UPS OPERATING INSTRUCTIONS PROTECT 1. PROTECT 1.100 PROTECT 1.150 PROTECT 1.
Thank you for deciding to purchase the PROTECT 1. UPS from AEG Power Solutions. The following safety instructions are an important part of the operating instructions are will protect you against problems from operating errors and possible dangers.
1 Notes on these Operating Instructions Duty to provide information These operating instructions will help you to install and operate the Uninterruptible Power Supply (UPS), PROTECT 1.100, PROTECT 1.150 or PROTECT 1.200 as well as the corresponding external battery units PROTECT 1.100 BP or PROTECT 1.BP20, all referred to as PROTECT 1 in the following, safely and correctly. These operating instructions contain important information for avoiding dangers.
liability for consequential damage. AEG will rescind all obligations such as warranty agreements, service contracts, etc. entered into by AEG or its representatives without prior notice in the event of maintenance and repair work being carried out with anything other than original AEG parts or spare parts purchased from AEG. Handling PROTECT 1. is designed and constructed so that all necessary steps for start-up and operation can be performed without any internal manipulation of the unit.
Table of Contents 1 2 Notes on these Operating Instructions .............................3 General Information ..........................................................7 2.1 Technology ................................................................7 2.2 System Description....................................................8 2.3 Technical Data.........................................................11 3 Safety Regulations ..........................................................15 3.
Start-Up...........................................................................37 6.1 Operating Modes .....................................................38 6.1.1 Normal Operation...............................................38 6.1.2 Battery Operation / Autonomous Operation.......39 6.1.3 Bypass Operation ..............................................40 6.1.4 Manual Bypass ..................................................41 6.1.5 Unit overload ......................................................
2 General Information 2.1 Technology i PROTECT 1. is an Uninterruptible Power Supply (UPS) for essential loads such as small data centres, servers, network components, telecommunications equipment and similar units.
2.2 System Description The UPS is connected between the public utility mains and the loads to be protected. The power section of the rectifier converts the mains voltage to DC voltage for supplying the inverter. The circuit technology used (PFC) enables sinusoidal current consumption and therefore operation with little system disturbance.
IGBT power semiconductors of the inverter, a voltage system of the highest quality and availability on the secured busbar. In the event of mains faults (such as e.g. current failures), the voltage continues to be supplied from the inverter to the load without any interruption. From this point onwards, the inverter draws its power from the battery instead of the rectifier. Since no switching operations are necessary, there is no interruption in the supply to the load.
Parallel system with PROTECT 1.150 Number of UPS units Available power Active redundancy degree 1 2 3 0 15 kVA 30 kVA 45 kVA 1 --- 15 kVA 30 kVA 2 --- --- 15 kVA Parallel system with PROTECT 1.
2.3 Technical Data Type rating PROTECT 1.100 10000 VA (cos ϕ = 0.7 ind.) 7000 W PROTECT 1.150 15000 VA (cos ϕ = 0.7 ind.) 10500 W PROTECT 1.200 20000 VA (cos ϕ = 0.7 ind.) 14000 W UPS input 3ph~ / N / PE Rated connection voltage Voltage range without battery operation 400 V/ 230 VAC 304 VAC – 478 VAC ± 3 % (rectifier) 176 VAC – 261 VAC VAC ± 3 % (bypass) Frequency 50 Hz / 60 Hz (autom. detection) Frequency tolerance range ± 4 Hz Current consumption at full load (max.) PROTECT 1.
Overload behaviour with mains supply Overload behaviour with battery operation Short-circuit behaviour Up to 105% continuous; > 105% – < 130% for 10 min. 130% for 1 s Following this, automatic, uninterrupted switchover to integrated bypass (SBS). Switch-off after 1 min if overload continues to be present. (Switch back if overload decreases = load < 90%) Up to 105% continuous; > 105% for 10 s 2.
Communication Interfaces Shutdown software on CD RS232 Sub-D (9-pin) Additionally: Communication slot for expansions (e.g. AS/400 / USB / remote signal indicator / SNMP, …) “CompuWatch” for all common operating systems, e.g. Windows, Linux, Mac, Unix, FreeBSD, Novell, Sun General data Classification Full load efficiency ( AC-AC / DC-AC ) Inherent noise (1m distance) PROTECT 1.100 PROTECT 1.150 PROTECT 1.
