iTrust Industry UPS Single Module And “1+1” (Redundancy)

User Manual

Version: V1.2
Revision date: September 6, 2005
BOM: 31011152

Emerson Network Power provides customers with technical support.

Users may contact the nearest Emerson local sales office or service
center.

Copyright © 2005 by Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to

change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District
518057, Shenzhen China

Homepage: www.emersonnetworkpower.com.cn

E-mail: support@emersonnetwork.com.cn
This manual contains information concerning the installation and operation of
the Emerson iTrust Industry single module (expandable) UPS.

All relevant parts of the manual should be read prior to commencing

installation.

The UPS must be commissioned by an engineer approved by the

manufacturer (or his agent) before being put into service. Failure to observe
this condition will invalidate any implied warranty.

The iTrust Industry UPS has been designed for Commercial/Industrial use only,
and is not for use in any life support applications.
This manual describes the following equipment

UPS

UPS BOM No.

3-phase in 1-phase out 30kVA UPS 01200172
3-phase in 1-phase out 40kVA UPS 01200175
3-phase in 1-phase out 60kVA UPS 01200178
3-phase in 1-phase out 80kVA UPS 01200181

Options

Options and part No. BOM No.

battery circuit breaker box 250A (for 30/40kVA UPS) 02350347
battery circuit breaker box 500A (for 60/80kVA UPS) 02350379
Battery circuit breaker control board 03025929
Battery temperature board (4532029V) 02350056
Parallel logic board 03034261
Parallel interface board 03025410
UPS AS400 interface signal board (4590055P) 03025412
UPS output interface signal board (4590056Q) 03025413

Safety Precautions

CONFORMITY AND STANDARDS

This equipment complies with the following requirements:

Normative references: Uninterruptible Power System (UPS)
*EN50091-1-1 General and safety requirements for use in operator access area
*EN50091-2 EMC requirements
*EN50091-3 Performance requirements and test methods
Continued compliance requires installation in accordance with these instructions and the use of
manufacturer approved accessories only.

WARNING

HIGH EARTH LEAKAGE CURRENT: EARTH CONNECTIONS IS ESSENTIAL BEFORE

CONNECTING THE INPUT SUPPLY.

This equipment must be earthed in accordance with local electrical codes.

 CAUTION

Earth leakage current exceeds 3.5 mA and is less than 1000mA.

Transient and steady-state earth leakage currents, which may occur when starting the
equipment, should be taken into account when selecting instantaneous RCCB or RCD devices.
Residual Current Circuit Breakers (RCCBs) must be selected insensitive to DC unidirectional
pulses (class A) and transient current pulses.

Note also that the earth leakage currents of the load will be carried by this RCCB or RCD.

WARNING

This system has a signal available for use with an automatic device, externally located, to
protect against backfeeding voltage through the mains static bypass circuit. If this protection is
not used with the switchgear that is used to isolate th bypass circuit, a label must be added at
the switchgear to advise service personnel that the circuit is connected to a UPS system.

ISOLATE THE UNITERRUPTIBLE POWER SYSTEM BEFORE WORKING ON THIS CIRCUIT.

General

As with other types of high power equipment, dangerous voltages are present within the UPS.
This risk of contact with these voltages is minimized as the live component parts are housed
behind the lockable front door. Further internal safety screens make the equipment protected to
IP20 standards.
No risk exists to any personnel when operating the equipment in the normal manner, following
the recommended operating procedures.
All equipment maintenance and servicing procedures involve internal access and should be
carried out only by trained personnel.

Battery

Battery manufacturers supply details of the necessary precautions to be observed when working
on, or in the vicinity of, a large bank of battery cells. These precautions should be followed
implicitly at all times.
Particular attention should be paid to the recommendations concerning local environmental
conditions and the provision of protective clothing, first aid and fire-fighting facilities.

The warning triangle indicates all the personal safety instructions.

 Contents

Chapter 1 General Description ................................................................................................ 1

1.1 Introduction ................................................................................................................. 1
1.2 Design Concept .......................................................................................................... 2
1.2.1 Introduction....................................................................................................... 2
1.2.2 Bypass Supplies ............................................................................................... 3
1.2.3 System Control Philosophy .............................................................................. 4
1.2.4 ECO Mode (For Single UPS Only)................................................................... 6
1.2.5 UPS Power Switch Configuration..................................................................... 6
1.2.6 Battery Circuit Breaker ..................................................................................... 7
1.2.7 Battery Temperation Compensation ................................................................ 7
1.2.8 Parallel System................................................................................................. 7
Chapter 2 Mechanical Installation............................................................................................ 8
2.1 Introduction ................................................................................................................. 8
2.2 Environmental Considerations.................................................................................... 9
2.2.1 UPS Location.................................................................................................... 9
2.2.2 Battery Location................................................................................................ 9
2.3 Mechanical Considerations ...................................................................................... 10
2.3.1 System Composition....................................................................................... 10
2.3.2 Moving The Cabinets ..................................................................................... 10
2.3.3 Clearances ..................................................................................................... 10
2.3.4 Fixing Of The Magnetic Components............................................................. 10
2.3.5 Cable Entry..................................................................................................... 11
2.4 Preliminary Checks................................................................................................... 11
2.5 Installation Drawings................................................................................................. 12
Chapter 3 Electrical Installation ............................................................................................. 18
3.1 Power Cabling........................................................................................................... 18
3.1.1 System Configuration ..................................................................................... 18
3.1.2 Cable Rating................................................................................................... 19
3.1.3 General Notes ................................................................................................ 19
3.1.4 Cable Connections ......................................................................................... 19
3.1.5 Safety Earth.................................................................................................... 20
3.1.6 Protective Devices.......................................................................................... 20
3.1.7 Cabling Procedure.......................................................................................... 21
3.2 Distance From Floor To Connection Point On The Equipment................................ 25
3.3 Control Cables .......................................................................................................... 25
3.3.1 Battery Control................................................................................................ 25
3.3.2 Auxiliary Terminal Block X4............................................................................ 27
3.3.3 Emergency Power Off .................................................................................... 28
3.3.4 Backfeed Protection ....................................................................................... 29
Chapter 4 Operator Control And Display Panel..................................................................... 30
4.1 Introduction ............................................................................................................... 30
4.1.1 Operator Control Panel .................................................................................. 30
4.2 The Displayed Information........................................................................................ 38
4.2.1 Start Screen ...................................................................................................... 38
4.2.2 Default Screen................................................................................................ 38
4.2.3 Help Screen.................................................................................................... 39
4.3 Prompt Window......................................................................................................... 40
Chapter 5 Operating Instructions ........................................................................................... 41
5.1 Introduction ............................................................................................................... 41
5.1.1 General Notes ................................................................................................ 41
5.1.2 Power Switches .............................................................................................. 41
5.2 Procedure For UPS Start-Up: Without Interrupting Power To The Load ................. 43
5.3 Procedure For UPS Start-UP: Without Power Initially Supplied To The Load......... 46
5.4 Switching UPS Into A Maintenance Bypass Condition From Normal Operation ..... 49
5.5 Procedure For Completely Powering Down A UPS ................................................. 51
5.6 RESET Procedure .................................................................................................... 53
5.7 Adding A Single Module To An Existing System...................................................... 54
5.8 Completely Switching ON/OFF The UPS At The UPS Display Control Panel ........ 55
5.9 Procedure To Switch ON/OFF The Inverter At UPS Display Control Panel ............ 57
5.10 Setting The Battery Test......................................................................................... 60
5.11 Language Selection ................................................................................................ 61
5.12 Changing The Current Date And Time................................................................... 61
Chapter 6 Display Panel Interpretation.................................................................................. 62
6.1 LED Interpretation..................................................................................................... 62
6.2 Display Panel Messages .......................................................................................... 64
Chapter 7 Communication ..................................................................................................... 67
7.1 RS232 Communication Ports ................................................................................... 68
7.2 RS485 Communication Ports ................................................................................... 68
7.3 AS400 Interface Signal Board (4590055P) Terminals ............................................. 69
7.4 Output Interface Signal Board (4590056Q) Terminals............................................. 72
Chapter 8 Maintenance And Service ..................................................................................... 74
8.1 Fan ............................................................................................................................ 74
8.2 Periodic Cleaning...................................................................................................... 74
8.3 UPS Status Check .................................................................................................... 75
Chapter 9 1+1 Redundancy Parallel System......................................................................... 76
9.1 General ..................................................................................................................... 76
9.2 Installation Procedure ............................................................................................... 77
9.2.1 Preliminary Checks......................................................................................... 77
9.2.2 Protective Devices.......................................................................................... 77
9.2.3 Power Cables ................................................................................................. 77
 9.2.4 Control Cables................................................................................................ 77
9.2.5 Emergency Power Off (EPO) ......................................................................... 78
9.3 Operating Instruction ................................................................................................ 79
9.4 Display Panel Message Interpretation...................................................................... 81

Chapter 10 Specifications ...................................................................................................... 82

10.1 Conformity And Standard ....................................................................................... 82
10.2 UPS Environmental ................................................................................................ 82
10.3 UPS Mechanical Characteristics ............................................................................ 82
10.4 UPS Electrical Characteristics (Input Rectifier)...................................................... 83
10.5 UPS Electrical Characteristics (DC Intermediate Circuit) ...................................... 84
10.6 UPS Electrical Characteristics (Inverter Output) .................................................... 85
10.7 UPS Electrical Characteristics (Bypass Input Mains)............................................. 86
10.8 UPS Electrical Characteristics (System Performance) .......................................... 86
10.9 UPS Electrical Characteristics (ECO Mode) .......................................................... 86
 Chapter 1 General Description 1

Chapter 1 General Description

1.1 Introduction

The iTrust Industry UPS system is connected between a critical load, such as a
computer, and its three phase mains power supply. With isolation transformer fitted
at both the input side and the output side, the UPS is designed to furnish a well
regulated 1 phase output power supply under all rated load and input supply
conditions. The system offers the user the following advantages:

Increased power quality

The UPS has its own internal voltage and frequency regulators, which ensure that
its output is maintained within close tolerances independent of voltage and
frequency variations on the mains power lines.

Increased noise rejection

By using isolation transformer, and rectifying the input AC power to DC power, and
then converting it back to AC, any electrical noise present on the input mains
supply line is effectively isolated from the UPS output, therefore the critical load
sees only clean power.

Power blackout protection

If the mains power fails, the UPS continues to power the critical load from its
battery source, leaving the load immune from power disturbances.

Isolation between AC bus and DC bus

The influences between the AC bus and DC bus eliminated.

Internal block diode fitted

When the user provides charge management equipment for his battery system, he
may use the internal block diode to disable the charge function of the UPS, so as to
perform centralized management of the battery system. When he need to use the
UPS to charge the battery, he may change the connection of the block diode to
enable the charge function.

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2 Chapter 1 General Description

1.2 Design Concept

1.2.1 Introduction

This section describes an individual module’s operating principles. The UPS

basically operates as an AC-DC-AC converter (see Figure 1-1). The first conversion
stage (from AC to DC) uses a 3 phase, fully-controlled SCR bridge rectifier to
convert the incoming mains supply into a regulated DC busbar.

Bypass AC supply

Rectifier Inverter Static switch

Rectifier AC supply UPS AC output

Battery

Figure 1-1 Single module block diagram

The DC busbar produced by the rectifier provides power to the inverter section.
Normally, the battery is connected to the DC busbar through a block diode to
disable the charge function of the UPS; in this case, additional charge equipment is
needed to charge the battery. The connection of the block diode can also be
changed to enable the charge function of the UPS; in this case, the DC busbar
provides both battery charging power-being equipped with a temperature
compensated battery charging system, to prolong battery life-and power to the
inverter section-which utilizes the latest IGBT switching pulse width modulation
(PWM) design and provides the second conversion stage, i.e., reconverting the DC
busbar voltage back into an AC voltage waveform.

During normal operation, both the rectifier and inverter sections are active and
provide regulated load power. Additionally, when the UPS is working in Direct mode
(with no block diode connected), the rectifier float charges the battery
simultaneously. In the event of a mains power failure, the rectifier becomes
inoperative and the inverter is powered solely from the battery. Critical load power
is maintained under these conditions until the battery is fully discharged,
whereupon the UPS shuts down. The end of battery discharge is assumed when
the battery voltages falls below a preset value (for example, for the 220Vdc busbar
(108 2V cells), if the end-of-discharge (EOD) voltage is set to 1.67V/cell, the EOD
voltage of the battery is 180Vdc).

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 Chapter 1 General Description 3

The period for which the load can be maintained following a mains power failure is
known as the system’s Autonomy Time and is dependent upon both the battery
A/Hr capacity and the applied percentage load.

1.2.2 Bypass Supplies

The circuit block annotated “static switch” in Figure 1-2 contains an electronically
controlled switching circuit which enables the critical load to be connected either to
the inverter output or to a bypass power source via the static bypass line. During
normal system operation, the load is connected to the inverter and the inverter side
of the static switch is closed; but in the event of a UPS overload, or inverter failure,
it is automatically transferred to the static bypass line.

UPS
Maintenance bypass isolator Q3

Bypass mains Bypass isolator Q2

supply
DC bus
Rectifier Inverter Static switch
Input mains UPS output
supply
Output
Input isolator Q1 Block diode isolator Q4

Battery + -
C.B.

Battery circuit breaker box

Figure 1-2 UPS power switches configuration

To provide a clean (no-break) load transfer between the inverter output and static
bypass line, the static switch activates connecting the load to the bypass supplies.
To achieve this, the inverter output and bypass supply must be fully synchronized
during normal operating conditions. This is achieved through the inverter control
electronics which make the inverter frequency track that of the static bypass supply
provided that the bypass remains within an acceptable frequency window. The
synchronizing window is pre-selected to ±2% of nominal frequency, giving an
acceptable frequency window ±1Hz.

A manually controlled, maintenance bypass supply is also incorporated into the

UPS design. Its purpose is to enable the critical load to be powered from the mains
bypass supply while the UPS is shut down for routine maintenance.

Note: The load equipment is not protected from normal supply aberrations when
operating on bypass side or in the maintenance bypass mode.

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4 Chapter 1 General Description

1.2.3 System Control Philosophy

Normal operation (in Block mode)

During normal operation, i.e. when the UPS input supply is present and within
specification, both the rectifier and inverter sections are active and the static switch
is turned on to connect the inverter output to the critical load busbars. The battery
circuit breaker is also closed, the battery is in standby state, and the rectifier is not
charging the battery.

