ABB MegaFlex 1000 UL S1, Installation Manual

Page 1: ... UPS INSTALLATION GUIDE MegaFlex 1000 to 1600 kW UL S1 MegaFlex 1000 to 1600 kW UL S1 ...

Page 2: ...oncern Date Copyright 2020 by ABB Power Protection SA All rights reserved The information contained in this publication is intended solely for the purposes indicated The present publication and any other documentation supplied with the UPS system is not to be reproduced either in part or in its entirety without the prior written consent of ABB The illustrations and plans describing the equipment a...

Page 3: ...installation of the UPS Thank you for choosing ABB Start up and commissioning An ABB Global Services Field Engineer must perform start up and commissioning of the UPS Please contact ABB Service Center at least two weeks prior to schedule start up and commissioning at 1 800 292 3739 Distributed in the USA by ABB Service Center ABB Power Protection SA Via Luserte Sud 9 CH 6572 Quartino Switzerland A...

Page 4: ...s a Category C3 UPS Product according to IEC 62040 2 This is a product for commercial and industrial application in the second environment installation restrictions or additional measures may be needed to prevent disturbances We recommend that this manual be kept next to the UPS for future references If any problems are encountered with the procedures contained in this manual please contact your A...

Page 5: ...r Input Output and Battery over current protection and wire sizing 30 4 8 6 Installation requirements 32 4 9 Wiring connection 33 4 9 1 MegaFlex 1000 to 1600 Power connection with Common Input Utility 35 4 9 2 MegaFlex 1000 to 1600 Power connection with Dual Input Utility 36 4 9 3 Use of MegaFlex 1000 to 1600 in eBoost Operation Mode 37 4 9 4 Use of MegaFlex 1000 to 1600 as Frequency Converter 38 ...

Page 6: ...ing Commissioning and Maintenance of the UPS for the following Damaged components squeezed wires and cables or not correctly inserted plugs After removing the sidewalls of the UPS make sure that all earth connections when reassembling are correctly reattached This UPS is intended for use in a controlled indoor environment free of conductive contaminants and protected against animals intrusion WARN...

Page 7: ...ate Battery terminals or to the cabinet or rack Do not lay tools or metal parts on top of the Battery and do not lay them where they could fall onto the Battery or into the cabinet 3 Disconnect charging source prior to connecting or disconnecting Battery terminals Install the Battery as shown on the drawing provided with the Battery When connecting cables never allow a cable to short across a Batt...

Page 8: ...defined Warning if instruction is not followed injury or serious equipment damage may occur Caution internal parts have dangerous voltage present Risk of electric shock PE Earth GND Ground Protective Grounding terminal A terminal which must be connected to earth ground prior to making any other connection to the equipment A terminal to which or from which an alternating sine wave current or voltag...

Page 9: ...alls application of authentication measures encryption of data installation of antivirus programs etc to protect the UPS product the network its system and interfaces against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB Ltd and its affiliates are not liable for damages and or losses related to such security breaches unauth...

Page 10: ...600 General view Fig 2 1 3 Control Panel Fig 2 1 4 Connectivity Rack Fig 2 1 2 MegaFlex 1000 to 1600 General view with open doors MGF_UL_1000 1600_UPS_ABB_02 SNMP CI J35DSP 1 2 MGF_UL_1000 1600_Connectivity interface_01 E P O E P O Q1 UVR J35µP XA MGF_UL_1000 1600_S1_UPS_04 1 2 XA RPA J35 P SNMP CR CI J35DSP E P O E P O Q1 UV R ...

Page 11: ...ernal Battery connection CI Customer Interface Board see Fig 2 1 4 CR Connectivity Rack J35DSP Serial port RS232 only for ABB Service Center J35µP Serial port RS232 for IMV protocol RPA RPA board Redundant Parallel Architecture for Parallel System option see Fig 2 1 2 SNMP 3 ph SNMP WEB plug in adapter option see Fig 2 1 4 XA Terminal block see Section 4 11 Caution Convenience test terminals are a...

Page 12: ...nmentally friendly material at the end of its service life must be recovered conforming to the local applicable regulations UPS packing materials must be recycled in compliance with all applicable regulations Recycling at the end of service life ABB in compliance with environment protection recommends to the User that the UPS equipment at the end of its service life must be recovered conforming to...

