Installation & Operation Manual Uninterruptible Power Supply Jupiter Series UPS Models 80KVA 160 KVA

Installation & Operation Manual Uninterruptible Power Supply Jupiter Series UPS Models 80KVA 160 KVA Important Safety & Installation Instructions. Save This Manual. Doc # 045904 Rev - Issue Date: 08/01/03 Last Revised: 12/23/04 Copyright 2003 Nova Electric. A Division of Technology Dynamics, Inc. All rights reserved. Reproduction in whole or in part without permission of Nova Electric is prohibited 1

Emergency Shut Down (Only On Units With EPO Option) In Case Of Emergency, Shut Down The UPS By Pressing The RED EPO Switch On The Top Of The UPS. Caution Hazardous voltage exists inside the UPS. All connection and maintenance should be done by a Technical and Qualified personnel only. High voltage capacitors are used in this unit, hazardous voltage may exist even after the unit is shutdown. Warning UPS should be operated within the specified power ratings. Prevent exposure to direct sunlight, rain or contaminating environment. 2

INDEX 1 System Overview... 5 1.1 Construction...5 1.2 Features & Advantages...6 1.3 Dimensions...7 2 Technical Specifications... 13 3 Installation... 15 3.1 Site & Environment Considerations...15 3.2 Unpacking...17 3.3 Cable Selection...18 3.4 Terminal Connections...19 4 Operations... 20 4.1 Switch ON Procedure...20 4.2 Switch OFF Procedure...20 4.3 Procedure to switch Unit from Normal Mode to Bypass Mode...21 4.4 Procedure to switch UPS, from Bypass Mode to Normal Mode...22 5 LCD Display... 23 5.1 Menu 0 Main...23 5.2 Menu 1 Select Menu...23 5.3 Menu 2 Status / Warning Menu...24 5.4 Menu 3 Real Time Data Menu...24 5.5 Menu 4 Historical Data...25 5.6 Menu 5 Parameter Setting Menu...25 5.7 Menu 6 Rectifier Data...27 5.8 Menu 7 Output Data...27 5.9 Menu 8 Other Data...27 5.10 Menu 9 Reserve Data...28 5.11 Menu 10 Boost Charge Setting...28 5.12 Menu 11 Date/Time Setting...28 5.13 Menu 12 Other Settings...29 6 Interface Connections...30 6.1 Dry Contacts...31 6.2 External Shutdown...31 3

7 Options... 32 7.1 Emergency Power Off (EPO) Switch:...32 7.2 Remote Control Panel (UPSCAN):...32 7.3 PC Monitoring Software (UPSCOM):...32 7.4 Web Monitoring Module (UPSWEB):...32 7.5 Power Management Module (ACMAN):...32 7.6 Battery Monitoring Module (DCMAN):...32 8 Storage... 33 9 Troubleshooting... 34 4

1 System Overview 1.1 Construction This UPS consists of the following major blocks: input breakers, input filter & protection network, rectifier, inverter, isolation transformer, output filter and battery. Under normal operation energy from the AC source is converted to DC power and supplied to the inverter. The Inverter converts DC voltage back to AC of required frequency and amplitude. The frequency and amplitude of output is controlled by the inverter to provide clean and stable AC power. The main function of a rectifier stage is to convert the AC input to DC power, and supply it to the inverter. The inverter then converts the DC power to AC power. The UPS uses a 12-pulse rectifier circuit. A front end inductor is used before the rectifier to improve power factor, smooth current waveform and reduce the harmonic currents. The control circuit regulates the DC bus within 1%. Soft start and current limit circuits are used to prevent over current or high surge currents. Under-voltage and Over-voltage protection circuits are used to improve reliability and to shutdown the rectifier in case of abnormal conditions. The power components used in the rectifier circuit are selected to handle extreme high voltage and high current. The rectifier circuit is designed to operate under wide range of AC input. The inverter stage is designed using IGBTs in a full bridge configuration. This stage converts the power from DC to AC. The IGBT switching frequency is selected above 20 KHz to prevent any audible noise. Voltage regulation circuits are used to limit the voltage variation to within 1%. Also special compensation circuitry is added to eliminate the output distortion. All components are selected with extra safe margins to achieve ruggedness. With a dynamic feedback loop the inverter stage provides a sine waveform output even under non-linear loads. The UPS uses an independent inverter for each phase. Each inverter has its independent feedback, so that the voltage is unaffected when the load is added to the adjacent phase, resulting in excellent voltage regulation even with an unbalanced load. The IGBTs are operated in saturation conditions to reduce losses and to obtain higher efficiency. Redundant protection circuits are added to protect the Inverter stage from failures. Strong snubber circuits are added to suppress spikes and noise in the output circuit. 5

