Gamatronic POWER+ PREMIUM Installation Manual
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Gamatronic POWER+ PREMIUM Installation Manual

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NSTALLATION
Release 1.7, August 2015
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17 Hartom St., PO Box 45029, Jerusalem 91450, Israel
Tel: +972-2-588-8222
Email:
info@gamatronic.co.il
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Cat. no. 101SPD6*
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Fax: +972-2-582-8875
Website:
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Summary of Contents for Gamatronic POWER+ PREMIUM

  • Page 1 + PREMIUM OWER Cat. no. 101SPD6* NSTALLATION UIDE Release 1.7, August 2015 AMATRONIC LECTRONIC NDUSTRIES 17 Hartom St., PO Box 45029, Jerusalem 91450, Israel Tel: +972-2-588-8222 Fax: +972-2-582-8875 Email: info@gamatronic.co.il Website: www.gamatronic.com 2MUM-PP/33...
  • Page 2 Gamatronic is not liable for and the Purchaser waives any right of action it has or may have against Gamatronic for any consequential or special damages arising out of any breach of warranty, and for any damages that the Purchaser may claim for damage to any property or injury or death to any person arising out of its purchase or the use, operation or maintenance of the subject product.

  • Page 3: Table Of Contents

    2.5 Initial startup of the system....................19 2.6 Initial configuration ......................20 2.6.1 Continuing first-time start-up process ..............24 2.6.2 Define the IP Address of Power+ Premium ............25 2.7 Testing..........................27 2.7.1 Blackout Test ......................27 2.7.2 Test Under Load ....................27 2.7.3...
  • Page 4 AMATRONIC LECTRONIC NDUSTRIES ........................49 ELATED PRODUCTS 9.1 G4 ............................49 9.2 G-Eye ..........................50 10. P ......................51 REVENTIVE MAINTENANCE 11. S ........................52 ERVICE AND REPAIRS 12. P ....................53 OWER REMIUM SPECIFICATIONS TABLE OF FIGURES Figure 1: POWER + System – major components ................1 Figure 2: Connection diagram (for completion by the customer) ..........
  • Page 5 AMATRONIC LECTRONIC NDUSTRIES Figure 41: Turning off a module ..................... 40 Figure 42: "Status > Modules" screen .................... 40 Figure 43: Remove the mounting block ..................42 Figure 44: Slightly loosen the nut on the mounting block ............42 Figure 45: Attach the mounting block to the rear of the LCD panel ..........42 Figure 46: Attach the screen to the receiver on the top front of the UPS ........

  • Page 6: Safety Precautions

    AMATRONIC LECTRONIC NDUSTRIES Safety Precautions The PowerPlus UPS system is designed for industrial applications and harsh environments. Nevertheless the PowerPlus should be handled with care, according to the following guidelines. WARNING! HIGH TOUCH CURRENT! (HIGH LEAKAGE CURRENT!) EARTH CONNECTION ESSENTIAL BEFORE CONNECTING SUPPLY. Do’s •...
  • Page 7 AMATRONIC LECTRONIC NDUSTRIES Don’ts • Do not open the cover of the UPS or the battery cabinets under any circumstances. All UPS panels and doors should be closed. • Do not insert any objects through the ventilation holes. • Do not put objects on the UPS. •...
  • Page 8 AMATRONIC LECTRONIC NDUSTRIES WARNING - RISK OF LETHAL ELECTRIC SHOCK: The UPS receives power from more than one source. Disconnection of all of the ac sources and the dc source is required to de-energize this unit before servicing. IN THE EVENT THAT SYSTEM OUTPUT CAPACITY IS INCREASED ABOVE THE ORIGINAL FACTORY CONFIGURATION, THE SYSTEM NAMEPLATE MUST BE UPDATED TO INDICATE THE NEW POWER AND CURRENT CAPACITY.