Normal operation (in Direct mode)

During normal operation, i.e. when the UPS input supply is present and within
specification, both the rectifier and inverter sections are active and the static switch
is turned on to connect the inverter output to the critical load busbars. The battery
circuit breaker is also closed and the battery is therefore permanently float charged
at the DC busbar voltage level.

Note: The UPS had been set to Block mode at factory before delivery. To
allow the UPS to operate in Direct mode, an authorized engineer shall change
the connection of the block diode within the UPS and change the operation
mode of the UPS from the operator control panel.

(1+1 redundancy parallel system) Note: As the unit outputs are connected in
parallel, the system checks that the inverter control circuits are perfectly
synchronized with one another and with the bypass mains in terms of both
frequency and phase and that they have the same output voltages. Current
supplied to the load is automatically divided among UPSs.

A module’s static switch cannot close until these conditions are satisfied.

Mains failure

If the power mains has a failure or is out of tolerance the rectifier will go off
automatically, while the inverter will continue to operate on power from the battery
for a period of time which depends on the load and the capacity of the battery.
During this process, either the mails failure or the mains return will interrupt the
load power. If the mains supply still does not return when the battery reaches its
end-of-discharge voltage, the inverter will go off automatically and an alarm
message will appear on the UPS operator control panel display.

Returen of power mains

During mains failure, the UPS provides power to the load from its battery source.
When the mains returns, the rectifier will start up again automatically and gradually
(power walk-in), supplying power to the inverter. The UPS resumes normal
operation with no power interruption to the critical load.

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 Chapter 1 General Description 5

Off-Battery

If the battery system only is taken out of service for maintenance, it is disconnected
from the rectifier/charger and inverters by means of the external disconnect breaker
in the battery circuit breaker box. The UPS shall continue to function and meet all of
the specified steady-state performance criteria, except for the power outage
back-up time capability.

UPS module fault

In the event of an inverter fault, the static transfer switch will automatically transfer
the load onto the bypass mains with not interruption. In such an event, please
contact the local customer service center to seek technical support.

(1+1 redundancy parallel system): In the event of a fault in a unit, the unit’s static
transfer switch will automatically exclude the unit from the system. The remaining
unit will continue to supply the load with no interruption.

Overload

In the event of an overload at the inverter output which lasts longer than the typical
time/current (refer to Chapter 10), the inverter will shut down and the static transfer
switch will automatically transfer the load onto the bypass mains with no
interruption. If the overload falls within the typical time/current that has been
specified, the load will be returned to the inverters when the power drops to a level
that can be supported by the system.

In the event of a short circuit in the output, the load will normally be transferred onto
the bypass mains, which will cause the inverter to shut down. This switch is
determined above all by the features of the protective devices in use in the system.

In either case, an alarm message will appear on the UPS operator control panel
display.

(1+1 redundancy parallel system) The control logic system constantly monitors
load requirements and controls the power supplied by the UPS modules. In the
event that an overload condition is sustained for greater than a preset time, the
load will transfer to the mains bypass supply when the system is unable to satisfy
load requirements. The load returns to the inverter supply if the power is reduced to
a value that can be sustained by the system.

Maintenance bypass

A second bypass circuit contained in the UPS cabinet, identified as the

maintenance bypass line is included to enable a raw mains supply to be made
available to the load while facilitating a safe working environment for carrying out
scheduled UPS system maintenance or trouble shooting. The circuit is manually
selected by the maintenance bypass switch, which is opened in the OFF position.

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6 Chapter 1 General Description

Note: Operate the maintenance bypass switch only when the UPS is operating on
the bypass. Operating the maintenance bypass switch is not permitted when the
UPS is providing load power from the inverter.

WARNING

CAUTION: If an automatic circuit breaking device is not present in the input distribution panel,
there remains a dangerously high voltage at the output busbars and also on the input busbars
of the UPS module that is switched off.

1.2.4 ECO Mode (For Single UPS Only)

In this operating mode the system prefers to put the load on the bypass mains, with
the inverter on stand-by. The load is switched over to the inverter when the mains
goes outside of standard frequency and voltage values (which can be modified
using the operator panel),

The ECO mode configuration requires a different setup in the default menu
configuration.

Operating procedures in ECO mode are provided in Chapter 5.

WARNING

In ECO mode, the load is not protected against mains distortion.

1.2.5 UPS Power Switch Configuration

Figure 1-2 illustrates the iTrust Industry UPS module in what is known as the “Split
Bypass configuration. In the “Split Bypass” configuration the static bypass line is
connected by a separate power switch to a dedicated bypass power source which
also feeds the maintenance bypass line. Where a separate power source is not
available, the L1 bypass (Q2) and U1 rectifier input supply connections would be
linked together to make the bypass and rectifier share the same mains source. In
this case, the external input wiring and protective devices should be configured
according to the bypass requirements.

With the exception of the maintenance bypass isolator Q3, all the isolators must be
closed during normal UPS operation.

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 Chapter 1 General Description 7

1.2.6 Battery Circuit Breaker

The battery should be connected to the DC busbar through an appropriately rated

battery circuit breaker (BCB) box, which should be installed adjacent to the battery.
The BCB box contains a BCB and a BCB control board. The BCB is closed
manually, but it contains an undervoltage release coil which enables it to be tripped
from the UPS control electronics following detected DC busbar undervoltage. It also
has a magnetic trip facility for overload protection.

1.2.7 Battery Temperation Compensation

iTrust Industry UPS offers a battery temperature compensation circuit, which is

designed for automatic adjustment of the charge voltage when the UPS is
operating in Direct mode. As the temperature inside the battery cabinet/area rises
the DC busbar voltage reduces in order to sustain the battery at its optimum charge
voltage. This must be used in conjunction with the battery temperature sensor
board.

1.2.8 Parallel System

If necessary, two single module systems can be connected in parallel to constitute

a 1+1 redundancy parallel system to provide increased reliability. A redundancy
parallel system requires a change of the menu setting from the control panel.

Note: Procedures for making a parallel system should be carried out only by trained
service personnel. The two individual modules in the redundancy parallel system
must be of the same power rating.

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8 Chapter 2 Mechanical Installation

Chapter 2 Mechanical Installation

2.1 Introduction

WARNING

Do not apply electrical power to the UPS equipment before the arrival of the authorized
commissioning engineer.

WARNING

The UPS equipment should be installed by a qualified engineer in accordance with the
information contained in this chapter and all equipment not referred to this manual is shipped
with details of its own mechanical and electrical installation.

WARNING: Battery hazards

Special care should be taken when working with the batteries associated with this equipment.
When connected together, the battery terminal voltage will exceed 200Vdc and is potentially
lethal.

Eye protection should be worn to prevent injury from accidental electrical arcs.
Remove rings, watches and all metal objects.
Only use tools with insulated handles
Wear rubber gloves.

If a battery leaks electrolyte, or is otherwise physically damaged, it must be replaced, stored in

a container resistant to sulfuric acid and disposed of in accordance with local regulations.

If electrolyte comes into contact with the skin the affected area should be washed immediately
with water.

WARNING

The UPS system can be connected to an IT (isolated neutral) power system.

This section describes the UPS system’s environmental requirements and

mechanical considerations that must be taken in account when planning the
positioning and cabling of the UPS equipment.

Because every site has its peculiarities, it is not the aim of this chapter to provide
step-by-step installation instructions, but to act as a guide as to the general
procedures and practices that should be observed by the installing engineer.

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 Chapter 2 Mechanical Installation 9

2.2 Environmental Considerations

2.2.1 UPS Location

The UPS should be located in a cool, dry, clean-air environment with adequate
ventilation to keep the ambient temperature within the specified operating range
(see Chapter 10).

All models in the iTrust Industry UPS range are cooled with the aid of internal fans.
Cooling air enters the module through ventilation grills located at various parts of
the cabinet and exhausted through grills located in the cabinet roof. When the
cabinet is located on a pedestal, and bottom cable entry is used, additional cooling
air also enters the UPS via the floor void. If necessary, a system of extractor fans
should be installed to aid cooling-air flow, and a suitable air filtration system used
where the UPS is to operate in a dirty environment.

Note 1: When batteries are cabinet-mounted adjacent to the UPS module, it is the
battery which dictates the designed maximum ambient temperature, not the UPS.

Note 2: Power loss from the system which may be used in an air conditioning
system are intended for operation using the inverter, as in the ECO mode
configuration they would be undersized.

2.2.2 Battery Location

Temperature is a major factor in determining the battery life and capacity. Battery
manufacturers quote figures for an operating temperature of 20°C, operating above
this temperature will reduce the battery life, operating below this temperature will
reduce the battery capacity. On a normal installation the battery temperature is
maintained between 15°C and 25°C. Keep batteries away from main heat sources
or main air inlets etc.

The batteries can be mounted in a purpose-built battery cabinet, which is

positioned adjacent to the UPS module. If the batteries are rack-mounted, or
otherwise located remote to the main UPS cabinet, and a BCB in BCB box is
needed for battery protection, the BCB box must be mounted as closed as possible
to the batteries themselves, and connected using the most direct route possible.

The cabling of the BCB boxes should be carried out in accordance with the
instructions provided in this manual.

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10 Chapter 2 Mechanical Installation

2.3 Mechanical Considerations

2.3.1 System Composition

A UPS system can comprise a number of equipment cabinets, depending on the

individual system design requirements, e.g. UPS cabinet, battery cabinet, power
distribution cabinet. In general, all the cabinets used in a particular installation are
of the same height and designed to be positioned side-by-side to form an
aesthetically appealing equipment suit.

2.3.2 Moving The Cabinets

WARNING

Ensure that any lifting equipment used in moving the UPS cabinet has sufficient lifting capacity.

Ensure that the UPS weight is within the designated surface weight loading
(Kg/cm2) of any handling equipment. See the UPS specification in Chapter 10 for
weight details.

The UPS cabinet can be moved by fork lift. For operations with a fork lift, it is
necessary to remove both the front, rear (or side) grille panels located at the base
of the cabinet.

2.3.3 Clearances

As iTrust Industry UPS has no ventilation grills at either the sides or the rear, no
clearances are required.

Back-access is not an essential requirement for maintenance. However, where

space permits, a clearance of approximately 600mm will ease access to magnetic
component parts. Clearance around the front of the equipment should be sufficient
to enable free passage of personnel with the doors fully opened.

2.3.4 Fixing Of The Magnetic Components

Before the UPS is in place, remove the transportation restraints that hold the output
transformer in place.

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 Chapter 2 Mechanical Installation 11

2.3.5 Cable Entry

Cables can enter iTrust Industry UPS either from below or through either side.
Optionally a top cable entry extension cabinet may be used if you need to use top
cable entry method.

Side entry is made possible by removing blanking pieces fitted in the side panel to
reveal the cable entry holes.

Side cable entry allows the equipment to be positioned on a solid floor without the
need for cable trenching and allows cables to pass from one module to the other
when positioned side-by-side.

Note: When selecting the power cables for side entry to a module located on a solid
floor, consideration must be given to the minimum permissible radius of the
proposed cables to ensure that they can be fashioned to reach the UPS connection
busbars.

2.4 Preliminary Checks

Before you install the UPS hardware you should carry out the following preliminary
checks:

1. Verify that the UPS room satisfies the environmental conditions stipulated in the
equipment specification, paying particular attention to the ambient temperature and
air exchange system.

2. Remove any packaging debris, then visually examine the UPS and battery
equipment for transit damage, both internally and externally. Report any such
damage to the shipper immediately.

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12 Chapter 2 Mechanical Installation

2.5 Installation Drawings

The following diagrams illustrates the key mechanical characteristics of the various
UPS system cabinets.
Side view Front view

Rear view
Top view

1. Removable grille for lifting with fork lift truck (660*100mm)

2. Air inlet grille
3. Removable grille-if using side cable entry (630*105mm)
4. Air outlet grille All dimensions in mm
Figure 2-1 iTrust Industry 30/40kVA UPS

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 Chapter 2 Mechanical Installation 13

4
2 1
3

1. Holes Ø14 for securing unit to floor (if required)

2. Surface loading of UPS 4×100cm2，2.7Kg\cm2
3. Grille for air entry from the bottom
4. Bottom cable access
All dimensions in mm
Figure 2-2 Base view for iTrust Industry 30/40kVA UPS

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14 Chapter 2 Mechanical Installation

Side view
Front view

Front

Rear view
Top view

1. Removable grille for lifting with fork lift truck (1210*100mm)

2. Air inlet grille
3. Removable grille-if using side cable entry (630*105mm)
4. Air outlet grille
All dimensions in mm
Figure 2-3 iTrust Industry 60/80kVA UPS

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 Chapter 2 Mechanical Installation 15

Base
底视图 view

Front
前门
Front dorr
door
2

1. Holes Ø14 for securing unit to floor (if required)

2. Surface loading of UPS 4×100cm2，2.7Kg\cm2
3. Grille for air entry from the bottom
4. Bottom cable access
All dimensions in mm
Figure 2-4 Base view for iTrust Industry 60/80kVA UPS

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16 Chapter 2 Mechanical Installation

Side view Front view

Front

5
Rear view Top view

1. Removable grille for lifting with fork lift truck (660*100mm)

2. Air inlet grille
3. Removable grille-if using side cable entry (630*105mm)
4. Air outlet grille
5. Top cable entry option
All dimensions in mm
Figure 2-5 iTrust Industry 30/40kVA UPS with top cable entry option

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 Chapter 2 Mechanical Installation 17

Side view Front view

Rear view Top view

1. Removable grille for lifting with fork lift truck (1210*100mm)

2. Air inlet grille
3. Removable grille-if using side cable entry (630*105mm)
4. Air outlet grille
5. Top cable entry option
All dimensions in mm
Figure 2-6 iTrust Industry 60/80kVA UPS with top cable entry option

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18 Chapter 3 Electrical Installation

Chapter 3 Electrical Installation

The UPS requires both power and control cabling once it has been mechanically
installed. All control cables, whether screened or not, should be run separate from
the power cables. The cabling should be planned carefully to achieve as short as
possible cabling route.

3.1 Power Cabling

WARNING

BEFORE CABLING-UP THE UPS, ENSURE THAT YOU ARE AWARE OF THE LOCATION
AND OPERATION OF THE EXTERNAL ISOLATOR THAT CONNECT THE UPS
INPUT/BYPASS SUPPLY TO THE MAINS DISTRIBUTION PANEL.
CHECK THAT THESE SUPPLIES ARE ELECTRICALLY ISOLATED, AND POST ANY
NECESSARY WARNING SIGNS TO PREVENT THEIR INADVERTENT OPERATION.