Page 13: ... lifted with a forklift in upright position Take note of the Center of Gravity marked on the package Warning Check for sufficient floor and elevator loading capacity Transport UPS only in upright position Do not stack other package on top of the UPS Crane Fig 4 1 2 Position of the carrying belts when moving the unpacked UPS Crane If the UPS has to be lifted by crane use suitable carrying belts tak...

Page 14: ...0 1100 1200 UPS complete 9150 lbs 4150 kg Power Section cabinet 4564 lbs 2070 kg In Out Section cabinet 4586 lbs 2080 kg MegaFlex 1500 1600 UPS complete 10274 lbs 4660 kg Power Section cabinet 5424 lbs 2460 kg In Out Section cabinet 4850 lbs 2200 kg Floor loading UPS complete MegaFlex 1000 1100 1200 MegaFlex 1500 1600 265 lbs sq ft 1294 kg m2 315 lbs sq ft 1538 kg m2 Note The weight of each single...

Page 15: ...xceeding 13 F 25 C to 131 F 55 C In case the Battery is included please refer to Section 4 3 2 Some important functions of the UPS such as the customized functions are defined by parameters stored in a RAM memory A small backup Battery located on the Control Unit board supplies the RAM If the storage time of the UPS exceeds 1 year these functions should be verified by an authorized Service Center ...

Page 16: ...hough some RFI Radio Frequency Interference filtering is inherent to the UPS there is no guarantee that the UPS will not influence sensitive devices such as cameras and monitors that are positioned close by If interference is expected the UPS should be moved away from the sensitive equipment 4 4 2 Later commissioning It s not recommended to unpack UPS until commissioning can be performed In any ca...

Page 17: ...the top and the bottom of the UPS cabinet for the connection of input and output cables Pay attention to the position of these openings when choosing the placement of the UPS These openings are covered with a protective plate Please remove the plate before drilling any holes see Fig 4 9 2 MGF_UL_1000 1600_S1_UPS view top_01US Frontal side Power Section cabinet In Out Section cabinet 35 63 905 mm 3...

Page 18: ...nts MGF_UL_1000 1600_S1_UPS fixing_01 A Detail A MGF_UL_1000 1600_S1_UPS fixing_02US Power Section cabinet Frontal side Seismic installations option 1 69 43mm Ø 0 55 14mm 2 57 65 5mm 14 37 365mm 29 13 740mm 14 37 365mm 5 00 127mm 19 72 501mm 21 30 541mm 2 59 65mm 2 76 70 5mm 18 11 460mm 36 77 934mm 39 37 1000mm 0 91 23mm 1 65 42mm 1 65 42mm Holes 16 73 425mm 3 35 85mm 16 73 425mm 2 59 65mm 39 37 1...

Page 19: ...never exceed the range 4 F 20 C to 104 F 40 C The life of valve regulated Battery will be reduced by 50 for each additional 18 F 10 C that the Battery ambient temperature is above 77 F 25 C The Battery System associated with larger UPS is usually either rack mounted or installed in multiple Battery Cabinets Installation and assembly must be made according to the local standards and Battery System ...

Page 20: ...air exhaust flow rate requirement of the UPS system Contact your ABB Service Center for appropriate solutions The below table indicates the heat dissipation at full Load at PF 1 and charged Battery up to 3280 ft 1000 m altitude for cooling air 77 F 25 C to 86 F 30 C UPS model Losses Cooling air flow VFI eBoost option VFI PF 1 PF 1 PF 1 MegaFlex 1000 145914 BTU hr 42753 kW 55495 BTU hr 16260 kW 733...

Page 21: ...e UPS cabinet Take care not to damage the UPS when moving by forklift A damaged UPS must never be installed or connected to Utility or Battery In case of any damage sustained during the transport immediately inform the shipping agent A detailed report of the damage is necessary for any indemnity claim Included in the delivery you can find the following parts An accessory bag Lower closures with ai...

Page 22: ... contact your ABB Service Centre Protective foil Fig 4 6 4 MegaFlex 1000 to 1600 Power Section cabinet Location of the Protective Foil MegaFlex 1000 to 1600 is provided with a Protective Foil on the roof and door front panels to prevent material from falling into UPS Warning It s mandatory to remove the Protective Foil but only just before the first start up of the UPS as indicated in the appropri...