  • Page 9: Ntroduction

    This document contains instructions for the set-up, installation, and first-time operation of the Power+ Premium UPS system. Before performing the installation it is recommended that you browse the Power+ Premium User Guide to obtain a basic familiarity with the system and the user interface.

  • Page 10: Installation

    S i t e P r e p a r a t i o n – E l e c t r i c a l Check circuit breakers on electrical boards Meet local code and Gamatronic 2.3.3 Step 1...
  • Page 11 AMATRONIC LECTRONIC NDUSTRIES 3-3 Config.: Phase-to-Phase: 3x400 Vac, -22 % / +15 % Verify ac input voltages 2.3.3 Step 3 Phase-to-Neutral: 230 Vac, -22 % / +15 % Verify the voltage between neutral and ground 0–2 Vac 2.3.3 Step 4 Verify dc voltage at battery cabinet switch +360 V and –...

  • Page 12: Connection Diagram

    AMATRONIC LECTRONIC NDUSTRIES LEASE SKETCH ON THE FOLLOWING PAGE A DIAGRAM OF YOUR SYSTEM CONNECTIONS INCLUDE A FORMAL CONNECTION SCHEMATIC WHEN SENDING THE CHECKLIST TO AMATRONIC Connection diagram 2: Connection diagram (for completion by the customer) Figure Power + PREMIUM, Installation Guide, rel. 1.7...

  • Page 13: Installation Procedure

    Site preparation – physical Perform the following procedures before connecting any external cables to Power+. Ensure that the ambient temperature in the immediate vicinity of Power+ complies with Gamatronic requirements. Minimum / maximum operating temperatures: -10 °C / +40 °C (+14 °F / +104 °F).

  • Page 14: Site Preparation - Electrical

    Perform the following procedure before connecting any external cables to Power+. Verify that circuit breakers on the electrical board that supplies Power+ are compliant with local and national codes and Gamatronic system specifications. Verify that the input and output power cable connections, GND, and neutral lines comply with local and national codes and are appropriate for the circuit breakers protecting them.

  • Page 15: Cabling

    AMATRONIC LECTRONIC NDUSTRIES 2.3.4 Cabling 2.3.4.1 NEUTRAL LINE During both installation and operation of the Power +, a neutral line must always be connected to the UPS. This neutral line must be connected at all times while the UPS is working and should not be disconnected at any time.

  • Page 16: Connecting The Ups

    AMATRONIC LECTRONIC NDUSTRIES 2.3.5 Connecting the UPS Figure 4 illustrates the UPS’s main input and output terminals. BYPASS AC INPUT RECTIFIER AC INPUT OUTPUT 3x400 V, 50/60 Hz 3x400 V, 50/60 Hz 3x400 V, 50/60 Hz Figure 4: Ac terminals on 50 and 100 kVA models Connect the rectifier ac input, bypass ac input, and output cables.

  • Page 17: Connection Diagram For Standard 3-3 Configuration

    AMATRONIC LECTRONIC NDUSTRIES 2.3.6 Connection diagram for standard 3-3 configuration Figure 5: Connection diagram for standard 3-3 configuration Power + PREMIUM, Installation Guide, rel. 1.7...

  • Page 18: Figure 6: Connection Diagram For 3-3 Config. W/ Input Isol. Transformer

    AMATRONIC LECTRONIC NDUSTRIES Figure 6: Connection diagram for 3-3 config. w/ input isol. transformer Power + PREMIUM, Installation Guide, rel. 1.7...

  • Page 19: Figure 7: Maximum Input Current

    AMATRONIC LECTRONIC NDUSTRIES Figure 7: Maximum input current Figure 8: Ac switch and circuit breaker recommendations SW1 and CB1 through CB6 appear in Figure 5 and Figure 6 Power + PREMIUM, Installation Guide, rel. 1.7...

