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Powervar 3200 Series User Manual

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3200 Series User's Manual
1
A55-00033 Rev. E
December 2015

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Summary of Contents for Powervar 3200 Series

  • Page 1 3200 Series User’s Manual A55-00033 Rev. E December 2015...
  • Page 2 A55-00033 Rev. E December 2015...

  • Page 3: Table Of Contents

    UPS Unpacking Instructions………………………………………………………………….10-12 UPS Installation…………………………………………………………………………………13 Clearance Guide……………………………………………………………………………..14 Wiring Guide…………………………………………………………………………..……….,15 UPS Connector Terminals and Lug locations……………………………………………….16-19 3. Product Specifications 3200 Series Product Specifications…………………………………………………………..21-22 4. Operation UPS Operational Overview………………………………………………………………….23-24 UPS Operation: Normal Mode………………………………………………………………….24 UPS Operation: Battery Mode………………………………………………………………….25 UPS Operation: Bypass Mode………………………………………………………………….26 UPS Operation: Emergency Bypass………………………………………………………..27 UPS Operation: Manual Maintenance Bypass Mode……………………………………..28...
  • Page 4 Control Functions………………………………………………………………………….48-62 Touch Screen Menu’s………………………………………………………………..…….63-80 5. Maintenance UPS Maintenance…………………………………………………………………………..82 Battery Maintenance………………………………………………………………………..83 Battery Replacement……………………………………………………………………..84-97 6. Warranty Product Warranty…………………………………………………………………………..99-100 7. Service and Troubleshooting Alarm Severity Definitions……………………………………………………………..102 Alarms Messages…………………………………………………………………………..103-106 8. Drawings UPS Outline Drawings………………………………………………………………………108 Block Diagram (UPS + External Battery Cabinet)………………………………………….109 Block Diagram (UPS + Input Transformer Cabinet)………………………………………..110 Block Diagram (UPS + Output Transformer Cabinet)………………………………...111 Block Diagram (UPS + Input/Output Transformer)……………………………………..….112 Block Diagram (UPS + 3 Breaker MBS)……………………………………………….…...113...

  • Page 5: Introduction And Safety

    Introduction and Safety A55-00033 Rev. E December 2015...

  • Page 6: Important Safety Instructions

    ****IMPORTANT SAFETY INSTRUCTIONS**** ****SAVE THESE INSTRUCTIONS**** This manual contains important instructions to be followed during installation and maintenance of the UPS and batteries. Please read all instructions before installing or operating the described equipment and PLEASE SAVE THIS MANUAL FOR FUTURE REFERENCE! SPECIAL SYMBOLS: The following are examples of symbols used on the UPS, or within this manual to alert you to important information.
  • Page 7 Do Not Discard--this equipment utilizes components that contain lead and must be disposed of properly. For more information, contact your local recycling/refuse or hazardous waste center. Do Not Discard-- never discard Waste Electrical or Electronic Equipment (WEEE) in the trash. For proper disposal contact your local recycling/refuse or hazardous waste center. Information of Special Note--Specific handling or operational instructions may apply.

  • Page 8: Note To Users

    NOTE TO USERS To ensure correct operation of the UPS, please read this instruction manual carefully. Please keep this manual handy for future reference. This UPS has dangerously high voltages on both its Input and output connections. Contact with these voltages may be life threatening.
  • Page 9 supplying power to the UPS, ensure that the breaker selected is not an ELCB type circuit breaker that detects earth leakage current. Please contact the manufacturer or an authorized distributor for any assistance with troubleshooting. The UPS should only be serviced or maintained by a factory authorized service technician.

  • Page 10: Installation

    Installation A55-00033 Rev. E December 2015...

  • Page 11: Ups Unpacking Instructions

    Note: POWERVAR encourages the end user to retain all shipping materials until the UPS has been inspected, installed and verified for proper operation. The POWERVAR 3200 Series UPS utilizes internal batteries which are pre-assembled in individual trays and shipped separately from the UPS. These trays come completely wired and ready for connection to the internal battery harness of the UPS.
  • Page 12 9. With the help of an assistant, carefully roll the UPS off the pallet and down the ramp to the floor of your facility. If the floor at your desired UPS location is uneven, the levelers may be used to steady the UPS, once it is in place. Please do not install batteries in the UPS.

