or shipment first ensure that everything is turned off completely and disconnected For additional safety instructions please use the Safety Manual as a reference Special Symbols The following symbols used on the UPS w...

Page 8: ...rference exists in many forms causing problems in AC power from lightning power company accidents and radio transmission motors air conditioners and vending machines Protection of sensitive electrical equipment is vital to protect against power outages low or high voltage conditions slow voltage fluctuations frequency variations differential and common mode noise transients etc To prevent power li...

Page 9: ...ons are available for the solution Planning a UPS system the following should be taken into consideration The total demand of the protected system shall dictate the output power rating VA Allow a margin for future expansion or calculation inaccuracies from measured power requirements Backup time required will indicate the battery size needed If the load is less than the UPS nominal power rating th...

Page 10: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 10 R90 20KVA FRONT VIEW R90 20KVA REAR VIEW DIAGRAM ...

Page 11: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 11 EBP32 REAR PANEL ...

Page 12: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 12 R90 20KVA UPS R90 EBP32 MOUNTED IN A RACK ...

Page 13: ...Xtreme Power Conversion Corporation Rev 3 7 14 Page 13 SHELF SHIPPED WITH UPS EBP32 FOR MOUNTING IN A RACK Note this shelf must be used in order to support the weight of the equipment Do not install UPS or EBP32 into a rack without using this shelf FRONT PANEL ...

Page 14: ...apacity 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 Temporarily connecting the UPS to a suitable AC source and activating the UPS for the time required to recharge the batteries is required To monitor the UPS with the software simply connect...

Page 15: ...E AWARE OF THE LOCATION AND OPERATION OF THE EXTERNAL ISOLATORS WHICH ARE CONNECTED TO THE UPS INPUT BYPASS SUPPLY OF THE UTILITY DISTIRBUTION 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 R90 20KVA 8 awg 8 awg 6 awg ...

Page 16: ... the UPS is totally isolated from its external power source and all circuit breakers to the UPS are open Check to see that everything is electrically isolated and post any necessary warning signs to prevent inadvertent operation of the breakers POWER CABLE CONNECTION DIAGRAM Select the appropriate power cable size paying attention to the diameter of the connection terminal of the cable which shoul...

Page 17: ...WIRING DIAGRAM WARNING IF THE LOAD EQUPMENT IS NOT READY TO ACCEPT POWER WHEN THE UPS INSTALLATION IS OCCURING ENSURE THAT THE UPS OUTPUT CABLES ARE SAFELY ISOLATED AT THE CABLE ENDS CAUTION The earth ground and neutral bonding arrangement must be in accordance with local and or national electrical code practices ...

Page 18: ...d positive batteries and the batteries between the neutral and cathode are called the negative batteries The connection is shown in the diagram below 192VDC BATTERY CONNECTION DIAGRAM INTERNAL EBP32 Note The BAT of the UPS Connection Terminals is connected to the anode of the Positive Battery The BAT of the UPS Connection Terminals is connected to the cathode of the Positive Battery and the anode ...

Page 19: ... mix batteries with different capacity or different 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 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 PROP...

Page 20: ... in the parallel system as shown in the diagram below Note If installing 5 6 units in parallel remove the jumper cap J30 on the control inspection board MHTBJHR1CU04 in all UPS to be connected in parallel If installing 7 10 units in parallel remove the jumper cap J30 J31 on the control inspection board MHTBJHR1CU04 in all UPS to be connected in parallel Make sure that each UPS input breaker is in ...

Page 21: ...l Cable Installation The shielded and double insulated control cables must be interconnected in a ring configuration between UPS modules as shown in the diagram below The parallel control board is mounted in each UPS module The ring configuration ensures high reliability of the control function PARALLEL CONNECTION OF UPS ...

Page 22: ...PO for parallel systems must be connected in parallel and installed as shown below Once the EPO function of one of the UPS in the parallel system is activated the UPS will send out a remote command and shut down the other UPS s in the parallel system CAUTION The remote emergency kill switch must be voltage free and normally open EPO CONNECTIONS FOR PARALLEL SYSTEMS ...

Page 23: ...per cap J30 J31 on the control inspection board MHTBJHR1CU04 in all UPS to be connected in parallel OPERATION Operation Modes The UPS is a double conversion online UPS that may operate in the following alternative modes Normal Mode The rectifier charger derives power from the AC input utility and supplies DC power to the inverter while floating and boost charging the battery simultaneously The inv...

Page 24: ... or increase reliability the output of up to ten 10 UPS modules can be programmed to operate in parallel with the built in parallel controller in each UPS ensuring automatic load sharing Turn On Off the UPS Connecting with Utility The UPS is a double conversion online UPS that may operate in the following alternative modes CAUTION MAKE SURE PROPER GROUNDING IS IN PLACE Set the Battery Breaker to t...

Page 25: ...t for approximately 30 seconds before pressing the ON BUTTON Inverter Off When the Utility is normal press OFF BUTTON for approximately 1 second until you hear a beep The INVERTER LED will extinguish the BYPASS LED will be illuminated then the UPS turns to bypass supply Disconnecting from Utility CAUTION This procedure should be followed to completely shut down the UPS and the LOAD After all power...