1.2 Features & Advantages Reliable input protection: Circuit breakers are used in the input circuit for damage control in the event of any circuit failure in the UPS. Input surge protection: MOVs (surge protector) used at the input provides protection to the converter and load from any lightning or surge caused by the effects of large loads in the grid system. EMI suppression: Jupiter series UPSs are designed to meet international EMI limits. When properly installed and operated it will not interfere with the operation of other equipments. High frequency design: The UPS uses high switching frequency, IGBTs and Pulse Width Modulation (PWM) to convert DC power to the required AC. This results in higher efficiency, lower weight and smaller size. True Galvanic Isolation: A transformer in the output stage provides True Galvanic Isolation between the input and load under all modes of operation. This prevents problems due to ground loop currents and also reduces common mode noise at the output. Modular design: Modular design is used in the Jupiter Series. This facilitates quicker maintenance and easier repairs. This results in very low down time. Fault tolerant operation: The UPS is designed with breaker on/off and power sensors. This will prevent damage to the converter if any operational mistakes are made by the user. Intelligent charger: The UPS will automatically recharge the battery every time after the battery is discharged to a voltage of 2V per cell, so that the battery can be recovered to the full capacity as soon as possible to be ready for the next back-up. Also, in order to keep the battery in the best condition, the UPS will boost charge the battery automatically when required. Intelligent battery test: The battery is tested after every boost charge (either initiated by battery discharge or after one month duration). The UPS informs the user about the battery condition, so that corrective action can be taken. High charge current: The battery charge current is selectable (Low/Mid/Hi) according to Ah capacity of the battery, and can charge battery banks for more than 8 Hrs back-up time without adding an extra charger. Data log capability: All Jupiter models have built in Static Memory. This is used to store all abnormal conditions encountered during its operation. This data is logged along with the date and time of the event. This helps in understanding and analyzing the UPS behavior and also helps to eliminate future problems. Data in static memory is not lost with power loss. Emergency stop (EPO) : This switch will stop the UPS in the event of any emergency such as fire, earthquake or electric shock to any personnel. 6

1.3 Dimensions Fig. 1 7

Fig. 2 Front Panel 8

Fig. 3 9

The Controls & Indicators of the panel are explained below. A. LCD display: Real time status, data or historical events are displayed on the LCD. The LCD is back lit to provide a sharp display. The LED light will turn off 3 minutes after last key was pressed. It will turn ON again when one of the up/down/enter keys are pressed. B. Status LEDs: The 24 status LED provide the following information. Inverter On The inverter is running. Inverter SS The inverter static switch is ON while the reserve static switch is OFF Short Circuit The UPS output is in short circuit state. Fuse/Over Temp SD The inverter shutdown due to either the fuse being open or temperature too high. Inverter Fail Shutdown The inverter shutdown due to inverter output voltage too low. Bypass On Shutdown The inverter shutdown due to the bypass breaker being closed while the inverter is running. High DC Shutdown The inverter shutdown due to DC bus too high when the inverter is running. Overload Shutdown The inverter will shutdown due to an overload of the inverter for a period of time longer than the inverter can endure. It will restart after 7 seconds. 70% Load The load connected to the output is 70% of the UPS rating. 110% Load The load connected to the output is 110% of the UPS rating. 125% Load The load connected to the output is 125% of the UPS rating. 150% Load The load connected to the output is 150% of the UPS rating. Reserve AC Fail The reserve AC magnitude is out of range. Reserve Freq Fail The reserve frequency is out of range. Battery Low The DC bus (or battery) is lower than 320VDC, when this occurs low battery shutdown is approaching. This is an advance warning. Battery Low Shutdown The inverter will shutdown due to the DC bus (or battery) being lower than 295VDC (lower than the acceptable DC voltage for the inverter.) Rect AC Fail The rectifier AC magnitude is out of range. Rotation Error The rectifier AC phase rotation is incorrect. Rectifier Shutdown The rectifier will shutdown due to the DC bus being too high (over 445VDC). It will automatically restart 30 seconds after the abnormal situation has been cleared. High DC When the DC voltage is over 430VDC the bus voltage will be limited to this voltage. Boost Charge The battery is being boost charged by the rectifier. Battery Test The battery is being tested. Emergency Stop The inverter shutdown due to the emergency stop switch being activated. 10

Data Line This blinks when data is transmitted to or received from the communication port. C. Warning indicators: When an abnormal condition occurs, these indicators will light up to warn the user according to the cause of the faulty condition. Therefore all of these indicators should be OFF under normal condition. These indicators are: Rect AC Fail When the rectifier AC input is abnormal either due to magnitude out of range or a phase rotation error, the rectifier will shutdown. Reserve Fail When the reserve AC input is abnormal either due to magnitude or frequency being out of range. Fuse/Temp Either the inverter fuse is blown or over temperature conditions have occurred. Overload The output is overloaded by over 110%, 125% or 150%. High DC This LED will turn ON if DC voltage is over 430VDC. Bat Low This LED will turn ON if DC voltage is less than 320VDC. Bat Low Stop The LED will turn ON if DC voltage is lower than 295VDC. Inverter is disabled. Fault The inverter is shutdown due to abnormal conditions such as overload, short circuit, high DC, Over Temperature, Blown Fuse, Bypass Breaker ON or EPO Activated. These LEDs are visible with door closed. D. Buzzer: Buzzer will beep under any of the following conditions: Inverter Is Overloaded >110%, beeps once / 3 seconds >125%, beeps once / second >150%, beeps twice / second Back- Up >320VDC, beeps once / 3 seconds <320VDC, beeps twice / second <295VDC, no beeping Inverter Is Short Circuited - beeps continuously Fuse Open - beeps continuously Heat Sink Over Temperature - beeps continuously High DC Shutdown - beeps continuously Bypass On Stop - beeps continuously Emergency Stop - beeps continuously The buzzer will also beep once every time the inverter is switched ON or OFF. E. Bypass LED: This LED will turn ON when the maintenance bypass breaker is closed. While the maintenance bypass breaker is closed, the inverter cannot be switched ON. F. Reserve LED: This LED will turn ON when the reserve breaker is closed, and AC power is present at the reserve terminals. 11