Housing colour: Weight: PROTECT 1. 100 PROTECT 1. 150 PROTECT 1. 200 PROTECT 1. 100 BP PROTECT 1. BP20 Dimensions W x H x D: PROTECT 1.100/1.150/1.200 PROTECT 1.100 BP PROTECT 1. BP 20 Blackline 39 kg 55 kg 55 kg 135 kg 170 kg 260 mm x 717 mm x 670 mm 260 mm x 717 mm x 670 mm 260 mm x 717 mm x 810 mm Directives The PROTECT 1. meets the product standard EN 50091.
3 Safety Regulations 3.1 Important Instructions and Explanations The instructions for operation and maintenance, as well as the following safety regulations must be complied with to ensure the safety of personnel as well as the continued availability of the unit. All personnel installing/dismantling, starting up, operating or servicing the units must be familiar with and observe these safety regulations.
♦ Verify that the unit is disconnected from the power supply ♦ Earth and short-circuit the unit ♦ Provide protection by covers or barriers for any neighbouring live parts 3.3 Qualified Personnel The PROTECT 1. may only be transported, installed, connected and serviced by qualified personnel who are familiar with the pertinent safety and installation regulations. All work performed must be inspected by responsible expert personnel.
For health and safety reasons, the unit must be earthed correctly! The PROTECT 1. may only be operated with or connected to a three-phase power system with protective grounding using a mains connection cable with PE conductor that has been tested according to German standards (VDE). Risk of burning! The battery has powerful short-circuit currents.
♦ Ensure that no fluids or foreign bodies can penetrate the housing! ♦ Do not block the air vents of the unit! Make sure, for example, that children do not insert any objects in the ventilation openings! ♦ Do not connect household appliances such as hairdryers to the UPS! Also take care when working with motor loads. It is essential to avoid back-feeding the inverter, e.g. if the load is intermittently operated in regenerative mode.
Therefore, take the following safety precautions when working with batteries: ♦ Take off watches, rings and other metallic objects! ♦ Only use tools with insulated handles! i Avoid using multiple outlet adapters with a central on/off switch as protection against uncontrolled load switch-off as well as for avoiding peak inrush currents. Switch OFF the UPS using its main switch if you do not intend to use it for some time. PROTECT 1.
3.
4 Set-up 4.1 Unpacking and Inspection The unit has been completely checked and inspected. Although the unit has been packed and shipped with the usual care, transport damage cannot be completely excluded. i Any claims due to transport damage must always be asserted against the transport company! Check the shipping container for damage on arrival.
Please keep plastic packaging bags away from babies and children in order to safeguard against suffocation accidents. Handle the components with care. Please take into account the weight. It may be necessary to engage the help of a second person. 4.2 Transport to Installation Site The PROTECT 1. is equipped with transport rolls for easy transport to the intended installation site.
4.3 Set-Up Note the following points when setting up the UPS system and its external battery units (special accessories): ♦ The contact surface must be smooth and level. It must also be sufficiently strong and sturdy to avoid vibration and shocks. ♦ Make sure that the mounting is able to support the weight, especially in conjunction with external battery units (special accessories). ♦ Set up the units so that adequate air circulation is assured.
4.4 Overview: Connections, Operating / Display Elements 4.4.1 Front view PROTECT 1.100 PROTECT 1.150 PROTECT 1.100BP PROTECT 1.BP20 24 PROTECT 1.
4.4.2 Display 12 11 10 9 8 7 3 6 4 5 2 1. 2. 3. 4. 5. 6. 7 – 11. 7. 8. 9. 10. 11. 12.
4.4.3 Rear view (connections): PROTECT 1.100 8 7 6 13 5 11 2 3 11 10 9 4 1.1 1.2 1.3 1 N L1 L2 L3 JP1 JP2 L N PROTECT 1.150 / 1.200 6 6 13 12 11 7 5 11 10 9 8 2 1 1.1 3 N L1 L2 L3 26 1.3 4 + - L N 1.
Explanations: 1. Connection terminal cover for mains/UPS input (1.1) and output (1.3), additional pair of terminals for setting individual or parallel operation (1.2); Battery connection terminals (PROTECT 1.150 / 1.200) 2. Mains input miniature circuit breaker 3. Manual bypass switch 4. Socket for external battery module (PROTECT 1.100) or connection terminals for external battery (PROTECT 1.150/1.200) 5. Connectors for parallel operation 6.