  • Page 13: Ups Installation

    “Off” position, and the Manual Maintenance Bypass is in the “Normal” position, before making any connections to this UPS. The POWERVAR 3200 Series requires a 208V three phase, four wire (+ ground) input for proper operation. Input over current protection and the output disconnect are to be provided by the user.

  • Page 14: Clearance Guide

    POWERVAR 3200 Series Clearance Guide Location Minimum Clearance (Inches) Top (Above) of Cabinet Front of Cabinet Rear of Cabinet Sides of Cabinet *Matching peripheral cabinets are considered to be part of the UPS system, so the 6” spacing should be taken from the outside edge of the peripheral cabinet.
  • Page 15 These levelers are located in the front of the unit below the door. POWERVAR recommends the following overcurrent device (provided by customer) to be used as the electrical supply (input) to the 3200 Series UPS:...
  • Page 16 Fig. 2-6 Fig. 2-7 UPS-front view UPS – front view with door open Once opened, the connection terminals can be accessed by removing the screws holding the terminal safety cover in place (Fig 2.8). This cover is located just below the three rotating handles used for the operation of the UPS.
  • Page 17 The terminals to accommodate the input and output conductors are laid out as follows (Fig. 2.9): AC Input Maintenance Bypass Battery Disconnect NORMAL BYPASS AC MAIN INPUT UPS OUTPUT Pos. Batt. Neg. Neut. Fig. 2-9 As shown above, the input (LINE or “L” designated terminals) conductors are connected to the (L-R) first four terminals.
  • Page 18 Top side of terminal- To Internal UPS wiring Bottom side of Terminal- To customer wiring 10/20kVA Terminal 30/40 kVA Lug Care should be taken when installing these conductors so as to not confuse the input (LINE) and output (LOAD) phase conductors. Keeping in mind this UPS requires an input neutral for proper operation.
  • Page 19 Terminal safety cover must be installed prior to operation of the UPS. POWERVAR recommends a disconnecting means with the following overcurrent ratings (provided by customer) to be used as the electrical supply (output) from the 3200 Series UPS to the critical load:...

  • Page 20: Product Specifications

    Product Specifications A55-00033 Rev. E December 2015...
  • Page 21 POWERVAR 3200 Series Specifications Applicable Standards: UL1778 and CSA 22.2 IEC, 62040 UPS Standard ISO 9001 Quality Assurance Program EMI compatibility: FCC Title 47 Part 15, Subpart B IEEE C62, 41-1991 OSHPD Special Seismic Certification # - OSP-0336-10 Model: Power Rating (kVA):...
  • Page 22 System Output: Nominal Output Voltage 208VAC 3 Phase 4 Wire Static Voltage Regulation +/- 2% Output Frequency 60Hz (tracks frequency of static bypass source) (Inverter Synchronous) +/- .2, .5, 1 and 2Hz (user settable) Output Frequency Slew Rate +/- 1 Hz per second Frequency Regulation 60Hz +/- .01% (free running) Output Voltage Harmonic Distortion...

  • Page 23: Operation

    Operation A55-00033 Rev. E December 2015...

  • Page 24: Ups Operational Overview

    The POWERVAR 3200 Series UPS is a continuous-duty, solid state, transformerless, 208V three phase 4 wire true online double conversion system, which provides uninterruptible power to critical loads. The POWERVAR 3200 Series UPS maintains power to the critical load during commercial electrical power brownout, blackout, overvoltage, undervoltage, and out-of-tolerance frequency conditions.

  • Page 25: Ups Operation: Battery Mode

    UPS Operation: Battery Mode In the event of an AC input failure, the batteries provide the power necessary to supply the inverter. The inverter continues functioning as in normal mode, supplying AC power to the critical load. Manual Maint. Bypass Static Bypass Switch CRITICAL...