G. Rectifier LED: This LED will turn ON when the rectifier is operating normally, it means the rectifier mains are within the specified range, the rotation sequence of the three phases is correct. H. Back-up LED: This LED will turn ON when the UPS is in back-up mode. This is also used as the indicator for battery test result. If the battery test does not pass, this LED will flash even if the UPS is not in back-up mode to prompt the user to change the battery. I. Inverter LED: This LED will is ON when the inverter is switched ON and is running OK. J. Inverter SS LED: This LED is ON when the inverter static switch is turned ON and the reserve static switch is turned OFF. Usually this LED will light 7sec. after the inverter is switched on. K. Reserve SS LED: This LED will turn ON when the reserve static switch is turned ON and the inverter static switch is turned OFF. That is, the load is supplied from the reserve. Since the reserve static switch and inverter static switch will never turn ON simultaneously, the Inverter SS LED and the Reserve SS LED should never be ON together. L. Output LED: This LED will be ON when there is AC power present at the output terminals. M. Up key: This is an LCD control key. It is for moving the cursor one item up when items are being selected or for changing the number/characters forward when data or a parameter of the UPS is being set. N. Down key: This is an LCD control key. It is for moving the cursor one item downward when items are being selected or for changing the number/ character backward when data or parameter of the UPS are being set. O. Enter key: This is a LCD control key. It is for changing backward to the previous page and also for confirming the number/character /item is selected. P. Inverter ON switch: This is the inverter control switch. When this key is pushed with the control key simultaneously, the inverter will be switched on. Q. Inverter control switch: When this key is pushed with the inverter ON key simultaneously, the inverter will be switched ON. Similarly, when this key is pushed with the inverter OFF key simultaneously, the inverter will be switched OFF. R. Inverter OFF switch: When this key is pushed with the control key simultaneously, the inverter will be switched OFF. 12

2 Technical Specifications KVA 80 100 120 160 Rectifier Input Voltage 120 / 208-230 / 400 VAC 3-Phase Input Voltage Range +10% to -15% Input Frequency 50 / 60 Hz + 5% Input Power Factor 0.8 Normal Input Current (120/208V) 290 A 360 A 430 A 580 A Max Input Current (120/208V) 370 A 460 A 560 A 740 A Normal Input Current (230/400V) 144 A 180 A 216 A 288 A Max Input Current (230/400V) 180 A 225 A 270 A 360 A Power Walk In 0% to 100% in 20 Sec Efficiency 99% Voltage Regulation 1% Battery Battery Type Sealed Lead Acid Type No. Of Cells 174 Nominal Voltage 295-410 VDC Charge Current (A) 40 A 50 A 60 A 80 A Battery Low Voltage 320 VDC Battery Low Stop Voltage 295 VDC Boost Charge 410 VDC Float Charge 395 VDC Inverter DC Input Range 285 415 VDC Wave Form Sinusoidal Output Voltage 115/200 230/400 VAC 3-Phase Voltage Regulation + 1 % Output Frequency 50 / 60 Hz +/- 0.1 Hz Phase 120 + 0.5 Degree THD (Linear Load) < 2 % 110% 2 Min Overload 130% 1 Min 150% 10 Sec Max Output Current 348 A 432 A 520 A 693 A Efficiency (100% Load) > 94 % 13

KVA 80 100 120 160 Overall Characteristics Input Voltage (Nominal) 120/208 230/400 VAC 3-Phase Output Voltage (Nominal) 120/208 230/400 VAC 3-Phase Overall Efficiency > 90% Temperature 0 40 o C Humidity 0% - 90% (Non-Condensing) Altitude < 2450 M Above Sea Level Max Heat Dissipation UPS Weight UPS Size (H x W x D) Max 1605 x 1100 x 813 mm (Note 1) EMC EN55022 A, EN61000-6-2, EN61000-4-3 Audible Noise < 65 db (At 1 M) Galvanic Isolation Between Input & Output Short Circuit Protection Yes Note 1: Height shown without hooks. 14

3 Installation 3.1 Site & Environment Considerations Bottom view of UPS and Battery Bank is shown in Fig 4 and Fig 5 respectively. Fig 4 Fig 5 15