Page 26: ... Rev 3 7 14 Page 26 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 choose system button ...

Page 27: ...AL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 27 Choose Software Parameter Setting and set selections as shown below and then save settings o COM COM1 o Baud Rate 9600 o Protocol HIP ...

Page 28: ... Power Conversion Corporation Rev 3 7 14 Page 28 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 29: ...R S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 29 Parallel Setting Connect the UPS with a computer Power ON the UPS Open Muser4000 software and choose System User Set ...

Page 30: ...PTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 30 Select Set at User Set window CAUTION When powered by inverter it is necessary to turn off the inverter before setting the voltage and frequency level in PC ...

Page 31: ...LE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 31 At the window of Data Set select Work Mode with Parallel for the Value then select Set as shown in the figure below If the UPS beeps it means the setting is correct ...

Page 32: ...urs re connect in accordance with the instructions described earlier in this manual CAUTION Parallel cable cannot be connected when setting the parallel parameters After setting the UPS s that need to be paralleled power OFF all the UPS s Connect all the UPS s according to parallel cable installation and then power ON the UPS s Note If installing 5 6 units in parallel remove the jumper cap J30 on ...

Page 33: ...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 port and UPS RS485 port PC DB9 male UPS DB9 female Description Pin 1 Pin 1 485 Pin 6 Pin 6 485 Available function of RS232 Monitor UPS power status Monitor UPS alarm information Monitor UPS running parameters Timing Off On setting RS 232 communication data format Bau...

Page 34: ...TENT DISPLAYED 01 CODE Operational status and mode 02 Input A Input L1 Voltage Frequency 03 Input B Input L2 Voltage Frequency 04 Input C Input L3 Voltage Frequency 05 Bat Voltage Current 06 Bat Voltage Current 07 Output A Output L1 Voltage Frequency Load 08 Output B Output L2 Voltage Frequency Load 09 Output C Output L3 Voltage Frequency Load 10 Load A Load 11 Load B Load 12 Load C Load 13 Total ...

Page 35: ...he UPS is connecting with Utility or Battery at Cold Start Mode the LCD displays shows as below Operational Status and mode If UPS is in single mode display shows NOA or ECO If UPS is in parallel mode display shows PAL 2 Press SCROLL BUTTON the UPS goes to the next screen as shown below PHASE A L1 INPUT VOLTAGE FREQUENCY ...

Page 36: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 36 PHASE B L2 INPUT VOLTAGE FREQUENCY PHASE C L3 INPUT VOLTAGE FREQUENCY ...

Page 37: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 37 BAT POSITIVE BAT NEGATIVE ...

Page 38: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 38 PHASE A L1 OUTPUT VOLTAGE FREQUENCY PHASE B L2 OUTPUT VOLTAGE FREQUENCY ...

Page 39: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 39 PHASE C L3 OUTPUT VOLTAGE FREQUENCY PHASE A L1 LOAD CAPACITY ...

Page 40: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 40 PHASE B L2 LOAD CAPACITY PHASE C L3 LOAD CAPACITY ...

Page 41: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 41 TOTAL LOAD CAPACITY INTERNAL TEMPERATURE AND AMBIENT TEMPERATURE ...

Page 42: ...R90 ONLINE USER S MANUAL UNINTERRUPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 42 SOFTWARE VERSION MODEL ALARM CODE ...

Page 43: ...ge 43 The charging status can also be shown on the display as shown below while the charger is operating BOOST FLOATING 3 Pressing SCROLL BUTTON steps through all messages from the first to the last and then returns back to the first message display 4 All alarm codes are present when abnormal behaviors occur ...

Page 44: ...en exiting setting mode in this option Save Settings by adjusting parameters on each setting screen a needed Once the last parameter screen has been reached parallel redundancy quantity setting press to exit and save all settings Mode setting MODE SETTING Note the information in the red box will be flashing After entering the setting menu mode setting is defaulted and the model setting line flashe...

Page 45: ...flashing When in mode setting press On or when in frequency setting press Off to go to the output voltage setting mode The output voltage line flashes as in the above image Use the Enter button to choose different output voltage There are 3 different voltages 220 230 240 Press Off or On to exit the output voltage setting save the output voltage setting and then goes to mode setting or frequency se...

Page 46: ...en in output voltage setting press On or when in battery capacity setting press Off to go to the frequency setting mode The frequency line flashes as in the above image Use the Enter button to choose different frequency There are 2 different frequencies 50 or 60 Hz Press Off or On to exit the frequency setting save the frequency setting and then goes to output voltage setting or battery capacity s...

Page 47: ...n or when in battery quantity setting press Off to go to the battery capacity setting mode The battery capacity line flashes as in the above image Use the Enter button to choose different battery capacity Battery capacity range is 1 200 Ah Note long press of Enter can adjust battery capacity quickly Press Off or On to exit the battery capacity setting save the battery capacity setting and then goe...