For cable entry, refer to section 2.3.5.

3.1.1 System Configuration

The power cables of the system must be sized with respect to the following
description.

Module input cables

The module input cables must be sized for the maximum input current, including
the maximum battery recharge current, given in Table 3-1, with respect to the
module rating and the input AC voltage.

Module bypass and output cables

The bypass and output cables must be sized for the nominal output current, given
in Table 3-1, with respect to the module rating and the output AC voltage.

Battery cables

Each UPS module has its own battery which is connected using two cables, one
positive and one negative. The battery cables must be sized for the battery
discharge current at the end-of-discharge voltage, as given in Table 3-1 with
respect to the module rating.

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3.1.2 Cable Rating

The power cables can be sized to suit the UPS module rating according to the table
below:

Table 3-1 UPS module cabinet power cable rating

Current, bolt and cable parameters (Amps/diameter/mm2)
UPS Battery discharge current
Input current at min. input Bypass input current at min.
rating Output current at full load at min. battery voltage
mains voltage bypass voltage
(kVA) (187Vdc)
Current Bolt Section Current Bolt Section Current Bolt Section Current Bolt Section
30 56 M8 25 168 M8 35 143 M8 35 143 M8 35
40 75 M8 25 225 M8 50 191 M8 50 191 M8 50
60 112 M10 35 334 M10 95 286 M10 95 286 M10 95
80 150 M10 50 450 M10 150 382 M10 150 382 M10 150

* For common bypass and rectifier inputs, the input cables and bolts should be
rated according to the bypass supply.

3.1.3 General Notes

The following are guidelines only and superseded by local regulations and codes of
practice where applicable.

1. the earth conductor should be sized at 2 times the output/bypass conductor (this
is dependent on the fault rating, cable lengths, type of protection etc.)

2. Consideration should be given to the use of paralleled smaller cables for heavy
currents, as this can ease installation considerably.

3. When sizing batter cables, a maximum volt drop of 3 Vdc is permissible at the
current ratings given in Table 3-1.

4. In most installations, especially 1+1 redundancy parallel systems, the load

equipment is connected to a distribution network of individually protected busbars
fed by the UPS output rather than being connected directly to the UPS itself. Where
this is the case the UPS output cables can be rated to suit the individual distribution
network demands rather than being fully load-rated.

3.1.4 Cable Connections

The rectifier input, bypass, output and battery power cables (all require lug type
terminations) are connected to busbars situated below the power isolator
switches-as shown in Figure 3-1 for 30/40kVA UPS and Figure 3-2 for 60/80kVA
UPS.

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20 Chapter 3 Electrical Installation

A terminal block X3 is used for connecting the control cables to the BCB and a
second terminal block X4 is used for the external emergency power off facility,
external OFF inverter, external bypass, etc. Please use the cable lugs delivered
with the UPS to fabricate the connecting cables. For details, see section 3.3.

3.1.5 Safety Earth

The safety earth busbar is located near the input and output power supply
connections as shown in Figure 3-1 and Figure 3-2. The safety earth cable must be
connected to the earth busbar and bonded to each cabinet in the system.

All cabinets and cable trunking should be earthed in accordance with local
regulations.

WARNING

FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES CAN RESULT IN

ELECTRICAL SHOCK HAZARD TO PERSONNEL, OR THE RISK OF FIRE, SHOULD AN
EARTH FAULT OCCUR.

3.1.6 Protective Devices

For safety reasons, it is necessary to install, external to the UPS system, circuit
breaking protective devices in the input AC supply and towards the battery. Given
that every installation has its own characteristics, this chapter provides general
useful information for qualified installation engineers, with knowledge of operating
practices, of regulatory standards, and of the equipment to be installed.

Rectifier and bypass input supply of the UPS

Protection against excessive overcurrents and short circuits in the mains supply
input:

The inputs must be protected, installing suitable protective devices at the

distribution panel of the incoming mains supply, considering that the protection
should discriminate with overload capacity of the system (see Chapter 10
Specification: Electrical Characteristics).

Split bypass: In the case of a split bypass being used, separate protective devices
should be installed in the incoming mains distribution panel.

The protective devices must be selected for the nominal input current, with respect
to the UPS rating and the input AC supply voltage as given in Table 3-1.

Protection against earth faults (RCD devices):

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 Chapter 3 Electrical Installation 21

In the event of a differential (RCD) device being installed upstream of the input
supply, one must take in account the transient and steady state earth leakage
currents that are produced during start-up of the UPS.

The presence of an RFI suppression filter inside the UPS determines a residual
earth current greater than 3.5 mA and less than 1000mA.

Battery

The UPS battery is protected by means of a control circuit that operates the tripping
mechanism of an automatic circuit breaking device (having a variable trip setting),
the tripping mechanism using an undervoltage release coil that operates on a
present minimum voltage level.

The circuit breaker is essential for maintenance of the battery and is normally
located near to the battery installation.

Output of the system

External protective devices should be selected according to the actual load

distribution.

3.1.7 Cabling Procedure

Once the equipment has been finally positioned and secured, please refer to Figure
3-1 and Figure 3-2 and use the following procedures to connect the power cables.

1. Verify that the UPS equipment is totally isolated from its external power source
and all the UPS power isolators are open. Check that these supplies are electrically
isolated, and post any necessary warning signs to prevent their inadvertent
operation.

WARNING

The handles of all UPS power isolator have big elasticity. To avoid injury, special care should
be taken when operating these isolators.

2. Open the door to the UPS cabinet and remove the lower protective cover to gain
access to the connection bars.

3. Connect the safety earth and any necessary earth cables to the copper earth
busbar located on the floor of the equipment

4. Verify that links are fitted between rectifier input and bypass busbars (this had
been done at factory before delivery).

Note: The earthing and neutral bonding arrangement must be in accordance with
local and national codes practice.

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Common Input Connections

For common bypass and rectifier inputs, connect the AC input supply cables
between the mains distribution panel and the UPS bypass input supply busbars
(U1-V1-W1 terminals), and tighten the connections to 13Nm (M8 bolt), and to
26Nm (M10 bolt).

ENSURE CORRECT PHASE ROTATION

Split Bypass Connections

If a split bypass configuration is used, remove the links fitted between rectifier input
and bypass busbars, and connect the AC input supply cables to the input busbars
(U1-V1-W1 terminals) and the bypass AC supply cables to the bypass busbars
(L1-N1 terminals) and tighten the connections to 13Nm (M8 bolt), and to 26Nm
(M10 bolt).

ENSURE CORRECT PHASE ROTATION

WARNING

Ensure that any links (
) fitted between rectifier input and bypass busbars are removed (see
Figure 3-1 and Figure 3-2).

Output System Connections

5. Connect the system output cables between the output busbars (L2-N2 terminals)
and the critical load and tighten the connections to 13Nm (M8 bolt), and to 26Nm
(M10 bolt).

WARNING

If the load equipment will not be ready to accept power on the arrival of the commissioning
engineer then ensure that the system output cables are safely isolated at their ends.

UPS Battery Connections

6. Connect the battery cables between the UPS terminals (+/-) and its associated
battery circuit breaker. Connect screened auxiliary cables from each battery circuit
breaker control board (03025929) to the auxiliary terminal block (X3).

As a safety precaution remove the battery fuse in the module until the arrival of the
commissioning engineer.

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 Chapter 3 Electrical Installation 23

Note

1. The UPS had been set to Block mode at factory before delivery, therefore it does not have
the battery charge function. If you need this function, please tell the commissioning engineer,
who will change the UPS setting to enable this function.
2. The voltages of the signals transmitted by the auxiliary cables exceed 200Vdc, please use
the cables supplied with the battery circuit breaker as the auxiliary cables. Should you prepare
the cables yourself, please ensure the safty of the cables.

OBSERVE THE BATTERY CABLE POLARITY

WARNING

Do not close the battery circuit breaker before the equipment has been commissioned.

Inter-module Parallel Connection

7. 1+1 redundancy parallel system

Inside the module there is a Parallel Connectors Board (03025410) mounted on the
left hand side. Connect one parallel cable between interface connector X1 of the
first UPS module and connector X2 of the second module, and the other parallel
cable between the interface connector X2 of the first UPS module and connector
X1 of the second module (see Figure 9-2).

If you need to monitor the two modules of the 1+1 redundancy parallel system
simultaneously, please use an RS485 cable to connect the two modules as shown
in Figure 9-3.
Auxiliary Connections

8. Connect the auxiliary cables of any external interface/signals to the respective

connections of the output auxiliary terminal block (X4).

9. Refit the lower protective cover.

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24 Chapter 3 Electrical Installation

Q2 Q4

Q1
X3 *

X4 Q3

+
- U1V1W1 L1 N1 Earth
保护地 L2 N2

Battery
电池输入Rectifier
主路输入 旁路输入 Bypass Output
输出
connections connections connections connections

Figure 3-1 Cable connections for iTrust Industry 30/40kVA UPS

Note: For split bypass operation ensure that the busbars (
) between bypass and
rectifier input are removed.

Q1 Q2 Q4
X3
*

X4
Q3

-+ U1V1W1 L1 N1 Earth
保护地
保护地 L2 N2

电池输入
Battery Rectifier
主路输入 Bypass
旁路输入 Output
输出
connections connections connections connections

Figure 3-2 Cable connections for 60/80 kVA UPS

Note: For split bypass operation ensure that the busbars (
) between bypass and
rectifier input are removed.

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3.2 Distance From Floor To Connection Point On The Equipment

Table 3-2 Distance from floor to connection point on the equipment

30/40kVA UPS min 60/80kVA UPS min
UPS
distance (mm) distance (mm)
Rectifier AC input supply 195 195
Bypass AC input supply 195 195
UPS AC output 195 195
Battery power 205 205
Auxiliary cables: battery
700 700
control/temperature compensation
Communications to AS400/external
800 800
alarm monitor
Remote emergency power off (EPO) 700 700
Ground 195 195

3.3 Control Cables

3.3.1 Battery Control

The battery circuit breaker is controlled by the battery circuit breaker controller
board. This board controls the circuit breaker’s undervolts release coil and also
provides a path for the circuit breaker auxiliary contacts to signal the circuit breaker
status back to the UPS control logic. All connections between the controller board
and the UPS module are made via the auxiliary terminal block which is located in
the base of the UPS cabinet.

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26 Chapter 3 Electrical Installation

1
Battery circuit breaker
电电电电电电电
controller board
2 Common
3 T Batt.
4 Common
5 Batt. Sw
6 Batt. Tip
7 Bus+
8 Bus-
9
X3 10
11
X1 12
X3 X4 1 2 3 4 5

1 Ext OFF Inv

2
3 Ext Sw Out
4
5 Ext EPO
6
7 Ext BYP
8
Auxiliary terminal block located in the UPS cabinet
UPS辅辅辅辅辅辅辅 9 Back Feed
X4 10
11 Int EPO
12

Figure 3-3 Auxiliary terminal block detail

Connect the battery circuit breaker control and temperature compensation cables
between the UPS auxiliary terminal block and battery circuit breaker controller
board as shown in Figure 3-3 and Figure 3-4.

Caution

If battery temperature compensation is not used the system must be de-activated by the
commissioning engieer.

Table 3-3 Auxiliary terminal block X3 at UPS

X3 terminal reference Reference label Description

2 Common Temperature sensor common (0V)

3 T Batt. Temperature sensor signal

4 Common Common (0V)

5 Batt. Sw Battery circuit breaker open

6 Bat Trp Battery circuit breaker trip control

7 Bus+ Positive bus voltage

8 Bus- Negative bus voltage

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 Chapter 3 Electrical Installation 27

Note: the auxiliary cables of the battery must be safety certified, and double
insulated.

Use the terminals (female) supplied with the product in battery connection.

3.3.2 Auxiliary Terminal Block X4

Table 3-4 Auxiliary terminal block X4 at UPS

X4 terminal Reference
Description
reference label
Remotely provides control for switching off the inverter.
1-2 Ext. OFF Inv
Normally open contact.

Indication to be provide at the UPS to note the opening of an

external module output isolator.
3-4 Ext. Sw Out
Normally closed contact.
If unused, leave the standard connectors in place.

Remotely provides control for switching off the UPS using a

remote emergency button.
5-6 Ext. EPO
Normally closed contact.
If unused, leave the standard connector in place.

Indication to be provided at the UPS to note the opening of an

external maintenance bypass switch.
7-8 Ext. BYP
Normally closed contact.
If unused, leave the standard connectors in place.

Signal from the UPS to indicate a return flow of energy in the

9-10 Back Feed bypass mains.
Normally open contact.

Availability of a contact for switching off the UPS in the same

11-12 Int EPO way as the internal emergency off button.
Normally closed contact.

Note: All auxiliary cables of terminal block X4 must be double insulated.

The cross-sectional area of the auxiliary cables is from 0.5 to 1mm2.

Connect the cables with the terminals (female) supplied with the product.

Maximum contact rating on auxiliary terminals: 50Vdc @ 1Amp.

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28 Chapter 3 Electrical Installation

Battery temp.
board 3
2 Battery temp. sensing cable
4532029V
1 X2 X10
Battery

Battery C.B.
Battery circuit breaker controller board
X5 4520057T
X6
U< X7
X8
X9
X1
- + X3X4 1 2 3 4 5

Battery power connections

1
2
3
4
5
6
X3 7
8 Battery control cable
9
10
- + 11
12

Figure 3-4 Battery Connection

3.3.3 Emergency Power Off

If an external emergency power off facility is required it is connected to terminals 5

& 6 of the auxiliary terminal block (X4) and connect the normally closed remote
stop switch between these two terminals using shielded cable. If this facility is not
used then terminals 5 & 6 must be linked-out as shown in Figure 3-3.

Note 1: The emergency power off action within the UPS shuts down the rectifier,
inverter and static bypass and trips the battery circuit breaker. It does not however
internally disconnect the input mains supply. If required, this additional action can
be facilitated by feeding the UPS input via a circuit breaker which can be tripped by
a second contact of the emergency power off switch.

Note 2: Terminals 11 & 12 of the auxiliary terminal block (X4) are connected to a
normally closed contact of the UPS display panel emergency power off button and
go open circuit when the button is pressed. This output can provide a signal
synchronizing with the emergency power off button action to initiate an external
action (such as tripping an external supply breaker).