The following precautions and recommendations should be taken into consideration for installation site for UPS and Battery Bank. a) The Unit should be located in a place with adequate ventilation. If the Unit is installed indoors, care must be taken to insure proper ventilation for removal of heat from the room. b) Because there are no Inlets / Outlets in the front, rear or sides of the unit, open space is not needed on each side of the unit. But adequate space (at least 1M) should be allowed in the front of the unit for opening of the door. c) Do not place any objects on top of the unit, this will block the ventilation. Do not install the unit near any heat source, or machinery which produces metallic dust or powder, or near a facility that produces corrosive vapors. d) Do not locate the unit immediately under the fire sprinkler heads. e) For long and trouble free life unit should be installed & operated within specified temperature and humidity specs. Considerations should be given to everyday variations as well as long term (annual) variations due to seasonal changes. Even though the UPS will work within 15 to 32 C, recommended optimal conditions are 25 o C or lower temperature and 80% or lower humidity. f) If the unit is installed outdoors, avoid direct exposure to sun and rain. It should also be protected from dust, sand and strong winds. g) The installation site floor should be strong enough to bear the weight of the unit. The UPS is provided with four right angle steel feet. These can be bolted to the ground using ½ inch diameter steel screws. h) Walls, ceilings, floors or anything near the unit should be constructed of non flammable materials. A convenient fire extinguisher should be available near the unit for emergencies. i) Areas around the unit should be kept clean. j) Access to the UPS should be controlled and preferably limited to authorized and qualified personnel. Operators should be aware of all control switches and turn ON / turn OFF procedures of the UPS. 16

3.2 Unpacking Carefully remove all packing material from the unit. Check the unit for any mechanical or structural damage during shipment. Check if all accessories and options are received as per packing list. The following items are included with the UPS. - Door Key - Instruction Manual - Spare Screws For Cover Plate - Spare Screws For Connection Terminals Etc. Finally, check if the specification of the UPS is identical to the specification of your order. The key items in the specification you must check are: - Rated Power. - Input Voltage & Frequency - Output Voltage & Frequency - No. Of Output Phases (1φ or 3φ) 17

3.3 Cable Selection Input, Output and Battery cable size should be selected for required current and according to local electrical codes and regulations. Inadequate cable size or over sized breakers can incur risk of fire or can cause damage to UPS. Following current and Circuit Breaker information is given for reference and general guidelines only. Table 1 Required Utility Circuit Breaker & Output Current of UPS Utility Circuit Breaker Output Current Amps / Phase Rating (KVA) 208/120V AC 380/220V AC 208/120V AC 380/220V AC 80 350 A / Ø 175 A / Ø 222A / Ø 121A / Ø 100 400 A / Ø 225 A / Ø 277A / Ø 152A / Ø 120 500 A / Ø 300 A / Ø 333A / Ø 182A / Ø 160 700 A / Ø 350 A / Ø 444A / Ø 243A / Ø 18

3.4 Terminal Connections Fig 6 Input & Output Terminals are shown in Fig 6. These are marked as IR, IS and IT for each phase. IN is Input Neutral. Output Terminals are makes as OR, OS and OT for each phase. ON is the Neutral for the output. Terminals for Battery Bank are shown in Fig 7. Connections are marked with polarity. A ground terminal is provided for the chassis ground Protective Earth should be connected to PE Terminal. Fig 7 19

4 Operations After all cables are connected, the UPS is ready to operate. Before turning on any switch or breaker, once again check the following points: a. Connected input voltage is same as the rated input voltage. b. Connected power source frequency is same as the rated input frequency. c. All loads at the output are switched off. d. All breakers on the front are open. e. Nothing is accidentally left inside the UPS (small tools or any other objects). 4.1 Switch ON Procedure To start the UPS from the OFF position to the ON position follow the steps listed below. Step 1: Close the Input Breaker & then the Reserve Breaker The reserve and output LED on the panel will light up, indicating that power is applied to the internal circuits. On some units there is no Input Breaker, in that case first step is to close the Reserve Breaker. Step 2: Close the Rectifier Breaker The rectifier stage will start automatically (if the power source connected is correct). The DC voltage will slowly rise up (15 30 sec.) until the designated voltage is reached. Now, the DC is ready to energize the inverter. Step 3: Close the Battery Breaker Now the battery is ready to take over the DC Bus if the AC utilities fail. Step 4: Turn ON the Inverter (Press Control Key & Inverter ON Key together on Panel) This will start the inverter stage. Output voltage will be established in 4 sec. Now the unit is running in normal operation mode. Step 5: Check UPS Status Check if all warning LED s and Indicator LED s are showing Normal Operating Mode for the unit. All warning LED s in the right row should be OFF. Two LED s: INVERTER ON and INVERTER SS in the left row should be ON. If the load is over 70%, the 70% LOAD LED will also be ON. 4.2 Switch OFF Procedure To switch UPS from Normal Operation Mode to Shut OFF Mode, follow the steps listed below. Step 1: Switch OFF the Inverter from panel (Press Control Key & Inverter OFF Key together) 20