  • Page 26: Ups Operation: Bypass Mode

    UPS Operation: Bypass Mode The UPS comes with a static bypass switch which provides an alternate current path to the critical load. This transfer will not affect the supply of output power to the critical load, but if a power outage occurs while in this mode, the critical load will not be maintained. This bypass circuit can be enacted in two ways: Normal Bypass This circuit may be enacted manually by use of the “stop”...
  • Page 27 Emergency Bypass: If an abnormal condition occurs the output to the critical load will be automatically transferred to bypass mode through the use of the static bypass switch. Manual Maint. Bypass Static Bypass Switch CRITICAL CUSTOMER LOAD SUPPLY Disconnect Battery Static Breaker Switch...

  • Page 28: Ups Operation: Manual Maintenance Bypass Mode

    UPS Operation: Manual Maintenance Bypass Mode When it becomes necessary to perform maintenance checks on the UPS, the critical load need not be interrupted. This is accomplished by means of a “make-before-break” manual maintenance bypass switch. This same switch simultaneously isolates the output of the UPS, which will allow the rectifier and inverter to be energized for troubleshooting and repair purposes, without affecting the critical load.
  • Page 29 THE TOUCH SCREEN The POWERVAR 3200 Series UPS utilizes a state of the art full color (262K colors) TFT LCD 5.7” (diagonal measure) touch screen as its primary user interface. This powerful tool allows the user to observe and control all operations of the UPS by moving through a series of menu screens.
  • Page 30 Description HOME Button UPS Model Size (HOME SCREEN ONLY) Title Bar Individual screen #, or in the case of the HOME screen only, the Firmware Revision Level User information text area Power flow diagram User information text External Battery cabinet (optional)—icon appears only when UPS is programmed for the External Battery Cabinet option Action buttons Scroll for hidden action buttons...
  • Page 31 AUTHORIZED PERSONNEL WILL VOID YOUR WARRANTY! UPS User’s Start-up Sequence: The POWERVAR 3200 Series UPS utilizes a hinged front door to access its three primary switches. These switches are described as (L-R): AC Input which will disconnect the UPS from...
  • Page 32 Cooling Fans (Hot Swappable) Communication Interface Board Battery Chamber Cover Manual Maint. AC Input Bypass Switch Switch Battery Connection Disconnect Terminal cover Fig. 4-6 The UPS will NOT start unless the Manual Maintenance Bypass Switch is in the “normal” position (Assuming the UPS has not been placed in “BYPASS” mode for servicing purposes.
  • Page 33 Fig. 4-7 Fig. 4-8 Fig. 4-9 Fig. 4-10 Fig.4-11 Step 2: The UPS will pre-charge the rectifier and start to energize the DC bus. Once the bus is fully charged, the unit will alarm to let the user know that the batteries are disconnected and the A55-00033 Rev.
  • Page 34 battery breaker may now be closed (Fig. 4-10 & 4-11). The UPS “on Bypass” alarm state will remain until the unit is started. Fig. 4-12 Fig. 4-13 Step 3: The UPS may now be started by pressing the “start” button at the bottom of this screen (Fig.4-12).
  • Page 35 Upon successful completion of the internal control checks, the inverter will turn on and the “UPS on Bypass” alarm will disappear. The title bar will turn from red (meaning alarm present) to plain white (Fig. 4-15). Fig. 4-15 The bypass path has now changed from green to gray and the main power path is now green. The battery section is now green and input, output, and battery charge information has appeared in columns above the power path.

  • Page 36: Ups Shutdown Sequence

    UPS Shutdown: If it becomes necessary to completely turn off your UPS, please follow these simple steps: Fig. 4-16 Step 1: Perform a sequential shutdown of your applied load. Once there is no critical load, the UPS may be transferred to its static bypass state by pressing the “stop” button at the bottom of the Home screen (Fig.
  • Page 37 Battery Disconnect Fig. 4-18 Fig. 4-19 Fig. 4-20 Step 3: Open the battery disconnect switch (Fig. 4-18) which is behind the hinged front door at the lower right side. An audible alarm will sound when the breaker is open. This alerts the user to the state of the battery breaker (Fig.