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3.3.4 Backfeed Protection

Using an auxiliary terminal (pins 9-10 of connector X4) the UPS provides a
normally openly contact to be used for opening of an external circuit protection
device, to protect the operator against backfeed of energy resulting from a
short-circuit fault of the Bypass line SCRs. This auxiliary contact can be used, for
example, in series with an external low voltage source, in order to supply the trip
coil of an automatic circuit breaking device, located upstream of the UPS bypass
mains input. In the event of energy being backfeed the auxiliary circuit will activate
closing the normally open contact and as a result opening of the external circuit
breaking device; the UPS is disconnected from the bypass mains supply. The
electrical characteristics of the auxiliary contact are 50V (ac or dc) @ 1Amp.

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30 Chapter 4 Operator Control And Display Panel

Chapter 4 Operator Control And Display Panel

4.1 Introduction

On the front of the UPS there is a display and control panel, from which it is
possible to easily verify the status of the UPS included all the measured
parameters and alarms of the UPS and battery. As shown in Figure 4-1, the
operator control panel is divided into three functional areas:

* Mimic LED display and inverter control switch

* Operator panel & LCD display

* Bar graph, alarm silence switch and alarm indicator

The left section consists of LEDs which indicate the operational and alarm status of
the system by turning ON or OFF or by flashing ON/OFF. The inverter control
switch is used to control the inverter.

The middle section of the operator control and display panel consists of a LCD and
its associated switches.

The following functional area (right section) shows the various UPS load and
battery charging conditions. The alarm silence switch is used to cancel the audible
alarm. And the alarm indicator is used to indicate UPS alarm.

4.1.1 Operator Control Panel

The control and display panel LED indications are illustrated in Figure 4-1 and
described in the following text:

Figure 4-1 Operator control panel

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Mimic indications

Six LED indicators mounted on a single line diagram represent the various UPS
power paths and show the current UPS operational status:

1. Bypass supply indicator

2. Rectifier indicator

3. Battery status indicator

4. Inverter output indicator

5. Load on inverter status indicator

6. Load on bypass status indicator

The above six LED indicators are described in Table 4-1.

Talbe 4-1 UPS mimic indications

Serial No. Indicator OFF ON Flash
Bypass frequency
Bypass supply Bypass frequency abnormal, Bypass frequency
1 abnormal,bypass
indicator bypass voltage abnormal normal
voltage normal
2 Rectifier indicator Rectifier blocked Rectifier not blocked —
Battery circuit breaker Battery circuit breaker
Battery status Battery circuit breaker closed,
3 closed, battery is open, battery fuse
indicator battery is not discharing
discharing blown
Inverter output
4 Inverter voltage abnormal Inverter voltage normal —
indicator
Load is not connected to the Load is connected to Load is connected to
Load on inverter
5 inverter, the output power switch the inverter, the output the inverter, the output
status indicator
is open voltage is normal voltage is abnormal
Load is connected to Load is connected to
Load is not connected to the
Load on bypass thebypass, bypass the bypass, bypass
6 bypass or the output power
status indicator frequency and inverter frequency or inverter
switch is open
voltage are normal voltage is abnormal

Inverter control switch

7. Inverter On — Manual inverter selection switch.

8. Inverter LED (Yellow) — Inverter status indicator contained above the switch
icon. The inverter LED illuminates when the inverter is switched OFF.

Warning indicator and alarm silence switch

13. Alarm indicator (red) — The red LED illuminates when an alarm is displayed
on the LCD screen, and is normally accompanied by an audible alarm.

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14. Alarm silence switch — Pressing the alarm silence switch cancels the audible
alarm but leaves the alarm message displayed until the inappropriate condition is
rectified.

Bargraph section

This functional area shows the various UPS load and battery charging conditions.

16. Low battery indicator (amber)

This indicator illuminates when the remaining battery autonomy time is less then 6
minutes.

This indicator extinguishes when the battery circuit breaker is open, or the battery is
being charged, or the battery is discharging and the remaining battery autonomy
time is more than 6 minutes.

17. Battery state autonomy time bar graph

When the battery is being charged, the five LEDs illuminates progressively from left
to right to indicate the state of battery charge, an LED illuminating for every
increase of 20% of battery capacity.

When the battery is discharging, the bar graph function charges to provide an
indication of the remaining battery autonomy time: When the remaining battery
autonomy time is 8 minutes, the five LEDS begin to extinguish progressively from
right to left, an LED extinguishing for a reduction of every 2 minutes of battery
autonomy time.

When the battery circuit breaker is open, all these bar graph indicators are off.

18. Load bar graph %

The five LEDs illuminate progressively from left to right to indicate the applied load
as a percentage of the rated maximum current, increasing in 20% steps to 100% of
full load. When the load capacity is less than 4%, the five LEDs are all off.

19. Overload indicator (amber)

This indicator illuminates if the applied load exceeds 100% of the module(s) rated
output current. This indication will be accompanied by an audible alarm and an
alarm message.

LCD and Menu Keys

Menu key (9, 10, 11, 12, 20)

There are totally five menu keys, some have two functions, and the functions are
defined in the following table.

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 Chapter 4 Operator Control And Display Panel 33

Key F1 F2 F3 F4 HELP

FUNCTION 1
SHIFT ENTER
?
LEFT RIGHT HELP

FUNCTION 2 ESC
EXIT UP DOWN

LCD (15)

The LCD provides 320 x 240 dots matrix graphic display. Through the graphic LCD
display and a user-friendly menu-driven operator system, the user can easily
browse the parameters for input, output, load and batteries, obtain the current UPS
current status and alarm messages, and carry out relevant functional setting and
control operations.

The LCD can display alarm information in real time. 500 historical records and 200
operation records can be stored and retrieved for reference and diagnosis. The
versions of the UPS control firmware and internal monitor firmware can be queried
from the LCD.

As shown in Figure 4-2, the LCD display is divided into five windows: UPS system
window, menu window, UPS data window, current record window, and keypad
window.

Pressing the F1 key can scroll through the windows that can be operated by the
user.

UPS system window

Menu window

UPS data window

Current record window

Keypad window

Figure 4-2 Sections of the LCD

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34 Chapter 4 Operator Control And Display Panel

 UPS system window

This window displays the basic UPS information and is only designed for view. The
information of this window is given in the following table.
No. Item Description
1 iTrust UPS name
2 2004-01-01 Current date
3 12:30:36 Current time
U: UPS, L: low frequency, 31: 3-phase in 1-phase out,.
4 UL31_0400
0400: UPS model is 40kVA
Unit Parallel system
5
Single UPS is configured as a single unit system running in Normal mode.
ECO UPS is configured as a single unit system running in ECO mode.
Normal UPS in normal operation, load on inverter, no alarm
6
Warning UPS has alarm

 Menu window UPS data window

Menu window – This window provides the menus (totally 9) of the UPS data
window.

UPS data window – This window displays the items of the menu selected in the
menu window.

UPS parameters can be browsed and functions can be set through the menu
window and UPS data window. Details are provided in the following table:
Menu
No. Menu items Description
name
Vout(V)
F Inv.(Hz)
1 OutputData
F Byp.(Hz)
Vbp(V)
RealPower(kW)
App.Power(kVA)
2 Load Data
Iout(A)
Load(%)
V Batt.(V)
I Batt.(A)
3 Batt.Data T Batt.(℃)
“****” is displayed when the battery is being
Batt.Chg.(%)
charged or under test
When the His. Record menu is selected, the
UPS historical records will be displayed in
4 His.Record Maximally 500 latest historical UPS alarms the UPS data window, including the alarm
name, sequence No. start time, end time,
and fault site code.

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 Chapter 4 Operator Control And Display Panel 35

Menu
No. Menu items Description
name
When the Op. Record menu is selected, the
Maximally 200 latest operation or configuration UPS operation records will be displayed in
5 Op.Record
records the UPS data window, including the setting
type, sequence No., setting point, and time.
Now
Automatic
Duration (min)
Batt. Test
Threshold (V/cell)
Period (day)
NextTest StartAt
Inv:Sync Inhibit
Generator Charge Inhibit
I/P Curr. Limit
LCD Contrast
Language
Panel Setup
Type
6 Function Change Password
Baud Rate (bps)
CDT
Address
Baud Rate (bps)
Address
MODBUS CRC Type
Com1
Parity Bits
Protocol
Stop Bits The Function, Maintain, Sys. Setup menus
Setup
IGMNET Module all require a password which is set by the
IGMNET
IGMNET Modules commissioning engineer. This manual does
Baud Rate (bps) not provide servicing instructions and the
LOCAL Address items on these menus are therefore not
Group described here. Only trained service
Com2 engineers should be authorized with a
Protocol The same as above password.
Setup
Inverter
On/Off UPS Bypass
6 Function Control Rectifier
Rectifier
Reload UPS Data
Reset Alarm History
Reset
Reset Event History
Buffers
Reset Alarms
Serial Number
7 Maintain Date&Time
Last Service Date
Power (kVA)
UPS Configure
UPS Setup
8 Sys. Setup Number Inverter OK
Power Walk In

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36 Chapter 4 Operator Control And Display Panel

Menu
No. Menu items Description
name
8 Sys. Setup Rated Volt (V) The Function, Maintain, Sys. Setup menus
Upper limit Vbp (%) all require a password which is set by the
Voltage Upper limit Vout (%) commissioning engineer. This manual does
Lower limit Vbp (%) not provide servicing instructions and the
Lower limit Vout (%) items on these menus are therefore not
Nominal Frequency (Hz) described here. Only trained service
Frequency Sync.Window (%) engineers should be authorized with a
SlewRate (Hz/s) password.
Battery Cells (cells)
Battery Capacity (Ah)
End Discharge (V/cell)
Battery Low (V/cell)
Battery Max. (V/cell)
Setup Boost Charge Now
Boost Charge Automatic
Boost Charge Duration(min)
Boost Charge Threshold(A)
Battery connect mode
UPS control firmware version, internal
9 Sys. Ver. monitor firmware version and Emerson’s
website

Note:

1. Sys. Setup menu is password-protected, the default password is “00000000”.

Please timely access Function=> Panel Setup=>Change Password to change the
password. In case the password is lost, please contact the technical support
personnel.

2. The password will not be changed when restoring the UPS default settings by
selecting “Reload UPS Data” on the Function menu.
 Current record window

This window displays the current UPS event and alarm messages.

Current and historical events, alarms and faults can be scrolled on the UPS display,
and can be queried from background PC. Multiple periodic groups of status and
parameters records prior to and after the occurrence of a serious fault can be
stored and queried from background PC for later diagnosis.

The UPS event and alarm messages are given in Chapter 6.

 Keypad window

This window uses symbols to explain the current meanings of the menu keys on
the keypad under the LCD display.

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 Chapter 4 Operator Control And Display Panel 37

Emergency power off

The emergency power off (EPO) switch is housed beneath a safety cover to
prevent inadvertent operation. When the EPO switch is pressed it disables the
static switch block entirely (so removing load power). It also disables the rectifier
and inverter, and trips the battery circuit breaker. Under normal circumstances it
does not remove UPS input power since this is applied through a manually
controlled external isolator; however, if the UPS input supply is connected via a
circuit breaker having an electrical trip facility, the EPO switch can be used to drive
the external circuit breaker’s trip circuit so as to remove the UPS input power.

Emergency
power off (EPO)
switch

Figure 4-3 Emergency power off (EPO) switch

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38 Chapter 4 Operator Control And Display Panel

4.2 The Displayed Information

4.2.1 Start Screen

At power up of the UPS, the start screen will appear showing the start progress bar,
as shown below, which takes about 30 seconds. Afterwards, the normal screen will
appear.

▌▌▌▌▌▌▌▌▌▌

F1 F2 F3 F4 H E LP

Figure 4-4 Start Screen

4.2.2 Default Screen

During UPS operation, if there is neither alarm nor keypad operation within 2
minutes, the default screen will appear, as shown in the following figure. 2 minutes
later, the LCD backlight will turn off. When an alarm occurs or a key is pressed, the
normal screen will return, and the LCD backlight will turn on.

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 Chapter 4 Operator Control And Display Panel 39

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si ng le No r ma l

Pr es s a ny ke y b ac k t o m a in me nu

F1 F2 F3 F4 H E LP

Figure 4-5 Default screen

The default screen shows the UPS operation status and Emerson Logo.

4.2.3 Help Screen

Use the HELP key to display the help screen, as shown below. This screen
describes the current meaning of the menu keys.

Help Information

The cursor is switched to the current record window

The cursor is switched to the previous menu option
The cursor is switched to the next menu option

Press “?” key to exit the help information

?
F1 F2 F3 F4 HELP

Figure 4-6 Help screen

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40 Chapter 4 Operator Control And Display Panel

Operation of the HELP key:

1. The HELP key is invalid before the UPS and the LCD start.

2. When the screen-saver is running while the backlight is off, pressing the HELP
key will only activate the backlight and will not switch the LCD screen to the Help
information page.

3. With exception of the situation described in item 2, the LCD screen always
switches to the Help information page whenever the HELP key is pressed. The
current meaning of the four menu keys would be displayed in the Help information
page to guide user operation.

4. When the HELP key is released, the Help information page will disappear and
the LCD screen will return to the previous information page.

4.3 Prompt Window

During system operation, when the system needs to prompt the user, or needs the
user to confirm or conduct some operations, a prompt window will appear, as
described in the following table:
Serial
Prompt Window Interpretation
No.
After pressing the alarm silence switch, the prompt
1 Alarm Silencing “Alarm Silencing” will appear on the LCD screen. But the
buzzer will beep again in the event of a new alarm
It is setting the parameters, which will be finished in
2 Setting, Pls. Wait
about 5 seconds
Please try again. If this prompt appears again, contact
3 Setup Fail!
the technical support personnel
The setpoint is outside the setting range. Please set the
4 Beyond Range! parameters within the setting range given in the prompt
box
After setting the parameters, you need to power off the
Setting,Pls. Wait system completely (all the LEDs and auxiliary power
5
AfterChange,Shut&Restart supply should be switched off) and then restart it to
validate the new settings.
Warning!Inv. Off After pressing the “INV” switch （to turn off the inverter）,
6
"Esc"Canel," "Enter this prompt will appear to require your confirmation.
"Esc"Canel," "Enter After selecting the “Reload UPS Data” command on the
7 Shut&Restart, After Setup “Function” menu, the prompt box will appear to require
Shut&Restart Again! confirmation.
This prompt appears to require you to enter the
8 Password
password. The default password is “00000000”.
9 Wrong Password, Try Again! The password is incorrect, please try again.
Please Enter the Whole In password changing, the password entered is not an
10
Password! 8-digit one. Please enter a complete 8-digit password.