This will shut off the inverter stage and will transfer the load from the Inverter stage to Reserve Mode. The load will still have power after this step. Step 2: Open the Battery Breaker This will disconnect the Battery Bank from the DC Bus. Step 3: Open the Rectifier Breaker Opening the rectifier breaker will remove the power from the Rectifier stage. The DC bus will start to drop slowly. After about 5 min the DC bus will drop to a safe level. Warning: After step 3 the load still has power. Step 4 will remove power from the load. Step 4: Open the Reserve Breaker & then Input Breaker ( Input Breaker is not used on some units) This step will remove all power from the output circuit. Hence all equipments connected to this UPS will cease operation. Step 5: Check UPS Status After this step all warning LED or LCD indicators should be Off. 4.3 Procedure to switch Unit from Normal Mode to Bypass Mode. This procedure should be used when the UPS is required for maintenance or repair without disturbing power to the load. Step 1: Switch OFF the Inverter (Press Control Key & Inverter OFF Key together) This will shut off the Inverter stage. This will transfer the load from Inverter stage to Reserve Mode. Step 2: Open the Battery Breaker This will disconnect the Battery Bank from the DC Bus. Step 3: Open the Rectifier Breaker Opening the rectifier breaker will remove the power from the Rectifier stage. The DC bus will start to drop slowly. After about 5 minutes the DC bus will drop to a safe level. Step 4: Close the Bypass Breaker When the maintenance bypass breaker is closed, power will flow through the bypass loop instead of the reserve loop. Step 5: Open the Reserve Breaker After this step the UPS is disconnected from power. The load will still be powered from a utility power source via a separate loop. Any UPS module can be removed for maintenance or repair. 21

4.4 Procedure to switch UPS, from Bypass Mode to Normal Mode. Step 1: Close the Reserve Breaker The reserve and output LED on the panel will light up, indicating the reserve static switch loop is energized. The power within the UPS will be restored and the fans will start operating. Step 2: Open the Bypass Breaker After the reserve circuit is operational, the bypass breaker can be switched off without interrupting the power to the load. Step 3: Close the Rectifier Breaker The rectifier stage will start automatically. The DC voltage will slowly rise until the designated voltage is reached. Step 4: Close the Battery Breaker This will connect the Battery to the DC Bus. Step 5: Turn ON the Inverter (Press Control Key & Inverter Key together) This will start the inverter stage. Output will be established in 4 seconds and the load will automatically be transferred to the inverter. Now the UPS is running in normal operation mode. Step 6: Check UPS Status Check if all of the warning LEDs and indicator LEDs are showing Normal Operating Mode. All warning LED s in the right row should be OFF. Two LED s: INVERTER ON and INVERTER SS in the left row should be ON. If the load is over 70%, the 70% LOAD LED will also be ON. 22

5 LCD Display The LCD display provides substantial information of UPS status. The LCD display is provided with back-light. Back light LEDs will turn off in about three minutes after the last key was pressed. The back light will turn ON again when any one of the Up, Down or Enter key is pressed. Information on the LCD screen is presented in multiple pages. The first page of the LCD which is also the default screen will appear once power is applied to the unit. (Values shown here are example only and differ for each model). 5.1 Menu 0 Main N O V A E L E C T R I C J U P I T E R S E R I E S X X K V A U P S M O D E L : X X X X X S / N : X X X X X X X X 1 D : 0 0 X X X K V A I : 1 2 0 / 2 0 8 V / 6 0 H Z O : 1 1 5 / 2 0 0 V / 6 0 H Z 2 0 0 3 / 0 8 / 1 1 M O N 1 0 : 2 1 A M The first row will display the unit name. The model number (MODEL) serial number (S/N), and the identification number (ID) are displayed in the second row. Third row will display the KVA rating, input rating and output rating of the UPS. These parameters are set at the factory and should not be changed. The serial number is factory set for convenience of maintenance and to keep a record on individual units. The identification no. is set only when external modules connect to more than one unit, each unit must have a unique number to identify it. This should be set after installation. The YEAR/MONTH/DATE, DAY OF THE WEEK, HOUR: MINUTE and AM/PM from the real time clock inside the UPS are displayed on the fourth row. This is also used for stamping the date and time in the historical data for abnormal condition events. Pressing one of the UP, DOWN or ENTER key will change display to MENU 1. 5.2 Menu 1 Select Menu < S E L E C T M E N U > S T A T U S / W A R N / F A U L T P A R A M E T E R S E T R E A L T I M E D A T A H I S T O R I C A L D A T A E X I T This is the main menu. From here a selection is made to view Status, Real Time Data, Historical Data, or to set Parameters. The Up and Down keys are used to move the curser to the required position, and the Enter Key is pressed to make the selection. Selection of Parameter Set will prompt for a password, if an incorrect password is entered for 3 times, the LCD display will change back to the Main Menu. 23