Page 23: ...Remove the top panel C For In Out Section cabinet proceed in the following way Open the doors D Open the Electronic Module E Remove the front protection panels F Remove the top panel G Fig 4 7 1 MegaFlex 1000 to 1600 Cabinets positioning and interconnection Once the 2 cabinets have been positioned and the various operations described in Fig 4 7 have been carried out you can proceed to the various ...

Page 24: ...ction is essential to ensure the electrical safety grounding of the Power Section cabinet Failure in grounding generates risks of electric shock Fig 4 7 1 1 MegaFlex 1000 to 1600 Cabinets positioning and interconnection for electrical safety grounding In Out Section cabinet MGF_UL_1000 1600_S1_UPS cabinets_Junction_01US Junction metal 18 Bolt M5x12 Bolt torque 22 Lb in 2 5 N m Power Section cabine...

Page 25: ... 2 Bus bar 80 5 x 310 mm L3 Rectifier Interconnection L3 Rectifier 2 Bus bar 80 5 x 310 mm Battery Interconnection Battery Bus bar 60 5 x 292 mm 1 for every module total 4 Battery Interconnection Battery Bus bar 60 5 x 292 mm 1 for every module total 4 Detail showing bus bars interconnection Rectifier and Inverter bus bars Pre fixed nut M8 M8 flat washer M8 spring washer Bolt M8x35 2 bus bars remo...

Page 26: ...e overly tightened 6x Connector 4 wires In Out Section cabinet Power Section cabinet Board P25 IM0323 J1 J2 J3 J8 J9 J10 6x Connector 26 poles In Out Section cabinet Power Section cabinet Board P25 IM0323 J16 J17 J18 J19 J20 J21 2x Connector J45 In Out Section cabinet Power Section cabinet Board P25 IM0323 J1_CAN and J2_CAN In Out Section cabinet Power Section cabinet MGF_UL_1000 1600_S1_UPS cabin...

Page 27: ...install them exposes to risk of electric shock Fig 4 7 4 1 MegaFlex 1000 to 1600 Lower closures with air inlet grids assembling Installation sequence of the lower covers with air grids of the UPS cabinet Assembling the 2 lateral lower covers 1a and 1b Assembling the 2 rear lower covers 2a and 2b Note In case the UPS in located against the wall the 2 rear covers 2a and 2b must be assembled before m...

Page 28: ...wered from a Common Input source or Dual Input sources if desired Dual Input Utility Configuration Rectifier Bypass Fig 4 8 1 1 Dual Input Utility Rectifier Bypass The Bypass and Rectifier use different power sources CB1 and CB2 inputs In this case when the Rectifier input breakers are opened the Automatic Bypass is supplied by the other connection Note Always verify that the received UPS is as pe...

Page 29: ...rt circuit capability of the UPS Inverter a short circuit in the Load will cause an immediate transfer to Utility The largest breaker in the output distribution should be at least 1 6 time smaller than breaker supplying Bypass line If Circuit Selectivity is required while the Load is fed from the Inverter Bypass Utility not available the Largest Circuit Breaker should be rated at no more than 20 o...

Page 30: ... 2 Common Input Utility Rectifier Bypass The AC values below are current ratings per phase These maximum and nominal ratings should be considered when choosing the appropriate AC over current protection device DC current rating is the nominal Battery discharge current with 1 8 V cell see Fig 4 8 4 1 Fig 4 8 4 2 Wiring shall not be sized for more than 2 0 Vdc cell UPS rating AC Input Rectifier AC I...

Page 31: ...input Bypass AC input AC output ports 3 phase 3 wire plus ground each conduit shall contain one cable per circuit s phase and one ground cable DC Input 2 poles positive and negative plus ground each conduit shall contain one positive one negative and one ground cable Maximum recommended cable size type THWN THHN copper 167 F 75 C per phase pole and ground conductors Each conduit shall terminate it...

Page 32: ...cumstance s low impedance or high impedance bonding shall be introduce inside UPS cabinet between internal mid point and ground Single UPS with Common Input Utility for Rectifier Bypass Single UPS with Dual Input Utility for Rectifier Bypass UPS Parallel System with Common Input Utility for Rectifier Bypass UPS Parallel System with Dual Input Utility for Rectifier Bypass ...