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 Chapter 5 Operating Instructions 41

Chapter 5 Operating Instructions

5.1 Introduction

The UPS can be considered to be in one of following operating conditions:

Normal operation (including Block mode and Direct mode)-----All relevant

power switches and circuit breakers closed, the load is powered by the UPS.

On Maintenance Bypass-----UPS shut down but the load connected to the

unprotected mains via the maintenance bypass supply line.

Shutdown----All power switches and circuit breakers open - no load power.

On Static Bypass----The load power is supplied through the mains static

bypass line. This may be considered as an intermediate operating condition
being utilized for the purpose of load transfers between inverter and
maintenance bypass or supply under abnormal operating conditions.

ECO mode----All relevant power supply switches and the battery switch are off,
and the load is fed by the bypass mains through the UPS static transfer switch,
while the inverter remains on stand-by.

This chapter contains instructions which enable you to switch between the above
conditions, to carry out a RESET and how to switch ON/OFF the inverter, etc.

5.1.1 General Notes

Note 1: All the user controls and LED indicators mentioned in these procedures are
identified in Chapter 4.

Note 2: The audible alarm may annunciate at various points in these procedures. It
can be canceled at any time by pressing the “ ” push-button.

5.1.2 Power Switches

The UPS can be separated by means of power switches, mounted inside the
cabinet and accessible after opening the front door, which has a key.

The location of the UPS power switches is shown in Figure 5-1.

The UPS module power switches are:

Q1 - Input isolator: connects the UPS with the mains supply.

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42 Chapter 5 Operating Instructions

Q2 – Bypass isolator: connects the UPS with the bypass supply.

Q3 – Maintenance bypass isolator (padlocked) permits supply of the load directly

by the bypass line for maintenance of the UPS module.

Q4 – Output isolator: connects the output of the UPS to the load.

Note: The battery circuit breaker is not expected inside of the UPS and should be
installed in the proximity of the respective battery.

Q1 Q2 Q4

Q3

Figure 5-1 Power isolator location

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 Chapter 5 Operating Instructions 43

5.2 Procedure For UPS Start-Up: Without Interrupting Power To

The Load

This procedure will describe how to start the UPS and how to transfer the load from
the maintenance bypass to the UPS inverter. It is assumed that the installation is
complete, the system has been commissioned by authorized personnel and the
external power isolator are closed. Refer to Figure 5-1 for corresponding isolator
Q1 to Q4.

Note: The UPS is supposed to be in Block mode in the following description.

ENSURE CORRECT PHASE ROTATION

1. Close the maintenance bypass switch Q3.

2. Close the output power switch Q4 and the bypass power switch Q2.

▌▌▌▌▌▌▌▌▌▌

F1 F2 F3 F4 H E LP

Start screen: After first connecting power to the UPS and closing the isolator, the
start screen will appear on the LCD. It persists for about 30 seconds while the
control firmware is loaded. It is followed by about 3 seconds of flash of all LED
indicators.

Afterwards, the bypass supply indicator (1) and the red alarm indicator (13) will
illuminate, the load on bypass status indicator (6 - amber) and the battery status
indicator (3) will flash.

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44 Chapter 5 Operating Instructions

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

R e c t if i e r S w i t ch O p en
Ba tt e r y C . B . O p e n
M a n ua l B yp a ss C l os e d

F1 F2 F3 F4 H E LP

The display window will show the present status of the UPS.

3. Open the maintenance bypass switch Q3 and lock it.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

Lo a d On B yp a s s
I n v er t e r : O f f

F1 F2 F3 F4 H E LP

The display window will show the present status of the UPS.

4. Close the rectifier input power switch Q1.

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 Chapter 5 Operating Instructions 45

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

Lo a d On B yp a s s
M an u a l B y p a ss C l os ed
I n v er t e r : O f f

F1 F2 F3 F4 H E LP

Note: In ECO mode the message “LOAD ON BYPASS” will not appear.

5. Wait for 20 seconds then close the battery circuit breaker.

The battery status indicator (3) should extinguish. Several LEDs on the battery
status of charge bar graph will illuminate showing the battery state of charge. The
rectifier will walk in and stabilize at the preset voltage.

During this process, the load on inverter status indicator (5 - steady green) will
illuminate, the load on bypass status indicator (6) will extinguish, and the load will
transfer from the bypass to the inverter automatically.

Note: In ECO mode, the load on bypass status indicator (6) will illuminate, and the
load on inverter status indicator (5 - green) will extinguish.

When the UPS is in normal operation mode, the default window is as follows:

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iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

Lo a d On B yp a s s
M an u a l B y p a ss C l os ed
I n v er t e r : O f f

F1 F2 F3 F4 H E LP

5.3 Procedure For UPS Start-UP: Without Power Initially Supplied

To The Load

This procedure should be followed when turning on the UPS from a fully powered
down condition - i.e. where the load is not being initially supplied at all. It is
assumed that the installation is complete, the system has been commissioned by
authorized personnel and the external power isolators are closed. Refer to Figure
5-1 for corresponding isolators Q1 to Q4.

1. Open the UPS door to gain access to the main power switches.

2. Close the rectifier power switch Q1.

The start screen will appear on the LCD. It persists for about 30 seconds while the
control firmware is loaded. It is followed by about 3 seconds of flash of all LED
indicators.

Afterwards, the rectifier indicator (2 - steady green) and the inverter output indicator
(4 - green) will illuminate, the battery status indicator (3) will flash, the alarm
indicator (13) will illuminate, and the following window will appear on the LCD:

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iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

B yp a s s S w i t ch O p en
B a t te ry C . B. O p en
O u t pu t S wi t c h O p e n

F1 F2 F3 F4 H E LP

Note: If input power is present but the display remains blank, then the Micro
Controller is not working, please contact the local customer service center of
Emerson.

WARNING

THE FOLLOWING ACTION WILL APPLY POWER TO THE LOAD EQUIPMENT －

ENSURETHAT IT IS SAFE TO DO SO.

3. Close the UPS output power switch Q4.

The load on inverter status indicator (5 - steady green) and the battery status
indicator (3) will flash, and the alarm indicator (13) will illuminate.

Note: In ECO mode the load on inverter status indicator (5) will extinguish.

The LCD window will display the following information:

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iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

B a t te ry C . B. O p en
B yp a s s S w i t ch O p en

F1 F2 F3 F4 H E LP

4. Close the bypass input power switch Q2.

The bypass supply indicator (1 – steady green) will illuminate, after 20 seconds the
inverter will synchronize with the mains bypass.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

B a t te ry C . B. O p en

F1 F2 F3 F4 H E LP

5. Before closing the battery circuit breaker check the DC busbar voltage. The “V
Batt.(V)” on the “Batt. Data” menu is the DC busbar voltage.

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iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si ng l e W ar ni n g

L o ad D at a B at t .D a t a H i s. R ec or d
V B a tt .( V ) 270
I B a tt .( A ) 143
T Ba t t. ( ℃ ) 2 5 .0
B a tt . Ch g . (% ) 100

B at t e r y C. B . Op en

F1 F2 F3 F4 H E LP

6. Manually close the battery circuit breaker.

The battery status indicator (3) should extinguish, and several LEDs on the battery
state of charge bar graph (17) will illuminate showing the battery state of charge.

When the battery circuit breaker has been closed and the inverter has stabilized the
screen will change to the default window.

5.4 Switching UPS Into A Maintenance Bypass Condition From

Normal Operation

The first part of this procedure details how to select the Inverter OFF and power the
load from the bypass mains via the static switch. This procedure should be followed
to transfer the load from the UPS inverter output to the maintenance bypass system.
This may be required during UPS maintenance procedures.

NORMAL OPERATION: Follow the procedure below to transfer the load from the
inverter output to the maintenance bypass of the UPS.

ECO MODE: Follow the procedure below to transfer the load from the output to the
maintenance bypass of the UPS.

Caution

The following window allows the operator to select the UPS inverter ON or OFF.
Before making this operation, read messages on display to be sure that bypass supply is
regular and the inverter is synchronous with it, not be risk a short interruption in powering the
load.
IF YOU ARE NOT SURE OF WHAT YOU ARE DOING - THEN DO NOT DO IT.

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50 Chapter 5 Operating Instructions

1. Press the INV switch (7) on the left side of the operator control panel.

2. Confirm this operation as instructed at the display:

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 3 1 _0 4 0 0 Single N o r ma l

L oad Data B a t t .D a t a H i s . R e c or d
V Batt.( V) 27 0
I Ba tt.(A ) 14 3
T B a t t. ( ℃ ) Warning!Inv. Off 2 5 .0
Batt. Chg.(%) "Esc"Canel," "Enter 10 0

N o r m al

F1 F2 F3 F4 H E LP

Press Enter for 1 second to confirm INV OFF, Press ESC to exit.

3. If Enter is pressed:

The load on inverter status indicator (5) will extinguish and the load on bypass
status indicator (6 - amber) will flash, and also the red alarm indicator (3) will flash,
normally accompanied by an audible alarm.

Pressing the alarm silence switch cancels the audible alarm but leaves the alarm
message displayed until the appropriate condition is rectified.

NORMAL OPERATION:

4.a The UPS inverter will now shut down and the load will transfer to the Bypass
supply.

The load on bypass indicator (6 - amber) will flash, and the load on inverter
indicator (5) will extinguish.
Your load is now powered via the static bypass system

ECO MODE:

4.b At this point the UPS inverter stops but the load continues to be supplied by
the bypass mains.

The load on bypass indicator (6 – yellow) flashes, and the load on inverter indicator
(5) goes off.

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Your load is now powered via the static bypass system

5. Unfasten the lock, release the internal safety bar and close the maintenance
bypass power switch Q3. Open the rectifier input power switch Q1, the output
power switch Q4, the bypass power switch Q2 and the battery circuit breaker. This
is located inside the battery cabinet (if used) or is otherwise located adjacent to the
battery racks. The unit will power down but the load will continue to be supplied by
the manual maintenance bypass.

WARNING

WARNING: Wait 5 minutes for the internal DC busbar capacitors to discharge.

WARNING

The following points will be live within the UPS:

Bypass AC input supply terminals and busbars

Maintenance bypass power switch

Static bypass power switch
UPS output terminals and busbars
Input and output terminals remain protected by a metallic cover.

Your load is now powered from the maintenance bypass system

and the UPS is completely shut down.

5.5 Procedure For Completely Powering Down A UPS

This procedure should be followed to completely power down the UPS and load. All
power switches, isolators and circuit breakers will be opened and there will be no
load power.

Caution

The following procedure will switch off all power to the load equipment.

1. Open the battery circuit breaker and the rectifier input power switch Q1.

The load on inverter indicator (5) will extinguish, the load on bypass indicator (6)
and the battery status indicator (3) will flash, and the battery bar graph LEDs will all
extinguish. The display window will show messages reflecting the actions taken (i.e.
Load on Bypass, Battery C.B. Open, Rectifier Switch open, etc.).

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iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

Lo a d On B yp a s s
B a t te ry C . B. O p en
R e c t if ie r S wi t c h O p e n

F1 F2 F3 F4 H E LP

Note: In ECO mode the messages “LOAD ON BYPASS” will not appear.

2. Open the output power switch Q4 and the bypass power switch Q2.

All LED indications and messages will extinguish as the mains driven internal
power supplies decay.

3. To completely isolate the UPS from the AC supplies, the mains external power
input isolator (both isolators, where separate supplies are provided for rectifier and
bypass) should be opened.

On the primary input distribution panel, which is often located distant from the UPS
area, a label should be posted advising service personnel that the UPS circuit is
under maintenance.

WARNING

Wait 5 minutes for the internal DC busbar capacitors to discharge.

The UPS is now completely powered down.

IMPORTANT

The maintenance bypass power switch may be operated at any time when the UPS is powered
down to connect the load to the maintenance bypass supply if required.
The load equipment is not protected from normal supply aberrations when operating in the
maintenance bypass mode.

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 Chapter 5 Operating Instructions 53

5.6 RESET Procedure

Once all appropriate measures have been taken to correct the problem indicated by
the alarm message appearing on the operator control panel display, carry out this
procedure to restore the UPS to regular operation following an emergency power
off or a shutdown of automatic switching.

Automatic switching may be shut down for the following reasons: the emergency
power off button is pressed, inverter overtemperature, cut-off overload, battery over
voltage, excessive switching (BYP: XFET DOUNT BLOCK), etc.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

Em e r g en c y S t o p
L oa d O n B y p as s
I n v : U n s yn c h r on i z e d

F1 F2 F3 F4 H E LP

1. Press the “ ” key to move the cursor to “Function”.

2. Press the “ ” key, a prompt “Password” will appear. Use the “ ” and “ ” keys
to enter the 8-digit password, and press “ ” to confirm.

3. Press the “ ” key to select “Reset Buffers”, press the “ ” key to confirm.

4. Press the “ ” key to select “Reset Alarms”, press the “ ” key to confirm.

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iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 3 1 _0 4 0 0 Si ng le Wa r ni ng

Op .R ec o rd F un c ti on Maintain
R es e t Bu ff e rs
-- - -- -- - -- -- - -- -- -
R es et Al ar m H is t or y
R es et Ev en t H is t or y
R es et Al ar m s

E m er ge n cy S t op
L oa d O n B yp as s
I nv : U ns yn c hr on i ze d

ES C ?

F1 F2 F3 F4 H E LP

These operations reset the logic circuitry to enable the rectifier, inverter and static
switch to operate normally.

Note: When the remote EPO switch has been activated it is necessary to manually
close the battery circuit breaker.

WARNING

When the EPO system incorporates a trip facility of the external AC input power supply circuit
breaker, the RESET switch would have no affect on it. First close the external AC input supply
circuit breaker, the UPS can be started in the normal manner, as the logic circuits will
automatically reset on return of the power supplies.

5.7 Adding A Single Module To An Existing System

This procedure should be carried out only by trained service personnel.

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5.8 Completely Switching ON/OFF The UPS At The UPS Display

Control Panel

1. Select the “Function” menu in the menu window, and press “ ” key, a prompt
“Password” will appear.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 3 1 _0 4 0 0 Single N o r ma l

Op.R ecord Fu nctio n M a i n t ai n

B at t. T e s t
Ge n e r a t or
Password
P a n e l S e tu p 00000000
C o m 1 Pr o t o c o l Se t u p
C om 2 P r o t o c o l S e t u p
O n / Of f U P S C o n t r o l

Norm al

ES C ?