The other three selections are available without a password. Each unit is shipped with a default password 1234 which can be changed by the user. 5.3 Menu 2 Status / Warning Menu < S T A T U S > B U Z = 1 < W A R N I N G > R E C T I F I E R = O N I N V E R T E R = O F F L O A D O N I N V E R T E R This menu displays the status and any warnings of operating the unit in real time. The left hand side of the display shows real time status of the rectifier, inverter and static switch. The right hand side of the display shows warnings or fault conditions in effect. Under normal conditions, the LCD display should be as shown above. Abnormal conditions in the UPS will be shown as Warning or Fault. Listed below are all the Warning conditions that can be displayed: 1 st row: BYPASS ON / RECT AC FAIL / RECTIFIER PHASE ERROR / RESERVE FREQ. ERROR 2 nd row: 170% OVERLOAD / 150% OVERLOAD / 125% OVERLOAD / 110% OVERLOAD Listed below are all the Fault conditions that can be displayed: 1 st row: HIGH DC SHUTDOWN 2 nd row: SHORT CIRCUIT! / FUSE / OVERHEAT / OVERLOAD SHUTDOWN / EMERGENCY STOP / INVERTER ABNORMAL The UP ( ) or DOWN ( ) key are inactive in this menu. 5.4 Menu 3 Real Time Data Menu < R E A L T I M E D A T A > R E C T I F I E R D A T A O T H E R D A T A R E S E R V E D A T A O U T P U T D A T A E X I T Selection of Real Time Data from the Main Menu will change the display as shown above. This is a sub menu for further selection of the type of data required. Available selections are RECTIFIER DATA, RESERVE DATA, OUTPUT DATA, and OTHER DATA. The cursor ( ) can be moved by the UP ( ) key or the DOWN ( ) key. The selection is confirmed by pressing ENTER. If EXIT is selected, the screen will go back to the MAIN MENU. 24

5.5 Menu 4 Historical Data < D A T E / T I M E / E V E N T S > R U N : 0 1 Y R 0 3 M O 2 0 0 3 / 0 3 / 2 9 0 9 : 3 2 S H O R T C I R C U I T 2 0 0 3 / 1 2 / 0 1 2 2 : 1 5 S H O R T C I R C U I T 2 0 0 3 / 0 1 / 1 0 1 5 : 4 7 H I G H D C S H U T D O W N Historical Menu will display the (3) most recent records of abnormal events stored in the unit s Non Volatile memory (EEPROMs). Jupiter series Converters are equipped with EEPROM memory which can store up to 77 historical events of abnormal operations. Up and Downs keys can be used to scroll thru all the historical events. Data stored in EEPROM is not lost even with a power failure. Following is the list of abnormal conditions that can be stored in the memory: HIGH DC SHUTDOWN / SHORT CIRCUIT! / FUSE / OVERHEAT / OVERLOAD SHUTDOWN / EMERGENCY STOP / INVERTER ABNORMAL / BYPASS ON SHUTDOWN On the upper right corner of the screen, the unit s run time is displayed in year/month format, this can be used to schedule the routine maintenance of the UPS. The display will go back to MAIN MENU on pressing the ENTER key. 5.6 Menu 5 Parameter Setting Menu < P A R A M E T E R S E T T I N G > I N V E R T E R = O N / O F F D A T E / T I M E B U Z Z E R = O N / O F F B O O S T C H A R G E E X I T To get into Parameter Setting will require valid password (Default password is 1234). If a valid password is not entered the display will change back to MAIN MENU. If a valid password is entered the LCD display will change to as shown above. The following changes can be made from this menu. INVERTER ON/OFF: Selecting Inverter ON/OFF will show the present status of the Inverter. The display will show INVERTER=ON or INVERTER=OFF depending on the status of the unit. If the Inverter is in the ON state the word ON will be blinking on the display. If the Inverter is in the OFF state the word OFF will be blinking on the display. Up and Down keys can be used to scroll the display to INVERTER=ON or INVERTER=OFF. The status of the Inverter can be changed to intended status by brining that status on the LCD screen by using UP or DOWN keys and pressing the Enter key. 25

BUZZER ON/OFF: Selecting Buzzer On/Off will show the present status of the Inverter. Display will show BUZZER=ON or BUZZER=OFF depending upon the present settings. If Buzzer is in on state, ON will be blinking on the display. If the Buzzer is in off state the word OFF will be blinking on the display. Up and Down keys can be used to scroll the display to BUZZER=ON or BUZZER=OFF. DATE/TIME: Date and Time can be changed from this selection, this is explained in more detail in Sec 5.12 under Menu 11. EXIT: This selection will change display of Main Menu. 26

5.7 Menu 6 Rectifier Data < R E C T I F I E R D A T A > R E C T I F I E R F R E Q U E N C Y = X X H Z R - N = X X X V A C S - N = X X X V A C T - N = X X X V A C This selection is made from MENU 3 (REAL TIME DATA MENU). This provides information about Input Power Source, RECTIFIER FREQUENCY, R-N / S-N / T-N VOLTAGE. The phase to phase voltage information is available when the input is a delta connected. The UP and DOWN keys have no function in this menu. The screen will go back to MENU 3 the (REAL TIME DATA MENU) when ENTER is pressed. 5.8 Menu 7 Output Data < O U T P U T D A T A > O U T P U T F R EQUENCY= XX H Z L O A D : R = X X X % S = X X X % T = X X X % R - N = X X X V A C S - N = X X X V A C T - N = X X X V A C This selection is made from MENU 3 (REAL TIME DATA MENU). This provides information about Output of the Frequency Converter, OUTPUT FREQUENCY, LOAD % on R/S/T, OUTPUT R-N / S-N / T-N VOLTAGE. The phase to phase voltage information is available when the input is delta connected. The UP and DOWN keys have no function in this menu. The screen will go back to MENU 3 the (REAL TIME DATA MENU) when ENTER is pressed. 5.9 Menu 8 Other Data < O T H E R D A T A > T E M P E R A T U R E = X X O C D C V O L T A G E = X X X V D C B A T T E R Y = 1 0 0 % C H A R G E C U R R E N T = X X X A This selection is made from MENU 3 (REAL TIME DATA MENU). This provides information about TEMPERATURE, DC VOLTAGE,.Charge and Discharge current. The UP and DOWN keys have no function in this menu. The screen will go back to MENU 3 the (REAL TIME DATA MENU), when ENTER is pressed. 27