5 Electrical Connection Caution Prior to commencing work, ensure that the connection cables are de-energised and that it is not possible to activate the power supply. i In order to avoid deformation of the supporting rail and to protect the base of the connection terminal against torsional forces, it is advisable to hold the cable in position when tightening the clamping screw. The protective measure of earth connection serves to prevent excessive touch voltage on freely accessible metal parts.
5.1 Safety of Personnel Note the following points when setting up the UPS system and its external battery units (special accessories): ♦ Disconnect the unit from the power supply ♦ Secure the unit against being switched back on ♦ Verify that the unit is disconnected from the power supply ♦ Earth and short-circuit the unit ♦ Provide protection by covers or barriers for any neighbouring live parts 5.
♦ Mechanically secure the cables with the strain relief clamps of the cable clamping unit. ♦ Mount the connection cover of the cable clamping unit. 5.3.1 Connection Cross-Sections and Fuse Protection The required dimensions can be found in the following table: Max. current consumption (bypass) PROTECT 1.100 PROTECT 1.150* PROTECT 1.200* 46A 68A 91A Incoming mains cable (UPS input) min. 10 mm² 16 mm² 25 mm² max. 16 mm² 35 mm² 35 mm² Load connection (UPS output) min.
Alternatively, the 10 kVA UPS system can also be connected via a multi-wire rubber-sheathed cable. 5.4 Mains Connection 5.4.1 Preparation for the three-phase mains connection Before connection work is performed on the UPS, make sure that: ♦ The values of the nominal voltage (supply) and frequency match those on the nameplate of the UPS.
♦ Place the “maintenance switch” manual bypass on the back of the UPS in the “bypass” position. To do this, first remove the 4 screws of the cover (no.3, p. 26/27). ♦ Put the mains input miniature circuit breaker (no. 2, p. 26/27) in the “OFF” position. Connect the UPS terminal “ / PE “ (earth) with the corresponding earth terminal in the distribution cabinet. Connect the supply cable from the MI distribution to the terminals 1.
5.4.4 Connection of the Loads In order to ensure the safety of personnel during installation work, make sure that the connections are made under the following conditions: ♦ No mains voltage present. ♦ The loads are switched off. ♦ UPS is switched off (display completely blank). To disconnect the PROTECT 1., carry out the following steps: ♦ Place the “maintenance switch” manual bypass on the back of the UPS in the “bypass” position. For this purpose, first remove the 4 screws of the cover (no. 3, p. 26/27).
5.5.1 Connection of the Battery Cubicle PROTECT 1.100 BP This battery cubicle is completely preconfigured. The connection to the UPS unit is ready to be plugged in as a result of the supplied battery connection cable. PROTECT 1.100 with 1 battery unit PROTECT 1.100 BP i PROTECT 1.100 BP is only intended for connection to the UPS type PROTECT 1.100. Connect further battery cubicles of identical design (!) to the second battery connection socket of the neighbouring battery cubicle.
5.5.2 Connection of the Battery Cubicle PROTECT 1. BP20 Fig.: Rear view of the PROTECT 1.BP20 with cover removed. The battery cubicle is supplied with a separate battery string and separately enclosed battery fuses for safety and transport protection reasons. Please also note the separate documentation enclosed with the battery cubicle. After the battery cubicle has been removed from the pallet, first remove the rear cover.
If the battery cubicle is used in connection with the PROTECT 1.1.50 or PROTECT 1.200, the strain relief is implemented with clamps. The battery system can now be activated. To do this, insert the two fuses . As the last step, fasten each cover that was initially removed. Fig.: PROTECT 1.BP20 in connection with the PROTECT 1.100 PROTECT 1.100 & 1.BP20: When connecting the battery connection cable, make sure that the plugs are inserted quickly and firmly in the battery connectors.
6 Start-Up Compare the setting of the nominal output voltage of the UPS with the rated voltage valid in your country. The factory presetting is 230 V. Changes to 220 VAC or 240 VAC can be made with the software “CompuWatch”. Switching on the PROTECT 1. on the mains 1. Make sure that all connections have been made according to the installation instructions. 2. Make sure that all loads are switched off. 3. Put the “maintenance switch” manual bypass switch (no. 3, p.