  • Page 20: Battery

    AMATRONIC LECTRONIC NDUSTRIES 2.3.7 Battery 2.3.7.1 BATTERY OVERVIEW The POWER + battery bank is used as a backup in the event that the utility ac input fails. Batteries are charged by the rectifier, which supplies both the inverter and the battery charger. •...

  • Page 21: Figure 9: Connections For Two External Battery Cabinets On 50 Kva Model

    AMATRONIC LECTRONIC NDUSTRIES WARNING: When connecting the battery cabinet to the UPS: the UPS’s ac input circuit breaker must be in the OFF position, AND the battery cabinet circuit breaker(s) must be in the OFF position. WARNING: After connecting the battery cabinet to the UPS, do not turn on the battery cabinet’s circuit breaker until the UPS’s AC INPUT circuit breaker is turned on.

  • Page 22: Table 2: Battery Lifetime Vs Environmental Temperature

    AMATRONIC LECTRONIC NDUSTRIES Protect the batteries from moisture, dampness, and foreign substances. The temperature of the battery's surroundings influences the batteries' useful lifetime. Table 2: Battery lifetime vs environmental temperature NVIRONMENTAL CHIEVABLE PERCENTAGE OF TEMPERATURE BATTERY S RATED LIFETIME 20 °C 100 % 30 °C 50 %...

  • Page 23: Special Terminal Connections

    AMATRONIC LECTRONIC NDUSTRIES Special terminal connections This section describes the special-purpose terminal connections of the Power+. On both the 50 kVA and 100 kVA models, special-purpose connections are located inside the static switch tray. To access the special-purpose terminals, the static switch tray must be partially slid out (after disconnection of the UPS from all voltage sources and following standard safety procedures).

  • Page 24: Load On Bypass Alarm

    To restart the UPS following use of the EPO, turn off all input circuit breakers (rectifier ac input, bypass ac input, battery) and then start the Power+ Premium as normal (Main Menu > Operation > Turn On/Off > System On).

  • Page 25: Input And Output Dry Contacts

    Figure 13, Figure 14, and Figure 16 show the location of the input and output dry contacts. The dry contacts can be set up and configured at any time. Refer to the Power+ Premium User Guide for detailed instructions on setup and configuration of the dry contacts.

  • Page 26: Figure 15: Close-Up Of Connectors On Left Rear Of Controller

    AMATRONIC LECTRONIC NDUSTRIES Figure 15: Close-up of connectors on left rear of controller Figure 16: Pin numbers in D9 connectors Table 3: Pin assignments for D9 connectors on rear of controller ALARM CONNECTOR RS232 RS485 INS FOR CONNECTOR CONNECTOR INS FOR DRY CONTACTS REMOTE PANEL Input dry contact #5 (AUX5) Not used...

  • Page 27: Initial Startup Of The System

    AMATRONIC LECTRONIC NDUSTRIES Initial startup of the system Initial startup refers to applying power to the UPS for the first time. Before initial startup of the system, make sure that no loads are connected to the UPS output. If a maintenance bypass switch is installed, make sure it is OFF (not conducting). Attach the LCD screen to the front of the controller (see section 5), then insert the controller module into any one of the module slots.

  • Page 28: Initial Configuration

    NDUSTRIES Initial configuration On the initial startup of the Power+ Premium, a series of configuration screens are presented on the display panel. Through these screens you supply the Power+ Premium with required, basic configuration information to enable initial operation of the Power+ Premium.

  • Page 29: Figure 19: Initial Config. Wizard: Set Number Of Modules

    Figure 19: Initial config. wizard: set number of modules You are now asked to tell the Power+ Premium the number of external battery cabinets (or internal battery compartments) currently connected to the UPS. Choose either 1, 2, or 3, then press "Next".