Page 48: ...ty setting press On or when in bypass voltage upper limit setting press Off to go to the battery quantity setting mode The battery quantity line flashes as in the above image Use the Enter button to choose different battery quantity Battery quantity range is 32 34 36 38 40 Press Off or On to exit the battery quantity setting save the battery quantity setting and then goes to battery capacity setti...

Page 49: ... voltage lower limit setting press Off to go to the bypass voltage upper limit setting mode The bypass voltage upper limit line flashes as in the above image Use the Enter button to choose different bypass voltage upper limit Bypass voltage upper limit range is 5 10 15 25 25 is only available for 220V output Press Off or On to exit the bypass voltage upper limit setting save the bypass voltage upp...

Page 50: ... setting press On or when in parallel ID setting press Off to go to the bypass voltage lower limit setting mode The bypass voltage lower limit line flashes as in the above image Use the Enter button to choose different bypass voltage lower limit Bypass voltage lower limit range is 20 30 45 Press Off or On to exit the bypass voltage lower limit setting save the bypass voltage lower limit setting an...

Page 51: ...er button to choose different parallel ID Parallel ID range is 1 4 Press Off or On to exit the parallel ID setting save the parallel ID setting and then goes to bypass voltage lower limit setting or parallel quantity setting CAUTION Parallel cable cannot be connected when setting the parallel parameters Note If installing 5 6 units in parallel remove the jumper cap J30 on the control inspection bo...

Page 52: ...er button to choose different parallel quantity Parallel quantity range is 2 4 Press Off or On to exit the parallel quantity setting save the parallel quantity setting and then goes to parallel ID setting or parallel redundancy quantity setting CAUTION Parallel cable cannot be connected when setting the parallel parameters Note If installing 5 6 units in parallel remove the jumper cap J30 on the c...

Page 53: ...ancy quantity Parallel redundancy quantity range is 0 3 Press Off or On to exit the parallel redundancy quantity setting save the parallel redundancy quantity setting and then goes to parallel redundancy setting or to exit the mode setting The UPS LCD panel setting is now completed CAUTION Parallel cable cannot be connected when setting the parallel parameters Note If installing 5 6 units in paral...

Page 54: ...r Fault Continuously Fault LED on 2 Inverter fault incl Inverter bridge shorted Continuously Fault LED on 3 Inverter Thyristor short Continuously Fault LED on 4 Inverter Thyristor broken Continuously Fault LED on 5 Bypass Thyristor short Continuously Fault LED on 6 Bypass Thyristor broken Continuously Fault LED on 7 Fuse broken Continuously Fault LED on 8 Parallel Relay fault Continuously Fault LE...

Page 55: ...Fault LED blinking 31 Bypass Over Current Once per second BPS LED blinking 32 Overload Once per second INV or BPS LED blinking 33 No Battery Once per second Battery LED blinking 34 Battery Under Voltage Once per second Battery LED blinking 35 Battery Low Pre warning Once per second Battery LED blinking 36 Internal Communication Error Once per 2 seconds Fault LED blinking EVENT LOG UPS ALARM WARNIN...

Page 56: ...UPTIBLE POWER SUPPLY UPS Xtreme Power Conversion Corporation Rev 3 7 14 Page 56 The slot called SNMP supports the MEGAtec protocol We advise NetAgent II 3 port is a tool to remotely monitor and manage any UPS system EXTERNAL SNMP CARD ...

Page 57: ...hing but no charge voltage and current Battery breaker does not switch on or batteries are damaged or battery is reverse 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 ...

Page 58: ...batteries CAUTION Do not open or mutilate the batteries Released electrolyte is harmful to skin and eyes and may be toxic CAUTION The battery can present a high risk of short circuit current and electrical shock The short circuit current capability of the battery is sufficient to burn wire or tools very rapidly producing molten metal Observe these precautions when replacing the battery 1 Remove al...

Page 59: ...Factor 3 1 Transfer Time Utility to Battery 0ms Utility to Bypass 0ms Overload Capacity 110 60 min 125 10 min 150 1 min 150 immediate shutdown Total Harmonic Distortion 2 with linear load 5 with non linear load Efficiency ECO Mode 98 Normal Mode 95 5 Battery Voltage 192 VDC programmable to 204 216 228 240 VAC Charge Current 1A programmable to 6A Backup Time over 290 minutes with 8 R90 EBP32 option...

Page 60: ...munications Local monitoring software RS232 RS485 Parallel Port SNMP card optional BATTERY RUN TIMES USING EBP32 Battery runtimes are shown in minutes and will vary based on battery age and site conditions Two or more EBP32 battery packs are recommended for loads over 15kVA 13 5kW SHIPPING LIST R90 20K UPS 1 Software CD 2 horizontal brackets front 3 shelf with mounting hardware 4 manual R90 EBP32 ...

Page 61: ...bers if possible A technician will 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 Material 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 packag...

Page 62: ...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 specifications or c the equipment has been used or stored in a manner contrary to the equip...