Page 33: ...minal Once the power cables have been connected re install the internal safety shields and close the cabinets by re installing all external panels MegaFlex 1000 to 1600 Access to the bus bars for the cable connections Fig 4 9 1 MegaFlex 1000 to 1600 Access to connection bus bars Note For UPS correct operation the input mains phase rotation must be clock wise To access Input Output and Battery conn...

Page 34: ...e B and or C removed from the UPS to avoid metal dust falling in the connection bars area Top entry cables the conduits must be of metal Bottom entry cables the conduit can be of plastic Please remove the plates B and C before drilling any wholes Bottom entry cables Utility input Load output and Battery MGF_UL_1000 1600_S1_UPSconnection_Conduits_01US C B Top entry cables Utility input Load output ...

Page 35: ...larity of the Battery connection Do not close the External Battery Breaker before the commissioning Negative pole of the Battery PE External Battery Ground Note To meet standards concerning electromagnetic compliance the connection between the UPS and external Battery must be done by using a shielded cable or suitable shielded steel conduit BR1 Interconnections links BR1 BR2 and BR3 must remain co...

Page 36: ...rect polarity of the Battery connection Do not close the External Battery Breaker before the commissioning Negative pole of the Battery PE External Battery Ground Note To meet standards concerning electromagnetic compliance the connection between the UPS and external Battery must be done by using a shielded cable or suitable shielded steel conduit BR1 Interconnections links BR1 BR2 and BR3 must be...

Page 37: ...xhibits a predominantly capacitive characteristic it may provide some degree of reactive power compensation when combined with lagging power factor loads Conversely depending on the load type and level the UPS input characteristic may exhibit a leading power factor in eBoostTM Operation Mode Please contact your ABB Service Centre for more information Note If an emergency generator set supplies the...

Page 38: ...tion Mode is automatically disabled Fig 4 9 4 1 MegaFlex 1000 to 1600 Interconnection links BR1 BR2 and BR3 In order to avoid improper operation only the Rectifier Utility input should be powered L1 1 L2 1 and L3 1 Fig 4 9 1 1 therefore the interconnection links BR1 BR2 and BR3 on the input bus bars must be removed See pictures above and Fig 4 9 4 1 Special care must be taken in choosing the fuse ...

Page 39: ...its of the Parallel System no phase shift allowed between units Note It is strongly recommended that no Transformers Automatic Circuit Breakers should be inserted between the unit s output and the Load common bus bars However it is recommended that a disconnection or isolation switch is installed in order to totally isolate a unit if needed Verify that power wiring and control wiring run in separa...

Page 40: ... between units in case one of the control cables should fail or be accidentally damaged or disconnected The standard length of the control bus cable between two parallel units is 40 ft 12m The maximal overall length of bus connection between the first and the last unit should not exceed 295 ft 90m Verify that control wiring run in an individual separate steel conduit Note Under no circumstance sho...

Page 41: ... 5 6 must be in position ON see Fig 4 10 2 2 Fig 4 10 2 3 Bus connection on intermediate units Note Intermediate units of an RPA Parallel System On the two boards P13 P14 IM0222 Bus Interface Board of the intermediate units of a Parallel System the switches SW1 1 2 3 4 5 6 must be in position OFF see Fig 4 10 2 3 J2 J1 J2 J1 B A J1A 1 J1B 1 1 2 3 SW1 4 5 6 O N MGF_UL_1000 1600_S1_RPA IM0222_02 J2 ...

Page 42: ...on The communication bus cable connectors are placed on the two boards P13 P14 IM0222 Bus Interface Board See Fig 4 10 3 1 Fig 4 10 3 2 View electronic module on intermediate unit Control bus cables connection Plug the cables J1A J2A 1 2 3 4 5 and J1B J2B 1 2 3 4 5 on the connectors J1A J2A and J1B J2B placed on the two boards P13 P14 IM0222 Bus Interface Board Fix the communication bus cables J1A...

Page 43: ...he UPS cabinet without disconnecting them from the two boards P13 P14 IM0222 Bus Interface Board For reliability reasons the cables J1A J2A 1 2 3 4 5 and J1B J2B 1 2 3 4 5 connecting the units should be run in separated protected conduits as indicated in Fig 4 10 3 3 separated from the power cables It is important that the cable J1A J2A 1 2 3 4 5 must be the same length as cable J1B J2B 1 2 3 4 5 ...