  • Page 30: Figure 20: Initial Config. Wizard: Number Of Battery Cabinets Or Battery Compartments

    AMATRONIC LECTRONIC NDUSTRIES Figure 20: Initial config. wizard: number of battery cabinets or battery compartments Indicate the total capacity of all connected battery cabinets, in ampere/hours (Ah), then press "Next". (This capacity figure is used by the UPS when in battery mode to calculate the amount of backup time remaining.) If you are not sure of your battery cabinet's Ah capacity, look at one of the batteries in the cabinet.

  • Page 31: Figure 22: Initial Config. Wizard: Set Time Zone

    AMATRONIC LECTRONIC NDUSTRIES Choose the appropriate time zone, then press "Next". Figure 22: Initial config. wizard: set time zone Press "Finish" to exit the wizard. Figure 23: Finish configuration wizard Continue with section 2.6.1 below. Power + PREMIUM, Installation Guide, rel. 1.7...

  • Page 32: Continuing First-Time Start-Up Process

    Turn ON the battery cabinet circuit breaker (if there is an external battery cabinet). On the Power+ Premium main menu, choose "Operation > Turn on/off > System on". Return to the main menu by tapping on the "house" (home) icon in the upper left corner of the Power+ Premium screen.

  • Page 33: Define The Ip Address Of Power+ Premium

    LECTRONIC NDUSTRIES Perform a brief battery test to verify that the Power+ Premium is ready and able to operate in battery mode when needed. To perform a battery test, from the main menu choose: "Operation > Battery test > Test battery". After 1 minute, cancel the test by pressing "Abort the test >...
  • Page 34 Press the "Confirm" key when you have finished entering all of the addresses. This causes the entered addresses to be saved in the Power+ Premium's non-volatile memory.

  • Page 35: Testing

    2.7.1 Blackout Test This test is designed to verify the operation of Power+ Premium in the event of a blackout, when no ac power is supplied to the UPS. Turn all ac input to the system OFF (turn OFF the ac input switches to both Bypass and Rectifier).

  • Page 36: Using The Ups With A Generator

    AMATRONIC LECTRONIC NDUSTRIES SING THE WITH A GENERATOR The Automatic Transfer Switch (ATS) At many sites a generator is used as a reserve source for feeding the UPS during mains power failure. In such cases, the switching between the two sources (the mains and the generator) is performed by an Automatic Transfer Switch (ATS).

  • Page 37: Figure 27: Example Of An Ats Control Panel

    AMATRONIC LECTRONIC NDUSTRIES Figure 27 is an example of the control panel of an ATS. The upper part of the control panel consists of a mimic diagram showing the control flow. “NS = 0” means the normal source is “OFF”. “NS = 1”...

  • Page 38: Cabling

    3.2.1 Neutral line During both installation and operation of the Power+ Premium, a neutral line must always be connected to the UPS. This neutral line must be connected at all times while the UPS is working and should not be disconnected at any time.

  • Page 39: Figure 29: Acceptable Connection For Grounded Generator And 4-Pole Switch

    AMATRONIC LECTRONIC NDUSTRIES Figure 29: Acceptable connection for grounded generator and 4-pole switch Figure 30: Preferred generator (neutralized) and connection (3-pole) Power + PREMIUM, Installation Guide, rel. 1.7...

  • Page 40: Inserting And Removing Power Modules

    AMATRONIC LECTRONIC NDUSTRIES NSERTING AND REMOVING POWER MODULES This chapter discusses the physical insertion and addition of modules to the system, the physical removal of power modules from the system, and the related changes to the system configuration. Note: If you remove a UPS module from the UPS while the module is operating, wait five minutes before reinserting the module.

  • Page 41: Physical Removal Of A Ups Module

    AMATRONIC LECTRONIC NDUSTRIES Figure 32: Front panel of the UPS module Physical removal of a UPS module Loosen the two screws that secure the module to the UPS frame – one screw on each side of the module face. Grip the module by the handle on the front face of the module and pull the module out, gently but firmly.