Please shut down the entire system again if you cannot solve a problem that occurs. To do this, press the OFF pushbutton for approx. 2 seconds. Disconnect the UPS from the mains by actuating the mains input miniature circuit breaker (no. 2, p. 26/27). Please contact our hotline (see p. 4). i 8. 6.1 When the displays are correctly lit as described, switch on your loads one after the other. When doing this, take care not to exceed the maximum permitted load capacity of the UPS.
continuously supplied with reliable and “clean” voltage with no interruptions in this operating mode. The bar graph LED (LED chain above the pictograph) indicates the current capacity utilisation of the UPS in this operating mode (see chapter 8, p. 45). 6.1.
The inverter is switched off if the battery voltage drops below a factory-set minimum voltage value. Never store the unit in this condition! The discharged battery system should be recharged within a week at the latest. When the voltage and frequency are within the tolerance range again after the mains is restored, the rectifiers switch back on automatically. The supply of the inverter through the mains is resumed and the battery charger charges the battery.
This so-called passive redundancy protects against the total failure of the voltage supply on the secured busbar; however, in this operating mode, mains faults would directly affect the load. As a result, the electronics continuously attempt to switch back to "online" / normal operating mode (e.g. when the overload or overtemperature goes away). The bypass consists of an inverse-parallel thyristor stack and functions as an extremely rapidly switching link between a load and the mains.
The manual bypass enables maintenance and service personnel to perform work on the PROTECT 1. without having to switch off the load circuit. If the current supply fails while the manual bypass is active, a total failure of the load supply results. For this reason, it should be switched back to normal operating mode as soon as possible. 6.1.5 Unit overload The load on the UPS should never exceed the specified rated load of the unit.
7 Interfaces and Communication 7.1 Computer Interface RS232 For the control of the UPS and convenient reading of status messages and measured values, various interfaces are available. The interface protocol is designed for operation with the "CompuWatch" shutdown and UPS management software from AEG. Use the supplied RS232 communication cable to connect your PC. Plug the cable into a corresponding serial port on your PC.
The "CompuWatch" shutdown software supports different operating systems, e.g. Windows 98SE/ME, Windows NT/2000/XP, Windows Vista, Linux, Novell Netware, IBM AIX, HP-UX, SUN Solaris, Mac OS X, and others. Example of a “CompuWatch” screen Refer to the manual on the CD for details about installing the software on the various operating systems. Download of updates at www.aegpartnernet.
8 Displays and Troubleshooting 8.1.1 Signalling 1. 2. 3. 4. 5. OFF pushbutton Press the button for approx. 2 seconds to switch off the UPS. ON button: Press the button for approx. 2 seconds to switch the UPS on. Deactivate acoustic alarm: Press the button during the alarm for approx. 2 seconds to switch off the alarm. UPS test: Press this button during normal mode for approx. 2 seconds to carry out a UPS self-test.
6. Line LED (mains status): The green LED lights up when the mains voltage present is within the specified tolerance range. If this LED flashes, either the UPS connection has an incorrect pin assignment (observe phase sequence / neutral conductor connection position) or the mains is outside of the specified tolerance range. 7. to 11. Bar graph LED as the measure of the UPS capacity utilisation or the remaining battery capacity.
Overview Table of LED Displays / Acoustic Warning Signals LED display (see chapter 8 on page 47) No. Operating mode Warning signal none 2 36% – 55% utilisation none 3 56% – 75% utilisation none 76% – 95% utilisation none 96% – 105% utilisation none 4 5 (mains present) 0% – 35% utilisation Normal mode 1 6 0% – 20% capacity 1 acoustic signal per sec.
Overview table of LED displays / warning signals, cont. LED display (see chapter 8 on page 47) No. Operating mode Warning signal 19 Short-circuit output side Continuous warning signal 20 BUS voltage abnormal Continuous warning signal 21 DC circuit faulty; poss. battery fault 1 acoustic signal per sec. 22 Battery faulty Continuous warning signal 23 Fan fault 1 acoustic signal per sec.
8.2 Faults PROTECT 1. outputs detailed error messages by means of which you or the service personnel can quickly and accurately localise and interpret any malfunctions that occur. You can find suggestions for action / solutions in the following to correct problems using error descriptions according to chapter 8.1.2: 8.2.1 Error Messages Message / display Cause Solution No display, no acoustic signal although system is connected to the mains current supply.