5.10 Menu 9 Reserve Data < R E S E R V E D A T A > R E S E R V E F R E Q U E N C Y = X X X H Z R - N = X X X V A C S - N = X X X V A C T - N = X X X V A C This selection is made from Menu 3 (REAL TIME DATA MENU). This provides information about voltage applied to load when the UPS is operating in Reserve Mode. RESERVE FREQUENCY, R-N / S-N / T-N VOLTAGE. The phase to phase voltage information is available when the input is delta connected. The UP and DOWN keys have no function in this menu. The screen will go back to MENU 3 the (REAL TIME DATA MENU), when ENTER is pressed. 5.11 Menu 10 Boost Charge Setting < B O O S T C H A R G E S E T T I N G > A U T O - B O O S T ( M O N T H ) = 0 4 H R A U T O - B O O S T ( B A T T L O W ) = 0 8 H R C H A R G E C U R R E N T = L O E X I T This selection is made from Menu 5 and is used to make changes to Battery Charger settings. When AUTO-BOOST (MONTH) is selected, all the valid values (04/08/12/16/20/24) will be shown. These values are charge time in hours. Current selection will be indicated by flashing value and will be applied when enter key is pressed. Similarly AUTO-BOOST (BATT LOW) (04/08/12/16/20/24) and CHARGE CURRENT (LO/ME/HI)Values can be selected. 5.12 Menu 11 Date/Time Setting < D A T E T I M E S E T T I N G > Y E A R = X X X X H O U R ( 2 4 H ) = X X M O N T H = X X M I N U T E = X X D A Y = X X D A Y O F T H E W E E K = M O N E X I T This selection is made from the Parameter Setting Menu and is used to set real time clock in the system. The display will show the current settings for date and time. Changes can be made by moving the cursor to a preset value and using the UP and DOWN keys to increase or decrease its value. Change is made by pressing the ENTER Key at the required value. Valid entries for different fields are as shown - YEAR: 1998-2097 - MONTH: 01-12 - DAY: 01-31 (internal calendar will correct itself if 31 is entered for 30 day month) 28

- HOUR: 0-23 - MINUTE: 0-59 - DAY OF THE WEEK: MON, TUE, WED, THU, FRI, SAT, SUN EXIT will take the display back to the MENU 5 (PARAMETER SETTING) menu. 5.13 Menu 12 Other Settings This is selected from the Parameter Setting Menu and is used to change the Title, Model, S/N and ID information on the Frequency Converter. Usually these settings are done at the factory and should not be changed by the customer or the end user. This menu should be used only to re-enter or correct any wrong information. The display will show the present values. Any value can be changed by moving the cursor at the value and pressing enter. The selected value will start blinking. Change this field to the required value by using the UP and DOWN keys. Selection of new values is made by pressing the ENTER key again. The following is a list of valid entries for data field as shown. TITLE: A Z, 0-9 and Blank MODEL: A Z, 0-9 and Blank S/N: A Z, 0-9 and Blank ID: 0 31 Selection of EXIT will cause the display to go back to MENU 5 (PARAMETER SETTING). 29

6 Interface Connections All interfaces are connected from PCB 3R. Please see the figure below. DET2 DET1 CNR16 3R PCB 1-INVON 2-OVL 3-FAULT 4-SS 5-BYPASS 6-BACK-UP 7-BATL 8-COM SWR2 CNR21 CNR10 CNR11 CNR8 RS232 RS485 RS485 RS485 CNR9 RS485 CNR15 CNR20 CNR19 CNR14 CNR18 CNR13 CNR17 CNR12 TO UPSWEB WEB MONITORING MODULE TO UPSCAN REMOTE CONTROL PANEL TO UPSCOM PC MONITORING TO ACMAN POWER MONITORING MODULE TO DCMAN BATTERY MONITOR COM BATL BACK-UP BYPASS SS FAULT OVL INVON **SHORT WHEN EVENT HAPPEN 30