  • Page 38: Maintenance Bypass Mode

    AC supply feeding this UPS may now be de-energized. Maintenance Bypass Mode The POWERVAR 3200 Series UPS is supplied with a make-before-break maintenance bypass switch as a standard feature. This switch allows the user to transfer the UPS to an alternate current path for service or troubleshooting, without affecting the applied load.
  • Page 39 Step 1: Transfer the UPS to Static Bypass mode by pressing the “stop” button at the bottom of the “Home” screen (Fig. 4-22). Drag and drop the red “stop” action square to the gray square at the right (Fig. 4-23). The inverter will now be offline. An alarm will alert the user to the fact the UPS is now in bypass mode and the critical load is no longer battery protected (Fig.
  • Page 40 Step 2: Once the offline state is confirmed via touchscreen, the Battery Disconnect breaker may be opened (Fig. 4-26). An audible warning will sound, but during this operation the warning may be disregarded (Fig. 4-27 & 4-28). Fig. 4-28 Maintenance Bypass NORMAL BYPASS Fig.
  • Page 41 Fig. 4-31 AC Input Fig. 4-32 Step 4: Open the AC Input breaker (Fig. 4-32). The UPS is now available for service or troubleshooting by an authorized service technician without affecting the applied critical load. Note: opening the AC Input breaker will remove power to the touch screen display and cause it to go completely dark.
  • Page 42 AC Input Fig. 4-33 Fig. 4-34 Fig. 4-35 Step 5: Close the AC Input breaker (Fig. 4-33). This will supply power to the UPS and cause the initializing screen to become illuminated (Fig. 4-34). This screen should be visible for approximately 15-20 seconds, and should transition into the start-up bypass screen (Fig.
  • Page 43 Fig. 4-36 Battery Disconnect Fig. 4-37 Fig. 4-38 Step 6: When prompted, close the battery breaker (Fig. 4-37). The display will confirm this operation (Fig. 4-38). Maintenance Bypass NORMAL BYPASS A55-00033 Rev. E December 2015...
  • Page 44 Fig. 4-39 Step 7: Rotate the Maintenance Bypass switch back to the “normal” position (Fig. 4-39). Fig. 4-40 Step 8: The UPS may now be started by pressing the “start” button at the bottom of this screen (Fig. 4-40). Fig. 4-41 Step 9: The “start/stop”...
  • Page 45 Fig. 4-42 Step 10: Upon successful completion of the internal control checks (Fig. 4-42), the inverter will turn on and the Normal Operation screen will appear. Fig. 4-43 Note: The bypass path has now changed from green to gray. The main power path is now green, the critical load will once again be battery protected (Fig.

  • Page 46: Monitor Functions

    Using the Monitor Function Fig. 4-44 The Monitor screen as shown above (Fig. 4-44) is designed to provide the user with real time information regarding the various operational states of the UPS. The buttons along the bottom, when pressed will render the following information to the user: INPUT: L-L and L-N voltage and current, frequency and total real &...

  • Page 47: A55-00033 Rev. E December

    ALARM HISTORY: gives time stamp and date plus details of last 100 alarm events BATTERY OPERATION HISTORY: shows time stamp and date of power fail history DATA LOG: shows summary of Input voltage & kVA, and output current. The sample rate for these values is set up in the control menu.