F1 F2 F3 F4 H E LP

Use the “ ” and “ ” keys to enter the 8-digit password (press the “ ” key
repeatedly until the first digit displays the character required, then press the “ ”
key to move on to the second digit, this action is repeated for all eight digits). When
the password has been completed press the “ ” key.

Caution

This operation gives the operator access to modify UPS’s operating mode, it is advised that
only trained qualified personnel should attempt to do that.

3. You now have access to all function windows.

4. Press the “ ” key to select the “On/Off UPS Control”, press the “ ” key to
confirm.

Caution

The following window allows the operator to select the UPS inverter ON or OFF, select the
rectifier ON or OFF, select the rectifier to manual or automatic and to switch OFF the line
(bypass) to the load.
IF YOU ARE NOT SURE OF WHAT YOU ARE DOING – THEN DO NOT DO IT.

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NORMAL OPERATION:

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31 _ 0 40 0 Single No r m a l

Op . R e co r d F u n c ti o n M a i n t ai n
O n / Of f U P S C o n t ro l
--- ----- ----- -----
In verte r On
B ypass Of f
R e c t if i e r On
Recti fier A u to

N o rm a l

ESC ?

F1 F2 F3 F4 H E LP

5. a Select INVERTER, press “ ”.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31 _ 0 40 0 Single No r m a l

Op . R e co r d F u n c ti o n M a i n t ai n
O n / Of f U P S C o n t ro l
--- ----- ----- -----
In verte r
On
B ypass
Of f
R e c t if i e r
On
Recti fier A u to

N o rm a l

ESC ?

F1 F2 F3 F4 H E LP

The OFF selection will be highlighted. Using the “ ” or “ ” key, rotate between
the selections offered (in this case it will be ON or OFF), select ON, press the “ ”
key to execute your order.

After approximately 20 seconds the load on inverter indicator (5 – steady green) will
illuminate, and the load on bypass indicator (6) will extinguish.

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The UPS is operating normally with its inverter supplying the load.

ECO MODE:

5.b Select BYPASS, and press “ ”.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31 _ 0 40 0 ECO No r m a l

Op . R e co r d F u n c ti o n M a i n t ai n
O n / Of f U P S C o n t ro l
--- ----- ----- -----
In verte r
On
B ypass
Of f
R e c t if i e r
On
Recti fier A u to

N o rm a l

ESC ?

F1 F2 F3 F4 H E LP

The OFF selection will be highlighted. Using the “ ” or “ ” key, rotate between
the selections offered (in this case it will be ON or OFF), select ON, press the “ ”
key to execute your order.

The load on bypass indicator (6) will illuminate, and the load on inverter indicator (5)
will extinguish.
The UPS is operating in ECO mode with the bypass mains
supplying the load.

5.9 Procedure To Switch ON/OFF The Inverter At UPS Display

Control Panel

Caution

This operation gives the operator access to modify UPS’S operating mode, it is advised that
only trained qualified personnel should attempt to do that.

1. Press the INV switch on the left side of the operator control panel.

2. Confirm this operation as instructed at the display:

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58 Chapter 5 Operating Instructions

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 3 1 _0 4 0 0 Single N o r ma l

L oad Data B a t t .D a t a H i s . R e c or d
V Batt.( V) 27 0
I Ba tt.(A ) 14 3
T B a t t. ( ℃ ) Warning!Inv. Off 2 5 .0
Batt. Chg.(%) "Esc"Canel," "Enter 10 0

N o r m al

F1 F2 F3 F4 H E LP

Press “ ” to confirm INV OFF, press ESC to exit.

3. If “ ” is pressed:

The load on inverter indicator (5) will extinguish and the load on bypass indicator (6
- amber) will flash, and also the alarm indicator (3) will flash and normally will
accompanied by an audible alarm.

Pressing the alarm silence switch “ ” cancels the audible alarm but leaves the
alarm message displayed until the appropriate condition is rectified.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le W ar n i n g

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

I n v : O f f Vi a D is p la y
L oa d O n B y p as s

F1 F2 F3 F4 H E LP

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 Chapter 5 Operating Instructions 59

Note: In ECO mode the message “LOAD ON BYPASS” will not appear.

4. Press the INV switch on the operator control panel to start up the inverter.

NORMAL OPERATION: After 20 seconds the load on inverter indicator (5 – steady

green) will illuminate and the load on bypass indicator (6) will extinguish.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 Si n g le N o r ma l

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

N o r a ml

F1 F2 F3 F4 H E LP

ECO MODE: The load on bypass indicator (6) will illuminate and the load on
inverter indicator (5) will extinguish. In ECO mode, the default screen is displayed
as shown in the following figure, and the load is supplied by the bypass mains.

iT ru s t 2 0 0 4 -0 1 -0 1 1 2 :3 0 :3 6
U L 31_0400 EC O N o r ma l

O u tp u t D at a Load Data B a tt . D ata

V o ut ( V ) 220
F I nv . ( H z) 5 0 .0
F B y p . (H z ) 5 0 .0
V b p (V ) 220

N o r a ml

F1 F2 F3 F4 H E LP

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60 Chapter 5 Operating Instructions

5.10 Setting The Battery Test

A software-controlled battery test facility can be initiated from the operator control
panel on an immediate or periodic basis. This test turns off the rectifier and runs the
inverter (and load) from the battery for a predetermined period. If the battery
voltage falls below a preset minimum level prior to the termination of the test period
a “BATTERY: TEST FAILED” alarm is annunciated and the rectifier is immediately
turned on to prevent the load transferring to bypass – and recharge the battery. The
instructions given below initiate an immediate battery test.

For the following test to be meaningful as part of the UPS commissioning

procedure, the batteries should be fully charged prior to the test being carried out.
The UPS rectifier section must therefore be allowed to operate with the battery
connected for several hours to provide the battery with an adequate initial charge.

Caution

Do not continue with this procedure if the battery has not yet been charged.

1. Select the “Function” menu in the menu window, press “ ”.

2. When the password has been completed press the “ ” key.

3. Select “BATTERY TEST”, press the “ ” key.

4. Verify that the parameters entered in the battery test setup menu are appropriate.
If not then enter the correct setup parameters.

5. Select “Now”, use the “ ” and “ ” keys to select “Y” (Yes), press the “ ” key
to initiate an immediate battery test.

6. Verify that the message “BATTERY UNDER TEST” is displayed in the current
record window. The green LED battery bar graph will indicate the remaining battery
autonomy time. Note: If the UPS is allowed to run in this condition the battery bar
graph LEDs will progressively turn off indicating the remaining autonomy time.

7. The battery will be tested for the selected “Batt. Test Duration (min)” time after
which the UPS will revert to normal operation. Note: If the battery fails the test, the
rectifier will immediately return to the float mode and the “BATTERY: TEST
FAILED” alarm will be displayed in the current record window.

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 Chapter 5 Operating Instructions 61

5.11 Language Selection

Chinese and English are available for your selection. If required, select the
appropriate language using the following procedure:

1. Select Function from the menu window>>press “ ”>>enter password >>press

“ ”>> Panel Setup >> Language。

2. Select LANGUAGE and press “ ”.

3. Use the “ ” and “ ” keys to select the desired language.

4. Press “ ” to accept and store the language selection.

5.12 Changing The Current Date And Time

Note: Ensure the data entered during the following procedures are recorded in the
appropriate commissioning documentation.

1. Select “Maintain” in the menu window>>press “ ”>>enter the password

>>press “ ”>> Date&Time。

2. Position the cursor on the row on which the date-time is displayed, and press
“ ”.

3. Use the “ ” and “ ” keys to enter the current time and date information.

4. Press “ ” to save the settings.

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62 Chapter 6 Display Panel Interpretation

Chapter 6 Display Panel Interpretation

6.1 LED Interpretation

The LED item number refers to the details shown in Figure 4-1 and the LED
references that are identified there.

LED Normal
Interpretation-action
No. state
If this green LED is OFF it signifies a problem with the bypass input AC.
Check the following:
1) Bypass input power switch Q2 is closed.
1 ON 2) Input supply voltage is within 10% of nominal.
3) Power supply fuses are OK – the LED on the AC power supply board will extinguish if
either fuse is ruptured.
If the above checks prove unsatisfactory then seek qualified assistance.

If this LED is off, a problem exists in the input power supply or in a part of the rectifier. An
alarm message is visible at the display.
Check that:
1) The rectifier input isolator Q1 is closed.
2 ON 2) The input voltage is within the limits of normal operation.
3) The phase rotation of the mians input is correct.
4) Verify that condition leading to an emergency power off has not happened, in which case
a Reset mustbe carried out.
If these checks do not give a positive result, request qualified assistance.

If this yellow LED is ON it signifies that the battery is not available. This could be due either
to the battery circuit breaker being open or that the DC busbar voltage is below the figures
stated in (item b) above.
Check the following:
1) Check that the conditions for LED 2 are satisfied.
3 OFF
2) DC busbar voltage – if not above 178V then carry out checks as for LED 2 (mains
rectifier failure) above. If the DC busbar voltage is greater than 178V but you are unable to
close the battery circuit breaker then seek qualified assistance.
3) Battery circuit breaker is closed.
If the above checks prove unsatisfactory then seek qualified assistance.

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 Chapter 6 Display Panel Interpretation 63

LED Normal
Interpretation-action
No. state
If this green LED is OFF it signifies that the inverter is not producing its correct output
voltage.
Check the following:
1) If “OVERTEMPERATURE” or “OVERLOAD” alarm messages are active then (after
allowingthe UPS to cool/checking that the load current on the bypass line is not excessive)
use the procedure to carry out the reset (See Chapter 5)
2) Check that the conditions for LED2 are satisfied.
4 ON
3) Check that the inverter LED (8 - yellow) is OFF, otherwise follow inverter switch ON
procedure.
4) Check that no conditions exist which will prevent switching the INV ON (e.g. PC
command).
5) Verify that condition leading to an emergency power off has not happened, in which case
a Reset mustbe carried out.
If the above checks prove unsatisfactory then seek qualified assistance.

If this green LED is OFF, then it signifies that the load has been transferred to the static
bypass supply. If this is an automatic change over it will be accompanied by a fault warning
5 ON
on the display panel: take the appropriate actions for the display indication (see the table in
section 6.2).

This LED is mutually exclusive to LED 5. If this amber LED is ON, the load has been
transferred to the bypass mains supply. Verify the cause by following the alarm indications
6 OFF
at the LCD display panel. If the above checks prove unsatisfactory then seek qualified
assistance.

This red LED will flash on and off and indicates that the UPS has detected a fault, it will be
accompanied by a message on the display panel, take the required actions for the display
13 OFF panel message (see the table in section 6.2). This will be accompanied by an audible
alarm. Pressing the alarm silence switch cancels the audible alarm, but leaves the alarm
message displayed until the appropriate condition is rectified.

If this yellow LED is ON it signifies that the battery voltage is low and that the end of battery
16 OFF
discharge is near. This will be accompanied by an audible alarm.

This is a bargraph indicating the battery charge state and would normally have four or five
17 N/A of the LEDs ON. When the unit runs on battery, this bargraph changes to give an indication
of the remaining battery autonomy time.

18 N/A This is a bargraph indicating the % of the total load that is being applied to the system.

If this yellow LED is ON it signifies that the applied load has exceeded the maximum. It will
be accompanied by all five laod bargraph LEDs being ON (item 18), the alarm indication
19 OFF
flashing RED (item 13) and an OVERLOAD message on the visual display. This will be
accompanied by an audible alarm. Reduce the load immediately.

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64 Chapter 6 Display Panel Interpretation

6.2 Display Panel Messages

The messages displayed on the iTrust Industry UPS can be categorized into two
types: (a) Alarm messages, these are messages which need urgent attention and
warn of a UPS shutdown or imminent shutdown, the load would normally transfer to
the bypass supply if it is available. All alarm messages are accompanied by an
audible warning; (b) Warning messages, these are messages generated to warn or
confirm to the operator of actions taken (i.e. if the rectifier AC input supply power
switch was opened the warning message would read RECTIFIER.SWITCH OPEN).

The following table lists the various messages displayed on the operator panel
together with a description of their interpretation.
No. Alarm messages Interpretation
This alarm indicates that the UPS was shut down by means of the local or
remote(if fitted) emergency power off push button (EPO) which is normally
due to operator action – investigate why the emergency power off push
1 Emergency Stop button was pressed.
If the emergency power off push button was not pressed then check the
continuity of the circuit to the remote switch. Customer connections;
auxiliary terminal block X4; pins 5 and 6; normally closed.
The INV.: OFF alarm is active whenever the inverter is not producing its
correct output voltage; either because it has been switched OFF or due to
2 Inverter: Off
an internal fault, it will normally be accompanied by one or more of the
other inverter fault conditions.
Most of the inverter fault messages are self explanatory however the
Inv: Overvoltage
WAVEFORM ERR. Informs the operator that the output voltage peak has
Inv: Undervoltage
flattened caused by an internal inverter problem and therefore the output
3 Output: No voltage
will be out of limits.
Output:Waveform Error
The FREQUENCY ERROR message indicates an error in the output
Inv: Frequency Error
frequency of the inverter.
Over temperature is sensed by a normally-close thermostat fitted to each
inverter heat sink. If an over temperature condition arises, the audible
4 Inv: Overtemperature
alarm will accompany this message: the inverter stops and load transfers
to bypass after 3 minutes.
This message informs the operator that the inverter has been switched off
5 Overtemper. Shutdown and that the load has been transferred to bypass due to an inverter over
temperature.
The inverter overload alarm will annunciate as soon as the load exceeds
100% of the UPS rating. The load will eventually transfer to the bypass
6 Overload Present
mains supply if the overload condition is present for greater than a
predetermined time.
This message informs the operator that the load has transferred to bypass
7 Overload Shutdown
due to an inverter overload.
This is a status alarm. the output switch must be selected “CLOSED” at all
8 Output Switch Open
times except when operating on the maintenance bypass supply.
9 Bypass Switch Open This is a status alarm. the bypass input switch must be closed at all times.

iTrust Industry UPS Single Module And “1+1” (Redundancy) User Manual
 Chapter 6 Display Panel Interpretation 65