6.1 Dry Contacts Eight alarm contacts are provided for monitoring the UPS performance. The maximum contact rating is 16A/250VAC (16A/30VDC). Contact operations are shown in the following table. UPS Operation COM BATL BACKUP BYPASS SS FAULT OVL INVON Normal C O O O C O O C AC Input Error C O C O O O O C Inverter Off C O O O O C O O Overload Shut Dn C O O O O C C O UPS On Battery C O C O C O O C UPS On Bat Low C C C O C O O C C = Close, O = Open INVON: Contact is normally open. Contact is closed when Inverter is on. OVL: Contact is normally open. Contact is closed when the unit is in Over Load condition. FAULT: Normally open. Contact is closed when any fault condition occurs. Contact remains closed for 30sec. after fault condition is removed or reset manually. COM: Normally open. Contact is closed if any of the above contacts are closed. Hence this is a logic or signal of all other contacts. 6.2 External Shutdown Two pairs of terminals CNR 16 (UPS Enable) are provided for external shutdown. 10mA is needed to turn the internal photo-coupler ON. This can be used to shut down the unit in case of emergency. This can also be configured to operate from some smoke detectors or other sensors. 31

7 Options 7.1 Emergency Power Off (EPO) Switch: An Emergency Power Off (EPO) Switch is available as an option. This can be installed outside the UPS or at a nearby location. When EPO Switch is pushed, the Inverter is turned Off and the static switch remains on the inverter. This action will remove the power from the Load. UPS will remain in this mode unless UPS is reset manually. 7.2 Remote Control Panel (UPSCAN): The UPSCAN is a hand held display module. This can monitor 1-99 UPSs with a DB9 connector from a remote location (less than 1000 meters). 7.3 PC Monitoring Software (UPSCOM): UPSCOM is a Windows Software that allows monitoring 1-99 UPSs using a personal computer. UPS is provided with RS-485 and RS-232 communication ports which connect to serial port of personal computer. RS-485 allows data transmission to longer distance than RS-232. 7.4 Web Monitoring Module (UPSWEB): Web Monitoring Module is a hardware / software package which allows remote monitoring of UPS from internet. A separate PC is not required with this option. UPS data is transmitted thru modem and telephone line. UPSWEB option will allow monitoring of 1-99 UPSs. 7.5 Power Management Module (ACMAN): Power Management Module can be used to manage, monitor and record the UPS power and Load conditions. This option can allow selective cut off of power to less critical loads, record brown out and black outs, record power drawn by the load and scheduled On / Off of the loads. 7.6 Battery Monitoring Module (DCMAN): This module allows monitoring of the individual batteries in the Battery Bank. Batteries can be tested at preset time intervals and data can be recorded. This helps in identifying the worn out batteries that needs replacements. 32

8 Storage For short term storage (For 30 days or less) the UPS should be turned OFF and disconnected from the Battery Bank. The both fuse should be removed from the Battery Bank. The UPS and the Battery Bank should be stored in clean environment. For long term storage (For more than 30 days) the UPS should be turned OFF and should be disconnected from Battery Bank. Both fuses and all the batteries should be removed from the Battery Bank. The UPS and The Battery Bank should be stored in clean environment. New Batteries or fresh recharged batteries should be installed in the Battery Bank to make UPS operational after long term storage. 33

9 Troubleshooting Some typical problems and recommended solutions are listed below Problem: AC Input is normal, but rectifier circuit does not operate. Solution: 1. Check if rectifier circuit breaker is closed. 2. Check if phase rotation of AC input is correct. Rotational Error Warning LED will be ON. LCD display will show Rect Phase Error. Problem: The Inverter cannot be switched ON. Solution: 1. Check from LCD Display that DC bus voltage is normal 2. Check that Bypass Circuit Breaker is Not Closed. 3. Check from LCD Display that output is not overloaded Problem: The Fault LED is ON and the buzzer beeps continuously. Solution: 1. Check that output load is not overloaded. 2. Check that output is Not Short Circuited. 34

A B C D E (A) R BYPASS FROM 3J (B) S (C) T N 4 4 AC INPUT FAN FAN RESERVE RES SS SW AC OUTPUT BAT + BAT - AC TO 3B BUS + INVERTER R (A) RECT 3 3 BUS + S (B) 3PH RECT BUS - R R R' R' S S S' S' T T T' T' INV SS SW BUS - T (C) TO RECT SCR TO INV & RES SS SW IGBT DRV IGBT DRV IGBT DRV 6 5 4 5 3P 3P 3P 3G 3G 3G 2 2 3S 3 4 1 1 1 3T 3T 3T 1 1 L C D 3R 3C 8 4 9 10 11 1 7 3A 3J 3 3B 6 5 3AG 3W 3L INTERFACE / CONTACT 1 4 7 4 5 4 5 3 4 DRVR DRVR DRVR 1 1 1 AC FROM RSRV DC FROM BUS SS SWITCH DRVR RECT SCR CONTROL 5 5 5 PHASE PHASE PHASE 2 2 2 up CONTROL FAN CONT 6 8 TO FAN CKT 1 2 PWR SPLY 5 WRN BUZ PNL SW LED Drwn By: VT 12/2202 WWW.NovaElectric.Com Size B Scale LCD DISPLAY NOVA ELECTRIC Div of Technology Dynamics Inc. 100 School St, Bergenfield, NJ 07621, USA 29019 Jupiter Series UPS Blk Diagram CAGE Code DWG NO Rev 045708 Sheet N 1 of 1 A A B C D E