  • Page 48: Control Functions

    Using the Control Function Fig. 4-45 The CONTROL screen (Fig. 4-45) allows the user to interact with the UPS and customize its functions for their specific applications. As with the MONITOR screen some blue action buttons are hidden from normal view, and the black scroll button must be utilized to bring them into view.
  • Page 49 Fig. 4-46 Setting the Date and time: The following screens(Figs. 4-47 to 4-53) take the user step by step through this self-explanatory process. Fig. 4-47 Fig. 4-48 A55-00033 Rev. E December 2015...
  • Page 50 Fig. 4-49 Fig. 4-50 Fig. 4-51 Fig. 4-52 Fig 4-53 A55-00033 Rev. E December 2015...
  • Page 51 Using the “ENT” button will input the desired numbers into the box. If a number appears in the box that is not desired, pressing the “CLR” button will clear it from the box. Once confirmed, the “CHANGE” action button must be pressed to input this new information into the UPS’ internal clock.
  • Page 52 Fig. 4-55 Fig. 4-56 Choosing the RS-232 COMM (Fig. 4-57) option from this menu, offers the user the ability to configure the communication speed (Fig. 4-58) and contacts of the port on the Communication Interface PCB (BM505) of the UPS. Fig.
  • Page 53 AS 400 Interface Communication Interface Board Connection RS 232 Port Parallel Parallel Fig. 4-58 Fig. 4-59 Front of UPS with door open. Expanded view of Communication Interface Board The user interface for this board (Fig. 4-59) consists of (2) DB9 connectors, (2) micro terminals, and (2) DB15 connectors.
  • Page 54 The pin configurations for the DB9 connectors are as follows AS 400 Interface RS 232 Port The pin assignments for the above connectors are as follows: Pin No. AS 400 Interface RS 232 (Serial Comm Port) Shutdown + No Connection Shutdown - No Connection Battery Discharge - NO...
  • Page 55 Fig. 4-60 Setting the I/O Contacts: When choosing the I/O contact option from the setup menu, it is important to remember that there are three options: Digital Inputs (Fig. 4-61), Output Contacts (Fig. 4-62), and AS/400 Interface (Fig 4-63). Fig. 4-61 Fig.
  • Page 56 Fig. 5-63 The Front Panel I/O Contacts are physically located on the PCB mounted on the back of the front display. There are six digital inputs (12 terminals) and six output contacts (18 terminals) in a horizontal row along the bottom edge of this PCB. These terminals are designed to accept wires from 24 to 14 AWG (.2mm 2.5mm ) with a torque spec.
  • Page 57 6. Remote Transfer to Inverter 7. Asynchronous Operation 8. Remote Alarm NOTE: Digital input #1 is reserved for use by POWERVAR and will have wires pre-installed on it from the factory. Please do not remove these wires without manufacturer’s consent. Fig. 4-64 Fig.
  • Page 58 attempt to exit this screen you will be reminded to save your contact choice before proceeding (Fig. 4-67). The OUTPUT contacts consist of three terminals; Normally Open (NO), Normally Closed (NC), and Common (C). Theses contacts when properly programmed, will change state when the appropriate signal is received from the main processor of the UPS.
  • Page 59 Fig. 4-68 Fig. 4-69 Fig. 4-70 Choose the desired action from the list of 30 available contact options (Fig. 4-69) and press SAVE. When properly programmed a SAVED! Message will appear in the lower portion of the screen. If you attempt to exit this screen you will be reminded to save your contact choice before proceeding (Fig.
  • Page 60 Fig. 4-71 To initiate a start time, touch DISABLE to negate any current program, and then touch the time box. A number pad will appear that will allow the input of your desired start time (Fig. 4-72). Fig. 4-72 Fig. 4-73 After the hours and minutes have been programmed, you will need to input the desired sample rate;...
  • Page 61 SELECT PIN: This function allows the user to input and program their own Personal Identification Number (PIN). When the “Enable PIN Security” box is checked the Start/Stop function will not be available unless this PIN is entered (Fig. 4-74). Fig. 4-74 BATTERY TEST: This function allows the user to immediately test the internal batteries.

  • Page 62: Touch Screen Menus

    Fig. 4-75c TOUCH SCREEN MENUS The following diagrams depict the structure of the available menus for this UPS. For ease of understanding the menus are separated into the following: A55-00033 Rev. E December 2015...