No. Alarm messages Interpretation

This is a status indication only. Note that if the UPS is operating with the
battery circuit breaker open and the mains power fails then the UPS output
10 Battery C.B. Open
will also fail together with load power, since the inverter has no battery
back-up.
This problem should be rectified as soon as possible. If the mains power
11 Battery: Fuse Fail fails then the UPS output will also fail together with load power, since the
inverter has no battery back-up.
The system has carried out a test of the battery. If this alarm is not
12 Battery: Test Failed accompanied by a [BATTERY C.B. OPEN] or [BATTERY: FUSE FAIL]
message then a full check of the battery back is required.
When the inverter is operating on the battery this message is displayed
13 DC Bus: Undervoltage when the battery voltage has fallen below a preset value. If the input AC
power cannot be restored you should shut down your load.
Battery discharge has continued beyond a preset value. The inverter will
14 Battery:End Discharge have shut down, the system will attempt a transfer to bypass: if there is no
bypass supply available, any loads still connected will be without power.
The RECT.: OFF alarm is active whenever the rectifier (battery charger) is
not producing its correct output voltage; this can be caused by, an
15 Rectifier: Off operator selection to off, an input supply failure, an open rectifier AC input
power switch or an internal fault which may be accompanied by one of the
fault conditions.
Rectifier Switch Open
Rect: Current Limit
Most of the rectifier fault messages are self explanatory however, the DC
Rectifier: Block
16 BUS: FAST OVER VOLTAGE and the DC BUS: SLOW OVERVOL
Rect: Fuse Fail
message informs the operator the DC busbar voltage is too high.
DC Bus:Slow Overvolt
DC Bus: Undervoltage
Byp: Absent
INPUT FAILURE: input AC supply failed or out of specified acceptable
Byp: Overvoltage
17 range. Do not switch OFF the inverter while this indication is active or the
Byp: Undervoltage
load will lose its power.
Byp: Frequency Error
One or more of the static switch SCRs has developed a fault. The bypass
18 Byp: SCR Failure would not support the load in the event of a UPS failure, immediate action
is required. Seek qualified assistance.
This message informs the operator that the input power lines have been
19 Main: Phase Rot.Error
cross-connected and the phases rotation is incorrect.
This is a status warning that the load is being powered through the
20 Manual Bypass Closed maintenance bypass line and is unprotected from mains supply
aberrations.
This warns that the inverter is not synchronized with the bypass supply,
which is normally due to a problem with the bypass supply being outside
21 Inv: Unsynchronized
an acceptable frequency window. Do not switch off the inverter when this
alarm is active or the load will experience a 200 msec power break.
This is a status warning that the battery is discharging. It normally
22 Battery: On Load
accompanies a [BYP: ABSENT] or [RECT: OFF] message.

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66 Chapter 6 Display Panel Interpretation

No. Alarm messages Interpretation

The micro monitors the battery percentage capacity while on charge and
the battery time remaining while on discharge. It calculates the time
23 BattAut. XXXX min remaining as function of the discharge current against the programmed
ampere hour capacity of the battery. It will update the time remaining as
the load is changed.
This message informs the operator that the system is carrying out a
24 Battery: Under Test
periodic battery test.
This message is only applicable to systems which include the boost
25 Boost: Time Expired charge option, boost time charge elapsed set value, battery should be
controlled by service personnel.
This is a status warning that the load is being powered through the static
bypass line and is unprotected from mains supply aberrations.
26 Load On Bypass
This action is either selected by the operator or a fault condition, check for
other fault messages.
Rectifier: Off This is a status message confirming that the rectifier has been selected off
27
Rect:Off Via Display by the operator from either the front panel display or an external PC.
Byp: Off This is a status message confirming that the bypass has been selected off
28
Byp: Off Via Display by the operator from either the front panel display or an external PC.
Inverter: Off This is a status message confirming that the inverter has been selected off
29
Inv: Off Via Display by the operator from either the front panel display or an external PC.
This message informs the operator that the load has been transferred to
the bypass more than eight times in one minute. After eight transfers the
30 Byp:Xfer Count Block
load will remain on bypass. This message could be initiated by a load
causing the UPS to overload, it requires investigation.
This message informs the operator that the battery is not longer isolated
31 Battery Ground Fault
from ground and there is a danger of electrocution.
This message informs the operator that failure of the bypass static devices
has resulted in voltage being fed back to the bypass supply input.
32 Backfeed Fault If the feature is used then check the circuit up to the remote switch.
Customer connections; auxiliary terminal block X4; pins 9 and 10; normally
open.

In addition to the above messages there are a number of software alarms (i.e.
“Error Lrc Par. Pag”, ” Mainboard Battery Low” etc.) that will require attention from a
qualified service engineer.

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 Chapter 7 Communication 67

Chapter 7 Communication

iTrust Industry UPS provides powerful communication function. The user can select
various communication interfaces to monitor the UPS according to the actual
needs.

The locations of the communication interfaces are shown in Figure 7-1, including
the RS232 ports, RS485 ports and dry contact alarm ports.

1. Monitor board

2. SNMP card slot

3. Dry contact alarm board

Input Bypass Output

isolator Q1 isolator Q2 isolator
Q4
Maintenance bypass
isolator Q3

Figure 7-1 Location of communication ports

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68 Chapter 7 Communication

7.1 RS232 Communication Ports

The monitor board provides two RS232 ports for monitoring of single UPS, as
shown in Figure 7-2. The RS232 ports are DB9 connectors (male), the pin
assignment and description of the RS232 ports are shown in Figure 7-3.

COM1
RS485辅接
RS485 port
COM1
COM2
Monitor board cover COM2
监电电监电 Monitor
监电电电监 PCB
电

COM1 COM2

RS232辅接
RS232 port

Figure 7-2 Location of communication ports on monitor board

NC 1
6 NC
RXD 2
7 NC
TXD 3
8 NC
NC 4
9 NC
信信信
GND 5

Pin 2: RECEIVE, to receive data from PC

Pin 3: TRANSMIT, to transmit data from UPS to PC
Pin 5: GND
Others: NC
Figure 7-3 Pin assignment and description of RS232 port

7.2 RS485 Communication Ports

The monitor board provides two pairs of RS 485 ports for monitoring of 1+1
redundancy parallel system, as shown in Figure 7-2. The RS485 ports are 3-pin
connectors, the pin assignment and description of the RS485 ports are show in
Figure 7-4.

TX+
TX-
GND

TX+: background communication RS485TX+

TX-: background communication RS485TX-
GND: communication ground
Figure 7-4 Pin assignment and description of RS485 port

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 Chapter 7 Communication 69

The following functions can be achieved over the single UPS and 1+1 redundancy
parallel system through the RS232 ports and RS485 ports respectively:

1) Monitoring of current UPS operating status;

2) Monitoring of current UPS alarm status;

3) Monitoring of current UPS operating parameters;

4) Timed turning-on and turning-off of the UPS, and system configuration.

The connection required for using RS485 ports for parallel system monitoring is
shown in Figure 9-3.

Note: RS232 COM 1 and the pair of RS485 COM 1 ports share the same serial port,
RS232 COM 2 and the pair of RS485 COM 2 ports share the same serial port, so
they can not be used at the same time.

7.3 AS400 Interface Signal Board (4590055P) Terminals

The AS400 interface signal board and output interface signal board (see section 7.4)
provides multiple groups of relay dry contact alarm signals for remote UPS control
and UPS status monitoring. The output interface signal board is fixed on the AS400
interface signal board at the location shown in Figure 7-1.

The terminal blocks on the AS400 interface signal board are described in Figure
7-5 (the dotted lines outline the output interface signal board).

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70 Chapter 7 Communication

1
空空空
Not Used 2 4590055P
3
Inverter电关关关（
off = apply
12V 信信） 4
12V
X5
5
发电发发发（
On generator 12V
= apply 信信）
12V 6

1
关关关逆电 2
Load on Inverter 3
4
维维维监维维
Load on Maintenance Bypass 5
6
7
自自维监逆电
Load on Bypass 8 X4
9
10
Low Battery (pre-alarm)
电电电电电电 11 4590056Q
12
13
Bypass Supply
维监发发
Failure 14
15

信信信
Common 1

整整关整整整整
Mains or Rectifier Failure 2

维维维监维电
Maintenance Bypass Open 3
X3
Low Battery (pre-alarm)
电电电电电电 4

Load on Bypass
自自维监逆电 5

Figure 7-5 Terminals of AS400 interface signal board

The three terminal blocks from the top down are described as follows:

1. X5: Control signal input

X5 provides two groups of control signal inputs for automatic control of the UPS.
Contact No. Signal name Description
Contact 1, 2 Not Used Not used.
12V signal, to remotely turn off the inverter to transfer the load
Contact 3, 4 Inverter off
to the bypass.
12V signal, indicating the generator is in normal operation.
After relevant function is configured from the operator panel,
Contact 5, 6 On Generator
this signal ensures that the generator will supply power to the
UPS rectifier after it steps into stable operation.

2. X4: alarm signal output

X4 provides 5 outputs of UPS operating status alarm signals to external equipment.

The relay contact rating is 50Vdc/1A.

Note: the low voltage power supply inside the UPS can not be used as the power
source of the external equipment, additional safe and reliable low voltage power
supply is required.

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 Chapter 7 Communication 71

Contact No. Signal name Description

When the load is on the inverer, contacts 2 and
Contact 1/2/3 Load on Inverter
3are closed.
Load on When the maintenance bypass is closed and the
Contact 4/5/6 Maintenance load is on the maintenance bypass, contacts 5 and
Bypass 6 are closed.
When the static bypass is closed, and the load is
Contact 7/8/9 Load on Bypass
on the static bypass, contacts 8 and 9 are closed.
When the battery low alarm is activated or the
Low Battery
Contact 10/11/12 battery circuit breaker trips, contacts 11 and 12 are
(pre-alarm)
closed.
Bypass Supply
Contact 13/14/15 Bypass supply abnormal or bypass switch open
Failure

3. X3: AS400 alarm signal

X3 provides 5 standard alarm signals to IBM AS400 computer. The relay contact
rating is 50Vdc/1A.
Contact No. Signal name Description
Contact 1 Common Providing low level signal.
Mains or Rectifier When the load is on bypass, if the rectifier stops,
Contact 2
Failure contact 2 will b econnectedc to contact 1.
Maintenance When the maint. bypass breaker opens, contact 2
Contact 3
Bypass Open will be connected to contact 1.
When the battery voltage falls below the battery
Low Battery
Contact 4 low alarm point during battery discharge, contact 2
(pre-alarm)
will be connected to contact 1.
When the load is transferred to the static bypass,
Contact 5 Load on Bypass
contact 5 will be connected to contact 1.

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72 Chapter 7 Communication

7.4 Output Interface Signal Board (4590056Q) Terminals

The output interface signal board is fixed on the AS400 interface signal board. Its
terminals are described in Figure 7-6.

1
2
通通通通Alarm
Common
3
4
5
关关关逆逆逆
Inverter Unsynchronized
6
7
X2 8
过过通通
Overtemperature
9
10
11
12
过过电电
Overload
13
14
15
电电逆电
Load on Battery

4590056Q
1
2 空空空
Not Used
3
4
5 Not
空空空 Used
6 4590055P
7 Rectifier Input Volts
8 主监主主电主电
Failure
9
X3
10
11 Bypass
维监旁旁 Static Switch
12 Blocked
13
14 风风通通
Fan Failure
15

Figure 7-6 Terminals of output interface signal board

The two terminals blocks from the top down are described as follows:

1. X2: alarm signal output

X2 provides 5 groups of UPS alarm signals to external equipment. The relay

contact rating is 50Vdc/1A.

Note: the low voltage power supply inside the UPS can not be used as the power
source of the external equipment, additional safe and reliable low voltage power
supply is required.

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 Chapter 7 Communication 73

Contact No. Signal name Description

Contacts 2 and 3 are closed when the following alarms
occur: static bypass breaker blocked, inverter
Contact 1/2/3 Common Alarm asynchronism, overheating, battery discharge, maint.
breaker closed, battery low/batery circuit breaker open,
bypass fault, overload.
Inverter When the inverter voltage does not synchronize with the
Contact 4/5/6
Unsynchronized bypass voltage, contacts 5 and 6 are closed.
When overheating alarm is activated, contacts 8 and 9
Contact 7/8/9 Overtemperature
are closed.
Contact When overload alarm is activated, contacts 11 and 12
Overload
10/11/12 are closed.
Contact When the load is on the battey, contacts 14 and 15 are
Load on Battery
13/14/15 closed

2. X3: alarm signal output

X3 provides 3 groups of UPS alarm signals to external equipment. The relay

contact rating is 50Vdc/1A.

Note: the low voltage power supply inside the UPS can not be used as the power
source of the external equipment, additional safe and reliable low voltage power
supply is required.
Contact No. Signal name Description
Contact 1/2/3 Not Used /
Contact 4/5/6 Not Used /
Rectifier Input When the rectifier input voltage is lower than 20% of the
Contact 7/8/9
Volts Failure rated voltage, contacs 8 and 9 are closed.
Contact Bypass Static When the bypass is blocked, contacts 11 and 12 are
10/11/12 Switch Blocked closed.
Contact When fan failure is detected, contacts 14 and 15 are
Fan Failure
13/14/15 closed.

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74 Chapter 8 Maintenance And Service

Chapter 8 Maintenance And Service

Operation of the iTrust Industry UPS in an environment within specification can

reduce repair and prolong the UPS life.

Safety

No risk exists to any personnel when operating the equipment in the normal manner, following
the recommended operating procedures.
All equipment maintenance and servicing procedures involve internal access and should be
carried out only by trained personnel.

Please read this manual carefully before maintaining or servicing the UPS.

The following basic maintenance and service works can be carried out by
personnel authorized by Emerson. When other maintenance or service works are
required, please contact the service personnel of Emerson.

8.1 Fan

The design life of the fan is 20000~40000 hours, but high ambient temperature will
shorten the fan life. Please regularly check that all fans run normally and air is
blown out from within the UPS.

8.2 Periodic Cleaning

1. Periodic cleaning of the system: check that the front, top and bottom ventilation
holes are not obstructed, air flows freely in the UPS, and clean the system with
vacuum cleaner when necessary.

2. Periodic cleaning of the dust mesh: normally, the dust mesh in the UPS should
be cleaned once every 3 months, and the cleaning period should be shorter in
dusty environment. The location and removing procedures of the dust mesh is
shown in Figure 8-1.

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 Chapter 8 Maintenance And Service 75

防尘网拆除方法：
Use 1．打开 UPS 前门
the following steps to remove the dust
mesh:
2．拧松防尘网上的不脱螺钉
Dust
防尘网 mesh 1. Open the UPS front door;
3．向侧面推动防尘网至合适位置
2. Unscrew the dust mesh;
4．从正面取下防尘网
防尘网的安装参照其拆除方法进行
3. Push the dust mesh sideward
appropriately;
安装。
4. Take off the dust mesh.
Refer to the removing steps to install it.