  • Page 42: Figure 33: Turning Off A Module

    AMATRONIC LECTRONIC NDUSTRIES From the system main menu, choose "Operation > Turn on/off > Modules off". On the screen, choose the module to be replaced. The modules are numbered from bottom to top. The outline of the module you choose becomes highlighted. Figure 33: Turning off a module Press the "Complete Shutdown"...

  • Page 43: Figure 35: Verifying Status Of Replacement Module

    AMATRONIC LECTRONIC NDUSTRIES Figure 32). Grip the module by the handle on the front face of the module and, gently but firmly, pull the module all the way out. Slide the replacement module into place. Secure the module by hand-tightening the two screws, one on each side of the front panel.

  • Page 44: Figure 36: Status > Modules > Output

    AMATRONIC LECTRONIC NDUSTRIES Figure 36: Status > Modules > Output If the output voltage of one or more phases is not within 2 % of the system nominal output voltage, then: 12.1 Navigate to "Setup > Modules > Ac output voltage adjustment". 12.2 Select the replacement module, and adjust the problematic phases up or down as required.

  • Page 45: Addition Of A Module In An Installed System

    AMATRONIC LECTRONIC NDUSTRIES Addition of a module in an installed system To add a module to an operational system: First, you must verify that the shelf where the module is to be added is "OFF". To switch off (power down) the shelf: From the system main menu, choose "Operation >...

  • Page 46: Figure 38: Turning On A Module

    AMATRONIC LECTRONIC NDUSTRIES Figure 38: Turning on a module To verify that the new module is operating normally, navigate to the module status screen ("Main screen > Status > Modules"), press on the icon of the module that was just switched on, and verify that the status is "ON"...

  • Page 47: Figure 40: Status > Modules > Output

    2% of the system nominal value. The Power+ Premium controller must be informed that a new module has been added to the system. On the LCD control panel, from the main menu navigate to "Setup >...

  • Page 48: Removing A Module From An Installed System

    AMATRONIC LECTRONIC NDUSTRIES Removing a module from an installed system To remove a module in an operational system: From the system main menu, choose "Operation > Turn on/off > Modules off". On the screen, choose the module to be replaced. The modules are numbered from bottom to top. The outline of the module you choose becomes highlighted.
  • Page 49 Grip the module by the handle on the front face of the module and pull the module out, gently but firmly. The Power+ Premium controller must be informed that a module has been removed from the system. On the LCD control panel, from the main menu navigate to "Setup >...

  • Page 50: Installing The Lcd Screen

    AMATRONIC LECTRONIC NDUSTRIES NSTALLING THE SCREEN When installed, the LCD screen is located in the front top of the UPS (see Figure 1). To protect the LCD screen from damage, it does not arrive installed. The LCD screen comes in its own box. Open the box, remove the screen from the box, and remove the mounting apparatus Figure 43: Remove the mounting block Loosen the nut on the rear of the mounting block (without removing the nut) so that the nut can get...

  • Page 51: Figure 46: Attach The Screen To The Receiver On The Top Front Of The Ups

    LECTRONIC NDUSTRIES Slip the LCD screen’s mounting block into the receiver on the top front of the Power+ Premium 60. You will need to hold open the catch on the receiver while doing this. Figure 46: Attach the screen to the receiver on the top front of the UPS There is a cable on the top front of the UPS which supplies power and communication to the LCD screen.

  • Page 52: Circuit Breaker Selectivity

    AMATRONIC LECTRONIC NDUSTRIES IRCUIT BREAKER SELECTIVITY When discussing power distribution, "discrimination" (also referred to as selectivity) is the selection and arrangement of circuit breakers such that in the event of a short circuit or overload in the line, the circuit breaker closest to the short will be tripped and the upstream circuit breakers will remain unaffected.
  • Page 53 NDUSTRIES Based on the principles explained above, in order to protect the UPS's bypass contactor and also the main input of the UPS, for all scenarios including short circuit, Gamatronic recommends the following: • The circuit breaker that feeds the bypass input line and the circuit breaker feeding the main input of UPS shall have no magnetic protection delay, or a maximum magnetic protection delay of 50 msec.