  • Page 63: Main Menu

    POWERVAR 3200 Series LCD Command Tree Main Menu HOME MAIN MENU MONITOR MENU (1.0) INPUT INPUT (1.1) VOUT (1.2) CURR OUTPUT IOUT (1.3) VOLT BATTERY STATUS (1.41) BATTERY STATUS ON AC (1.4) BATTERY (Depends on mode) ON BAT (1.5) BYPASS BYPASS (1.6)
  • Page 64 POWERVAR 3200 Series LCD Command Tree Main Menu Part B MAIN (0) See MAIN - A MONITOR MENU (1.0) CONTROL MENU (2.0) See tree in MAIN - A START/STOP SETUP SETUP MENU (2.10) DATE/TIME SETUP DATE/TIME (2.11) CHANGE DATE/TIME CHANGE TIME ZONE (1.50) COMM PORTS COMM PORTS MENU (2.6)
  • Page 65 Home Screen # 000 Fig. 4-76 The HOME screen and its self-explanatory start-up variations………. Fig. 4-77 Fig. 4-78 The UPS will initialize then automatically go to static bypass. Press Start button to activate UPS. A55-00033 Rev. E December 2015...
  • Page 66 Fig. 4-79 Fig. 4-80 Once START is initiated the rectifier will start, after system checks the inverter will come on line. Fig. 4-81 Fig. 4-82 HOME screen during “normal” and “battery” operations, once BATTERY breaker is closed Fig. 4-83 Fig. 4-84 A55-00033 Rev.
  • Page 67 Fig. 4-85 If the “STOP” sequence is initiated, the UPS will transfer to static bypass (Fig. 4-85). If a fault condition is detected, the unit will alarm and transfer to bypass. Fig. 4-86 When the “MAINTENANCE BYPASS” switch is placed in the “bypass” position, the maintenance bypass path will appear on the “HOME”...
  • Page 68 Monitor Screen # 1.0 Fig. 4-87 Fig. 4-88 During normal operation the MONITOR screen can be accessed by pushing the blue “MONITOR” button at the bottom of the HOME screen. Once accessed, the blue buttons at the bottom of this screen can be pushed and scrolled, or the individual sections of the power path may be touched to gain access to the following informational screens: Fig.
  • Page 69 Fig. 4-90 OUTPUT (CURRENT): Individual phase current values in RMS and percentage of total available current Fig 4-91 Fig. 4-92 BATTERY (With AC Present): Battery voltage and charge current, # of times on batteries, and % of battery charge BATTERY (When on batteries): # of times on batteries, battery voltage, discharge current and estimated runtime at current load level A55-00033 Rev.
  • Page 70 BYPASS: L-L voltage, RMS phase current, and frequency of the available bypass source ALARM DETAIL: description, type, time of alarm, and code of the alarm. Pressing “ACK” (acknowledge) will silence the audible alarm. Pressing “CALL SERVICE” will display the phone # of local service provider or POWERVAR Fig. 4-94 Fig. 4-95 OPERATION SUMMARY: # of times on batteries, inverter &...
  • Page 71 Fig. 4-96 Fig. 4-97 ALARM SUMMARY: Displays details of any current alarms BATTERY HISTORY: shows time stamp and date of power fail history Fig. 4-98 Fig. 4-99 DATA LOG: shows summary of input voltage &kVA, and output current. The sample rate for these values is set up in the control menu.
  • Page 72 CONTROL SCREEN # 2.0 Fig, 4-100 During “normal” operation the CONTROL screen can be accessed by pushing the blue “CONTROL” button at the bottom of the HOME screen. Once accessed, the blue buttons at the bottom of this screen can be pushed or scrolled to gain access to the following interactive screens: Fig.
  • Page 73 Fig. 4-102 Fig. 4-103 Fig. 4-104 Fig. 4-105 Fig. 106 Fig. 4-106 These screens guide the user through the process required to set the year, date, time and time zone on the internal clock in the UPS. A55-00033 Rev. E December 2015...
  • Page 74 Fig. 107 COMM PORTS SETUP MENU: allows user access to the RS-232 and LCD COMM ports available on this unit Fig. 4-108 Fig. 4-109 These two screens allow the user to configure the available COMM ports. I/O CONTACTS: Choosing this option will allow the user to custom configure the DIGITAL INPUTS, the OUTPUT CONTACTS and the AS/400 INTERFACE.
  • Page 75 Fig. 4- 110 Fig. 4-111 Fig. 4-112 Fig. 4-113 DIGITAL INPUT: press the numbered contact to configure it from the pre-determined “SELECT ACTION” menu. Fig. 4-114 Fig. 4-115 A55-00033 Rev. E December 2015...
  • Page 76 Fig. 4-116 Fig. 4-117 Press the desired option, once highlightedyou will be asked to SAVE the change, then reminded befroe exiting this screen. There are a total of eight options for the digital inputs. OUTPUT CONTACTS: press to highlight the desired output contact, then choose from the predetermined ”SELECT ACTION”...
  • Page 77 Fig. 4-120 Fig. 4-121 UPS CONTACTS, COUNT = 4: 5. Summary Alarm 6. Rectifier Overload OPTIONS: 7. Inverter Overload 8. Inverter Voltage Out of Margins 1. Mains Fail – Battery discharge 9. Maintenance Bypass- Inverter 2. Load on Bypass Not Available 3.
  • Page 78 28. Battery Abnormal 29. UPS Fault 30. Battery Temperature Abnormal via Digital Input As with the INPUT contacts, the desired change will not take effect until the “SAVE” button is pressed. The user will be reminded before leaving the set up screen. LANGUAGE: Allows user to set default language of all screens.
  • Page 79 Fig. 4-125 SELECT PIN: allows user to enable password security to start/stop unit and configure the time/date stamp. Not checking the “enable” box will leave unit with no password protection. Fig. 4-126 BATTERY TEST: allows user to immediately test batteries or set up a recurring test schedule A55-00033 Rev.
  • Page 80 Fig. 4-127 A55-00033 Rev. E December 2015...