Message / display Cause Solution Duration of the emergency power supply shorter than setpoint. Batteries not completely charged / batteries aged or faulty. Charge the batteries for at least the recharging time acc. to chapter 2.3, and check their capacity. If the problem remains, contact your dealer. “Line” LED and “Fault” LED light up, continuous warning signal (error description no. 17).
9 Parallel Operation 9.1 Principle of Operation PROTECT 1. has been designed for parallel operation with n+x technology (“n” here stands for the number of units required for load supply, “x” for the degree of redundancy). Up to 3 units of the same type can be connected in parallel here to increase the output power and/or achieve higher availability.
The actively redundant parallel operation automatically switches to power-increasing operation if the output power requirement exceeds the UPS single block power, i.e. the degree of redundancy is decreased or is completely eliminated. Conversely, the active UPS redundancy degree automatically increases again when the power consumption decreases.
communication of the units switched in parallel takes place via the 25-pin parallel operation cable(s) included in the scope of delivery. For this purpose, first remove the parallel port covers (no. 5, p. 26/27) and connect the UPS units with each other with one parallel operation cable each. Use one parallel operation cable for 2 units and two parallel operation cables for 3 units (do not create a ring structure!). (Communicative) parallel operating connection ... for 2 units: ...
4. 5. 6. i each UPS are in the “Bypass” position and all mains input miniature circuit breakers (no. 2, p. 26/27) on the back of each UPS are in the “OFF” position. Check the position of the central external manual bypass. This must be in the “Bypass” position, i.e. supply of the load busbar by the supplying mains. Now close all isolators in the output of each UPS, i.e. connect the output of each UPS with the parallel operation busbar.
7. 8. i 9. i 10. i Now actuate the mains input miniature circuit breakers (no. 2, p. 26/27) on each UPS one after the other. Move them to the "ON" position. Move the “maintenance switch” manual bypass switches (no. 3, p. 26/27) on the back of each UPS to the “UPS” position. Finally, fasten the covers on each UPS again using the 4 respective screws that were previously removed.
11. 9.3.2 When the displays are lit as described, switch on your loads one after the other. When doing this, take care not to exceed the maximum permitted load capacity of the UPS systems. Also take into account the reserve capacities if active redundancy should be required. Changes to the parallel system If you would like to add a UPS to the parallel system or remove a UPS from the parallel system, this step is always done by returning the UPS systems to BYPASS operating mode.
10 Maintenance The PROTECT 1. consists of state-of-the-art, non-wearing components. We do, however, recommend visual checks (above all battery and fan checks) at regular intervals (at least every 6 months) to maintain continuous availability and operational reliability. CAUTION! Ensure that the work area is cordoned off and always observe the safety instructions! 10.1 Charging the Battery The battery is automatically charged when the mains is connected, irrespective of the operating mode.
CAUTION! PROTECT 1. must be disconnected from the power supply prior to carrying out the following work. If large quantities of dust have accumulated, the unit should, as a precaution, be cleaned with dry compressed air, in order to ensure adequate heat dissipation. The intervals at which visual checks should be performed are largely determined by the site conditions. 10.2.2 Checking the Battery Progressive ageing of the battery system can be detected by regular capacity checks.
11 Storage, Dismantling and Disposal 11.1 Storage Long storage times without charging or discharging the battery at regular intervals may lead to permanent damage of the battery. If the battery is stored at room temperature (20 C to 30 C), it will automatically discharge at a rate of 3-6% per month due to internal reactions. Storing the battery at temperatures above room temperature should be avoided. A high storage temperature also means greater battery self-discharge.
12 List of Terms 12.1 Technical terminology DC/DC booster Circuit technology for increasing a DC voltage to a higher voltage level SBS Static Bypass Switch Appliance protection Term from overvoltage technology Classic mains overvoltage protection consists of a lightning surge arrester (class B), overvoltage protection (class C) and, finally, the so-called appliance protection (class D) – see also http://www.phoenixcontact.
Guarantee Certificate Type: …….…………………...................................................... Unit number: ………….…………….......................................... Date of purchase: .…………………...........……………………. Dealer stamp / signature Errors and changes excepted. AEG Power Solutions GmbH Emil-Siepmann-Str.