Figure 8-1 Location and removing procedures of the dust mesh

Note

Only trained personnel shall open the front door to clean the dust mesh.
Do not open the inner door of the UPS.

8.3 UPS Status Check

1. Check whether the UPS is faulty: Is the fault indicator on? Does any fault alarm
exist?

2. Check whether the UPS is operating in Bypass mode: Normally, the UPS
operates in Normal mode; if it is operating in Bypass mode, please find out the
reason, for instance: operator intervention, overload, inner fault, ECO mode, etc.

3. Check whether the battery is discharging: When the mains supply is normal, the
battery should not discharge; if the UPS is operating in Battery mode, please find
out the reason, for instance: mains failure, battery test, operator intervention, etc.

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76 Chapter 9 1+1 Redundancy Parallel System

Chapter 9 1+1 Redundancy Parallel System

9.1 General

Two UPS modules of the same power rating can be connected in parallel to make a
1+1 redundancy parallel system without the need for a centralized mains static
bypass. Instead the bypass static switches of each UPS share the load when the
system transfers to the mains bypass supply.

From a “power” viewpoint each module is internally identical to the “single module”
configuration. A 1+1 parallel system requires inverter and bypass supplies,
inter-module control signals to manage current sharing, synchronizing and bypass
switching between the module. In the figure 9-1 this is shown as the “inter-module
control bus”, which is facilitated through the use of multi-way ribbon cables
connected between the two units of the system.

For each module it is necessary to program the display panel with the correct
rating.

UPS1
Bypass Maintenance bypass isolator Q3
mains
supply
Bypass isolator Q2
DC bus Output
Input
isolator UPS
mains Rectifier Inverter Static switch
Q4 output
supply L
N
Input isolator Q1 PE

- X4
+
Battery 1
External UPS L
C.B. Parellel cable output isolator
open signal
N
Battery circuit breaker box 1 UPS2
Bypass Maintenance bypass isolator Q3 PE
mains
supply
Bypass isolator Q2
Input DC bus Output
mains isolator UPS
Rectifier Inverter Static switch output
supply Q4
L
N
Input isolator Q1 PE

+ - X4
Battery 2
External UPS
C.B. output isolator
open signal

Battery circuit breaker box 2

Figure 9-1 Block diagram of 1+1 redundancy parallel system with separate batteries

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 Chapter 9 1+1 Redundancy Parallel System 77

9.2 Installation Procedure

9.2.1 Preliminary Checks

Be sure that a parallel kit is present and fitted in each of the modules, and that the
modules are of the same rating and with the same software and hardware release.

WARNING
Fitting of the parallel kits and board setting required to convert from single module to 1+1
redundancy parallel system must be made by trained personnel.

9.2.2 Protective Devices

Refer to section 3.1.5.

9.2.3 Power Cables

For power cabling the installation is the same for each module as described in
Chapter 3.

9.2.4 Control Cables

Inter-module control

Modules are interconnected as shown in Figure 9-2 via parallel connector board
with shielded 34-way cables.

These cables are connected between the two modules to pass control signals
which govern module synchronization, load sharing, battery charge current sharing
(in a common battery installation), load transfer operation and other general control
and alarm functions. These signals are necessary to ensure correct system
operation.

Cables entry is as identified in the mechanical drawings in Chapter 2.

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78 Chapter 9 1+1 Redundancy Parallel System

UPS UPS
module
1 1 UPS module
UPS 22
To辅接发
parallel
PCBPCB
电 To 辅接发
parallel
PCBPCB
电

X3 X3
Parallel connect. Parallel connect.
接发电
board 接发电
board

X1 X1

X2 X2

Figure 9-2 Connection of parallel signal bus cables of 1+1 redundancy parallel
system

RS485辅接
1 RS485 port RS485辅接
1 RS485 port
2 2
3 3
监电电电监电
4 Monitor PCB 监电电电监电
4 Monitor PCB

1 2 3 1 2 3

RS232辅接
RS232 port RS232辅接
RS232 port
External
外外监电外外 monitoring equipment

Figure 9-3 Connection of communication bus of 1+1 redundancy parallel system

9.2.5 Emergency Power Off (EPO)

The external emergency power off facility is identical to that described for the single
module installation – that an individual emergency power off button is provided for
each module.

Auxiliary terminal block

Auxiliary terminal block

Module 1

Module 2

EPO push button

Figure 9-4 Connection of EPO push button

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 Chapter 9 1+1 Redundancy Parallel System 79

9.3 Operating Instruction

Starting and stopping the 1+1 redundancy parallel system is the same as a single
module, however the module response depends on whether it is configured on the
menu of the operator control panel.

WARNING
If differential circuit breakers are used on UPS unit inputs, use a common device only on the
system’s bypass mains. At the instant of electrical connection, the current may not be split
instantaneously and this may cause the residual current circuit-breakers to trip separately.

These operations must be performed one at a time, progressing to the next step
only after having completed the previous step on both UPS modules.

1. System start-up

This procedure should be followed when turning on the UPS from a fully powered
down condition – i.e. where the load is not being initially supplied at all. It is
assumed that the installation is complete, the system has been commissioned by
authorized personnel and the external power isolators are closed.

1) Open the UPS door to gain access to the power switches.

WARNING
THE FOLLOWING ACTION WILL APPLY POWER TO THE LOAD EQUIPMENT – ENSURE
THAT IT IS SAFE TO DO SO.

2) Close the bypass power switch Q2.

The UPS LCD and LED status during start-up is the same as a single module. The
bypass supply indicator (1 – steady green) will illuminate, the battery status
indicator (3) and load on bypass indicator (6 - amber) will flash, and the LCD will
display the start screen.

3) Close the rectifier input power switch Q1 and UPS output power switch Q4.

After approximately 20 seconds, the load on inverter indicator (5 – steady green)

will illuminate and the load on bypass indicator (6) will extinguish.

4) Before closing the battery circuit breaker check if the DC busbar voltage is
satisfactory: select “Batt. Data” in the menu window, the DC busbar voltage will be
displayed in the data window.

5) Manually close the battery circuit breaker.

The battery status indicator (3) should extinguish. Several LEDs on the battery
state of charger bar graph (17) will illuminate showing the battery state of charge.

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80 Chapter 9 1+1 Redundancy Parallel System

When the battery circuit breaker has been closed and the inverter has stabilized the
screen will change to the default window.

6) Follow the foregoing procedure for the other UPS.

The UPS started later will transfer to Normal state automatically and constitute a
1+1 redundancy parallel system along with the UPS started earlier.

2. Switching the system to maintenance bypass from normal operation.

Follow the procedure for the single UPS by referring to section 5.4.

For a system configured in the “1+1 redundancy parallel system”, the changeover
from “load on inverter” to “load on bypass” will occur only when the operation
described in point 3 has been completed on both UPS modules.

3. Switching the system ON from a maintenance power down condition.

Follow the procedure for the single UPS, referring to section 5.2.

4. Switching off and isolating one UPS while the other remains in service.

1) In sequence, open the UPS isolators Q4 (output), Q1 (rectifier input) and Q2

(bypass input).

2) Open the circuit breaker inside the battery cabinet.

To completely isolate the UPS, open the AC power supply circuit breaker (both
circuit breakers if separate supplies are provided for the rectifier and the bypass
supply) and the output circuit breaker on the power distribution switchboard. If
individual UPS output isolation circuit breaker (and its auxiliary contacts) are not
installed on the power distribution switchboard, remember that voltage supplied by
the other UPS which remains in service will still be present on the output terminals
of the shutdown UPS.

WARNING

If individual UPS output isolation circuit breaker are not installed on the power distribution
switchobard, remember that voltage supplied by the others UPS which remains in service will
still be present on the output terminals of the shutdown UPS.
WARNING: Wait 5 minutes for the internal DC busbar capacitors to discharge.

5. Switching on a UPS that was previously switched off and isolated from the
system.

1) Close the circuit breakers relative to the shutdown UPS that were previously
opened on the power distribution switchboard.

2) Close the switches Q1 (rectifier input) and Q2 (bypass input) of the UPS.

3) Check that the battery voltage level has reached the rated value from the menu
window and data window on the LCD display.

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 Chapter 9 1+1 Redundancy Parallel System 81

4) Close the battery circuit breaker.

5) Close the UPS switch Q4 (output), wait about 20 seconds and check that the
message NORMAL OPERATION appears on the LCD display.

6. Complete system shutdown

Follow the procedure described in section 5.6 by working on both UPS modules.

7. Complete system reset

Follow the procedure described in section 5.7 by working on both UPS modules.

9.4 Display Panel Message Interpretation

The alarms are the same as the single module, as given in section 6.2, with the
following additional alarms:
No. Alarm messages Interpretation
The parallel board has detected a wrong sharing of
44 INV.: PARALLEL ERROR the loadand has blocked its inverter. Seek qualified
assistance.
The number of active inverters is below the preset
46 NR. INVERTERS NOT OK
capacity value.

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82 Chapter 10 Specifications

Chapter 10 Specifications

The chapter provides the specification of the iTrust Industry series of UPS.

10.1 Conformity And Standard

The UPS has been designed to conform to the following standard:

Description Year Normative references
Safety requirements 1997 EN 50091-1-1
Conduction 1995 EN 50091-2 CLASS A
Emission 1995 EN 50091-2 CLASS A *
Design and test methods 1998 EN50091-3

10.2 UPS Environmental

The UPS shall be able to operate under the following environmental conditions
without damage or degradation in electrical operating characteristics:
Units
Rated power kVA 30 40 60 80
Operating
°C 0 to 40
temperature
Relative humidity - 95% at 20°C
1500m asl
Altitude of operation
(de-rate power by 1% per 100m between 1500 and 3000m)
Storage/transport
°C -40 to 70
temperature

10.3 UPS Mechanical Characteristics

Units
Rated
kVA 30 40 60 80
power
Height mm 1900
Width mm 900 900 1250 1250
Depth mm 875
Weight kg 750 850 1150 1350
Ventilation - By internal fans
Airflow m3/h 1500 2000 2600 2600
Cable entry - Bottom or either side (top optional)

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10.4 UPS Electrical Characteristics (Input Rectifier)

Units
Rated power kVA 30 40 60 80
Rated mains voltage Vac 380
Supply Three phase without neutral
①
Input voltage tolerance % -15% to +20%

Frequency Hz 50
Input frequency tolerance % !10

Rated input power② KVA 36 47 70 93

Rated input current② A 55 71 106 141

Maximal input power③ KVA 44 57 86 113

Maximal input current③ A 67 86 130 171

Duration of progressive power walk-in④ sec 2 to 10

Note:

① Recommended battery cell number, -15% of input voltage, rated load, rated
output voltage, no battery discharging.

② EN50091-3(1.2.39):UPS, rated load, input rated voltage 380V, rated bus voltage,
no current to battery.

③ EN50091-3(1.4.40):UPS, rated load, input rated voltage 380V, battery on boost

charge with maximal allowed current.

④ Set with jumper on rectifier control board.

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10.5 UPS Electrical Characteristics (DC Intermediate Circuit)

Units
Rated power kVA 30 40 60 80
Voltage range for inverter operation Vdc 187~290
Bus voltage in Block mode Vdc 290
①-②
Recommended number of lead-acid cells CELL 108

Recommended float charge voltage 2.25V/el.① Vdc 243

Recommended boost charge voltage 2.40V/el.① Vdc 259

Recommended end of discharge voltage

Vdc 189
1.75V/el.①

Maximum voltage on manual charge 2.45V/el.① Vdc 264

Characteristics to DIN 41772 I-U, boost to floating

Battery boost charge cycle③ － charge switching, with current measuring criterion
plus control of charging time.

Maximum boost charge duration③ hour 1~15

Boost-float threshold current③ A 1

Ripple voltage superimposed④ % 2

Note:

① (According to rated voltage)

② Factory set for Block mode, different cells number and voltage per cell in direct
mode may be set by software and/or trimmers on rectifier control board.

③ Set by software

④ Battery disconnected, RMS percentage value referred to DC voltage.

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10.6 UPS Electrical Characteristics (Inverter Output)

Units
Rated power kVA 30 40 60 80
①
Rated mains voltage Vac 220
Supply L-N
②
Frequency Hz 50
Rated power at cos∮=0.8 kVA 30 40 60 80
Rated power at cos∮=1 kW 24 32 48 64
60, 1.1
min
Overload③ 10, 1.25
I/In
1, 1.5
Maximal non linear load allowed④ 100%Pn

Voltage stability, steady state test⑤ % ±1

Voltage stability, transient test⑥ % ±5

Maximum rate of change of
Hz/sec 0.1
frequency⑦

Note:

① Factory set 400V, 380V or 415 voltages with software setting.

② Factory set at 50Hz; 60Hz with software setting.

③ EN50091-3(1.4.50).

④ EN50091-3(1.4.58) crest factor 3.

⑤ EN50091-3(4.3.4).

⑥ EN50091-3(4.3.7) also for 0~100~0%, load transient, store time 20ms to ±1%.

⑦ Factory set at 0.5Hz/sec; up to 1 Hz/sec with software setting.

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10.7 UPS Electrical Characteristics (Bypass Input Mains)

Units
Rated power kVA 30 40 60 80
①
Rated mains voltage Vac 220
Supply L-N
Rated current (220 Vac) A 136 182 272 364
②
Bypass voltage tolerance % !15
Delay time to recognise bypass
sec 15
voltage returned to window
Frequency③ Hz 50

Input frequency tolerance④ % !10

Maximum frequency slew rate Hz/sec 2
To avoid series fuses, the bypass line should be protected using
Protection, bypass line an external device in the input distribution system. This device
should be sized to discriminate with the load protection.

ms 10 20 50 100 200 500 1000 2000 5000

Transient overload
I/In 14.3 12.6 11.0 10.0 9.0 8.0 7.1 6.8 5

Note:

① Factory set at 220V.

② Other values 1~15% with software setting.

③ Factory set at 50Hz.

④ Other values 0~10% with software setting.

10.8 UPS Electrical Characteristics (System Performance)

Unit

Rated power kVA 30 40 60 80

No load losses kW 1.8 2.0 2.1 2.4

Full load losses (100%) kW 4.93 5.9 6.0 6.1

10.9 UPS Electrical Characteristics (ECO Mode)

Units
Rated power kVA 30 40 60 80
Full load losses
kW 0.3 0.4 0.6 0.8
(100%)

iTrust Industry UPS Single Module And “1+1” (Redundancy) User Manual