  • Page 81: Maintenance

    Maintenance A55-00033 Rev. E December 2015...

  • Page 82: Ups Maintenance

    UPS Maintenance POWERVAR recommends maintenance checks of this UPS at regular intervals to ensure that it will perform within its specifications for many years. To ensure proper operation of this UPS POWERVAR encourages daily visual inspection to affirm the following: •...

  • Page 83: Battery Maintenance

    Battery Maintenance The Batteries in the POWERVAR 3200 Series UPS are sealed lead-acid. POWERVAR recommends the replacement of the internal UPS batteries every two years. When replacement is necessary, proper disposal and recycling is required. Please consult your local codes for disposal requirements.

  • Page 84: Battery Replacement

    ****SAVE THESE INSTRUCTIONS**** This manual contains important instructions to be followed during installation of the batteries in the POWERVAR 3200 Series UPS (10-40kVA). Please read all instructions before installing or operating the described equipment and PLEASE SAVE THIS MANUAL FOR FUTURE REFERENCE! The servicing and installation of batteries should be performed by factory authorized personnel.
  • Page 85 When replacing batteries, replace with the same type, and number of batteries. Manufacturer: CSB Battery (www.csb-battery.com) Quantity: 36 Model: Rating: Terminal Type: HR 1234W (10kVA) 12v 34W .250 Fast ON HR 1251W (20kVA 12v 51W .250 Fast ON GP 12260B1 (30/40kVA) 12v 26 AH Recessed tab with M5 hole...
  • Page 86 Additional Precautions: CAUTION: Do not dispose of batteries in a fire. There is a severe risk of explosion. CAUTION: Do not open or mutilate batteries. Released electrolyte can be toxic and is harmful to the skin and eyes. CAUTION: Batteries present risk of electric shock and high short circuit current.
  • Page 87 For 10/20kVA UPS models: Tools Required: A #2 Philips screwdriver, voltmeter, small pliers Upon receipt of the battery trays, POWERVAR recommends a thorough inspection with the following in mind: • Verify that you have received the six trays (for each unit) required for installation •...
  • Page 88 Verify that all connections between the batteries within the tray are secure; if not, using the small pliers; secure these connections to the battery tabs (Fig. 5-3). If any interconnection cables are missing from the harness, please contact POWERVAR immediately.
  • Page 89 CAUTION: Potentially dangerous DC voltages will be present at the cable connectors. Please proceed with great caution. • Using the voltmeter, insert measuring probes into the battery tray connector to verify full tray DC voltage at the harness connector. The range of DC voltage present should be 72-81 vDC.
  • Page 90 These trays are heavy (35 lbs.) and it is recommended that assistance be sought if necessary. 4. Slide battery trays (one at a time), onto the shelves of the UPS. The connector should face the front of the UPS. Make sure the trays are installed so that they are in contact with the tray stops located at the rear of each shelf (Fig.
  • Page 91 5. Once all trays on any shelf are in place the tray keepers may be re-installed (Fig. 5-7). 10/20 kVA Units 3 Battery trays per shelf 1 Tray Keeper per Shelf Secure with 3 screws Fig. 5-7 6. The individual battery trays may now be connected to the UPS’ internal battery harness.
  • Page 92 Expanded view: Single shelf—10/20kVA 7. Once all of the tray connections have been made, the battery chamber cover may be re-installed. 8. Once secured, the UPS may be started. A55-00033 Rev. E December 2015...
  • Page 93 • Verify that all connections between the batteries within the tray are secure; secure these connections to the battery terminals. If any interconnection cables are missing from the harness, please contact POWERVAR immediately. CAUTION: Potentially dangerous DC voltages will be present at the cable connectors.
  • Page 94 1. Open front door of the UPS by pulling on the left-hand side (Fig 5-8). 2. Uninstall battery chamber cover by removing perimeter cover screws (eleven total). Fig. 5-8 Fig. 5-9 3. Uninstall battery tray keepers by removing screws (3 total) at the front of the individual shelves.
  • Page 95 installed so that they are in contact with the tray stops located at the rear of each shelf (Fig. 5-10). 30/40kVA units 4 battery trays per shelf 3 batteries per tray Total: 12 trays; 36 batteries Fig. 5-10 5. Once all trays on any shelf are in place the tray keepers may be re-installed (Fig.
  • Page 96 30/40kVA units 4 Battery Trays per Shelf 1 Tray Keeper per Shelf Secure with 3 screws Fig. 5-11 6. The individual battery trays may now be connected to the UPS’ internal battery harness. CAUTION: Once a single battery tray connection has been made, dangerous DC voltages will be present at the cable connectors.
  • Page 97 Expanded view: Single shelf—30/40kVA Once all of the tray connections have been made, the battery chamber cover may be re-installed. Start UPS per start up procedure. A55-00033 Rev. E December 2015...