Page 44: ...ase Command Contact 24Vdc Command Contact for the Remote Control of the external Battery Breaker option 4 11 2 XA Terminal block Q1 Auxiliary Contact Fig 4 11 2 1 XA terminal block Q1 Auxiliary Contact Q1 Auxiliary Contact Auxiliary Contact for Q1 External UPS Output Circuit Breaker status recognition The dedicated Auxiliary Contact to be connected to the UPS is required 4 11 3 XA Terminal block 2...

Page 45: ...d this contact causes the immediate opening of the Contactors K3 K6 and K7 as well as the shut down of Rectifier Inverter and Static Switch Note This procedure could imply a Load shut down Keep SELV cables separated from high voltage cables In a Parallel System a separate NC Normally Closed contact must be connected individually to each unit Fig 4 11 4 2 XA EPO Emergency Power Off RPA Parallel Sys...

Page 46: ...sh button EPO Emergency Power Off contact on XA EPO 1 EPO 2 is closed again Perform the Inverter OFF command from the screen Commands 1 Inverter OFF see User Manual to Section 6 5 In case of a Parallel System perform the Inverter OFF command from the screen Commands 1 Inverter OFF of each unit connected on the Parallel Bus and having its output switch Q1 UPS Output External supplied by others clos...

Page 47: ...y boards max 3 Customer Interface boards for each UPS max 2 3 ph SNMP WEB Plug in Adapter boards for RPA Parallel System Note The installation of any option board must be performed only by an ABB Service Technician Prior to the installation connection and cabling of any option board the UPS must be completely powered down and all the power sources that will be connected to the option board must be...

Page 48: ...g of measurements alarms and parameters see Section 6 4 SETUP PRINTER Fig 5 1 2 Serial port J35µP connection to PC with RS232 1 1 cable DB9m DB9f The serial port J35µP RS232 is enabled on all the units of the RPA Parallel System Fig 5 1 3 Connector J1 RJ45 8P8C Note The serial port J35µP RS232 is enabled also in case the J1 RJ45 connector of the P4 Customer Interface see Section 5 2 1 is already c...

Page 49: ...Open C Common NC Normally Closed Output signals on voltage free contacts Programmable functions on input contacts On terminals X1 6 of the following 27 signals can be selected from the display entering with the appropriate Service Code Some UPS functions can be activated with parameters when an external Normally Open NO contact is closed on X1 10 21 or X1 11 22 Selectable functions by changing par...

Page 50: ...NC LOAD ON INVERTER def Parameter RL 3 X1 7 8 9 NO C NC STOP OPERATION def Parameter RL 5 X1 12 13 14 NO C NC LOAD ON MAINS def Parameter RL 2 X1 15 16 17 NO C NC GENERAL ALARM def Parameter RL 4 X1 18 19 20 NO C NC BUZZER ACOUSTIC ALARM def Parameter RL 6 In case different alarms or operating status are required they can be configured on the same terminals via software from the Control Panel The ...

Page 51: ...1 22 See Fig 5 2 1 X1 Since the Parameter for of the reading of the Generator function is Service Code protected call the nearest ABB Service Centre for it s activation When this contact closes it changes certain programmable functions such as Enabling or disabling of synchronization and consequently the Load transfer to generator Reduction or elimination or delay of Battery recharging during the ...

Page 52: ...t be connected to a separate AUX contact of the External Maintenance Bypass Switch 5 2 7 X1 terminal block eBoost control signal The UPS operation in either eBoost operating mode can be controlled via a NO Normally Open contact by installing the eBoost signal routed to the programmable function contacts see Section 5 2 3 When this contact closes eBoost operation mode is inhibited The Parameter for...

Page 53: ...on Guide REV A 6 Notes 6 1 Notes Form It is recommended to note in this section Notes with date and short description all the operations performed on the UPS as maintenance components replacement abnormal situations etc Date Description Done by ...

Page 54: ...https library abb com ABB Power Protection SA Via Luserte Sud 9 6572 Quartino Switzerland abb com ups Copyright 2020 ABB All rights reserved Specifications subject to change without notice ...