  • Page 54: Using A Maintenance Bypass Switch

    AMATRONIC LECTRONIC NDUSTRIES SING A MAINTENANCE BYPASS SWITCH An external maintenance bypass switch can be connected to the UPS. Putting the UPS into maintenance bypass mode When present, an external maintenance bypass switch allows the UPS to be manually shut down for servicing without affecting the loads.

  • Page 55: Remote Monitoring Panel ( Option )

    AMATRONIC LECTRONIC NDUSTRIES EMOTE MONITORING PANEL OPTION The remote monitoring panel (Figure 49) enables you to monitor the UPS from a distance. It can be located a maximum distance of 50 m from the UPS. The remote monitoring is connected directly to the UPS with a 4-wire cable via the D9-type Alarm connector on the rear of the controller (Figure 50).

  • Page 56: Figure 50: Connecting The Remote Monitoring Panel

    AMATRONIC LECTRONIC NDUSTRIES Figure 50: Connecting the remote monitoring panel See also Figure 15, Figure 16, and Table 3 Power + PREMIUM, Installation Guide, rel. 1.7...

  • Page 57: Related Products 9.1 G4

    AMATRONIC LECTRONIC NDUSTRIES ELATED PRODUCTS Figure 51: GMACi G4 The G4 adds value to your Power+: • Option to connect external temperatures sensors. • Input dry contacts available for on/off external sensors. • Output dry contacts for control of external devices. •...

  • Page 58: G-Eye

    AMATRONIC LECTRONIC NDUSTRIES G-Eye Figure 52: G-Eye G-Eye adds value to your Power+: • Option to connect external temperatures sensors, humidity sensors, and frequency sensors. • Inputs for ac/dc current and voltage measurements through various sensors. • When the measured value moves outside a user-defined range, G-Eye immediately informs pre- selected targets of the alarm condition.

  • Page 59: Preventive Maintenance

    It is important that the UPS owner continue to arrange regular preventive maintenance inspections even after the expiration of the initial warrantee period. Gamatronic bears no liability for damage caused to the UPS due to improper maintenance by third parties, in particular after the expiration of the warrantee or service agreement.

  • Page 60: Service And Repairs

    Without a written agreement, Gamatronic is under no obligation to provide service after expiration of the initial warrantee period. Gamatronic will not be responsible for maintenance or changes to the UPS that are performed by an agent without written authorization from Gamatronic.

  • Page 61: Power + Premium Specifications

    AMATRONIC LECTRONIC NDUSTRIES 12. P OWER REMIUM SPECIFICATIONS Table 5: System technical specifications Topology On line battery, double-conversion, VFI Construction Modular, parallel hot-plugged modules Operation Continuous Input 3×400 (4 wires + Gnd) Nominal voltage (Vac) Voltage range (%) –22 / +15 Nominal current (A) 3 ×...
  • Page 62 AMATRONIC LECTRONIC NDUSTRIES SYSTEM CONTROLLER – TECHNICAL DATA Display LCD flat panel, touch-sensitive Other indicators Audible alarm Analog input channels 4 input dry contacts (N.O. / N.C.) Real Time Clock (RTC) Yes, with backup Power meter kVA, kW, PF Volt-free outputs (dry contacts) 6 outputs, rated 50 V / 1 A TCP/IP, GPRS/SMS wireless communications Communication...
  • Page 63 Headquarters and Factory 17 Hartom Street, POB 45029, Jerusalem 91450, Israel Gamatronic Singapore Sales Office email: singapore@gamatronic.co.il Gamatronic (UK) Ltd. 15 Chester Road, Eaton Socon, St. Neots, Cambridgeshire PE19 8YT United Kingdom Tel: +44 (0)1480 479 889 Fax: +44 (0)1480 407 865 email: info@gamatronic.net...

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