  • Page 98: Warranty

    Warranty A55-00033 Rev. E December 2015...

  • Page 99: Product Warranty

    3200 Series Products 3200 Series products (hereafter referred to as “Product”) are warrantied to be free from defects in material and workmanship for the lesser of twenty four (24) months from Product start-up or thirty (30) months from Product shipment from POWERVAR on the chassis, electronic components and batteries.
  • Page 100 POWERVAR for the Products, their merchantability, or fitness for any particular purpose. In no event shall POWERVAR be liable for lost profits, goodwill, or any other special or consequential damages. A POWERVAR Corporate Officer must approve any warranties, programs or policies not stated herein in writing before they will be implemented with any Customer.

  • Page 101: Service And Troubleshooting

    Service and Troubleshooting A55-00033 Rev. E December 2015...
  • Page 102 Troubleshooting the POWERVAR 3200 Series The POWERVAR 3200 Series utilizes a complex proprietary firmware program to control and oversee its many functions. This program is continually monitoring the input line and output load while simultaneously running internal diagnostic checks designed to keep track of all meaningful internal behavioral parameters of the UPS.
  • Page 103 A55-00033 Rev. E December 2015...
  • Page 104 A55-00033 Rev. E December 2015...
  • Page 105 A55-00033 Rev. E December 2015...
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  • Page 107: 8. Drawings

    Drawings A55-00033 Rev. E December 2015...
  • Page 108 POWERVAR 3200 Series 10/20kVA Dimensions A55-00033 Rev. E December 2015...
  • Page 109 POWERVAR 3200 Series 30/40kVA Dimensions A55-00033 Rev. E December 2015...
  • Page 110 A55-00033 Rev. E December 2015...
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  • Page 118 POWERVAR 3200 Series Shipping Weights and Dimensions: Model UPS Crate Battery Pallet (kVA) 24” W x 41”D x 56”H 40”W x 48”D x 32”H 441 lbs. 479 lbs. 24” W x 41”D x 56”H 40”W x 48”D x 32”H 449 lbs.

  • Page 119: Facility Data Planning Guide

    Facility Data Planning Guide - 3200 Series 10 - 40kVA UPS (208V input, 208V output) UPS AC Input (208V) AC Output (208V) Mechanical Information (UPS only) Battery System Power Min. Input Floor Rating Heat Cooling Voltage Current Current Dimensions Weight...

  • Page 120: A55-00033 Rev. E December

    North American addresses: POWERVAR Inc. 1450 Lakeside Drive Waukegan, IL 60085 Toll Free: (800) 369-7179 Inside Illinois: (847) 596-7000 FAX: (847) 596-7100 POWERVAR Mexico Camino a la Montana No. 178-101 PB4 Fracc. Industrial La Perla 53340 Naucalpan, Edo. De Mexico...

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