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Powerware 5075 kVA Installation & Operation Manual

Harsh environment ups 50–75 kva
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  • Page 1 BPIII Harsh Environment UPS 50–75 kVA INSTALLATION & OPERATION MANUAL www.powerware.com...
  • Page 2 Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation ---------------------------------- SAVE THESE INSTRUCTIONS Conserver Ces Instructions concernant la sécurité.

  • Page 3: Table Of Contents

    Installing a Remote Monitor Panel Installing a Relay Interface Module Installing a Supervisory Contact Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Table of Contents ..........
  • Page 4 Using the Menu Options Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation ..........
  • Page 5 Printing Selected Information Entire Log (Ctrl + P) Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 ........
  • Page 6 ............Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation .
  • Page 7 Figure 23. UPS Monitor Panel Figure 24. Parts of the LCD Screen (Typical for Powerware BPIII HE 75 480/480V Unit) Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 List of Figures ..... .
  • Page 8 Figure 45. System Meters Figure 46. Battery Test Log Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation viii ......

  • Page 9: Introduction

    Powerware BPIII online power protection can be utilized to prevent loss of valuable electronic information, minimize equipment downtime, and/or minimize the adverse effect on equipment production due to unexpected power problems. The Powerware BPIII Harsh Environment (HE) Uninterruptible Power Supply (UPS) system continually monitors incoming electrical power and removes the surges, spikes, sags, and other irregularities that are inherent in commercial utility power.

  • Page 10: Figure 1. Powerware Bpiii Harsh Environment Ups System

    UPS CABINET ENVIRONMENTAL CABINET Figure 1. Powerware BPIII Harsh Environment UPS System Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 11: Using This Manual

    Using This Manual This manual describes the Powerware BPIII HE UPS installation, operation and routine maintenance. The information in this manual is divided into the sections and chapters listed. Introduction The Introduction provides a brief description of the UPS system, a description of the content of each chapter, safety, text conventions used in the manual and reference information.

  • Page 12: Conventions Used In This Manual

    The rectifier and inverter are internal UPS components that are together referred to as the power processing unit (PPU) of the UPS. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 13: Safety Considerations

    If you need to schedule initial startup, need regional locations and telephone numbers, have a question about any of the information in this manual, or have a question this manual does not answer, please call Powerware at: United States Canada Outside the U.S.
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  • Page 15: Section I Installation

    Section I Installation Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
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  • Page 17: Getting Started

    Cabinet and outlets are on the top of the UPS cabinet. You must allow clearance in front of and above each cabinet for proper air circulation. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 18: Environmental Considerations

    Carefully inspect the outer packaging for evidence of damage during transit. CAUTION: Do not install a damaged cabinet. Report any damage to the carrier and contact your local sales or service office immediately. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation OUTER PACKAGING FOAM CUSHION...

  • Page 19: Unloading The Ups System From The Pallet

    After the foam cushions clear the floor, remove the hardware loosened in step 3. Pull the foam cushions out from under the cabinet, and discard or recycle them in a responsible manner. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 in.) above the floor...

  • Page 20: Wiring Requirements

    For external wiring requirements, including the minimum AWG size of external wiring, see Tables A and E of Appendix A. The power wiring for this equipment is rated at 90˚C. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation FRONT SUPPORT...

  • Page 21: Installing The Harsh Environment Ups System

    Environmental cabinets assembled. The top view shows the cable entry plate in the Environmental cabinet. TOP VIEW FRONT VIEW Figure 4. UPS and Environmental Cabinets Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 UPS System...

  • Page 22: Installing The Ups Cabinet Sections

    Use the holes provide in the cabinet sides. Attach a ground to the joined cabinets using the procedure “Grounding Joined Cabinets” in this chapter. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 23: Grounding Joined Cabinets

    HARDWARE REMOVED BEFORE PLACING LUG OVER GROUND STUD GROUNDING CABLE FRONT CABINET BASE (side view) Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 PERMANENTLY ATTACHED HARDWARE Figure 5. Cabinet-to-Cabinet Grounding...

  • Page 24: Installing Ups Internal Power And Control Wiring

    Environmental cabinet through the cutout in cabinet sides. Connect connectors P20, P22, and P23 to connectors J20, J22, and J23 respectively. Reinstall UPS Cabinet sheetmetal shield. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 25: Installing Ups External Wiring

    Startup and operational checks should be performed only by authorized service personnel. Contact service in advance (usually a two week notice is required) to reserve a preferred startup date. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 26: Completing The Installation Checklist

    Installation Checklist to be sure you have completed all applicable equipment installation. NOTE: The Installation Checklist MUST be completed prior to starting the UPS system for the first time. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 27: Installation Checklist

    Adequate workspace exists around the UPS and other cabinets. Adequate lighting is provided around all UPS equipment. A 120V service outlet is located within 25 feet of the UPS equipment. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
  • Page 28 Notes Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 29: Installing A Remote Epo Control

    Connect the Remote EPO wiring as shown in Tables A and B: Table A. Remote EPO Wire Terminations From REPO Station(s) TB1---4 TB1---5 Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 UNINTERRUPTIBLE POWER SYSTEM to other equipment Figure 6. Remote EPO Control...
  • Page 30 Table B. Remote EPO switch wiring must be in accordance with UL Class II requirements. Secure the UPS by reversing all steps taken to prepare it for Remote EPO installation. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Table B. Remote EPO TWISTED WIRES (2)

  • Page 31: Installing A Remote Monitor Panel

    Table C. Optional Monitoring Accessories Number and Type of Accessories Permitted Remote Monitor Panel — — — Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Relay Interface Panel Supervisory Contact Module — — —...

  • Page 32: Figure 7. Remote Monitor Panel (Rmp)

    Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation FLUSH MOUNT Figure 7. Remote Monitor Panel (RMP) SURFACE MOUNT (FOR HANGING) WIRES MUST BE TWISTED 164291261 Rev. F 111503...

  • Page 33: Figure 8. Terminal Block Bracket

    Communications Panel. Connect to Port 1 (DB---9) on Communications Panel Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Figure 8. Terminal Block Bracket FUSE TERMINAL...

  • Page 34: Figure 9. Wiring An Rmp To The Ups

    TB1---7 From RMP B (if used) TB1---4 TB1---5 TB1---6 TB1---7 Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation DB---9 CONNECTOR (ON COMMUNICATIONS PANEL OF THE UPS) TB1 TB2 Figure 9. Wiring an RMP to the UPS Table D. RMP Wire Terminations...
  • Page 35 6, respectively; otherwise, secure the UPS cabinet by reversing the steps contained in procedure “To Prepare the UPS for Wiring to an RMP , RIM, SCM, or Remote EPO” of Chapter 2. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
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  • Page 37: Installing A Relay Interface Module

    Figure 10 shows the RIM with its four 15-pin connectors labeled J1 through J4. Drawing 164201261---8 in Appendix A outlines the enclosure dimensions. 15-PIN D-SUB CONNECTORS Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 FLUSH MOUNT Relay Interface Module Figure 10.

  • Page 38: Figure 11. Terminal Block Bracket

    Figure 12). Use two screws from the spare parts kit to secure the terminal block bracket to the Communications Panel. Connect to Port 1 (DB---9) on Communications Panel Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Figure 11. Terminal Block Bracket in. knockout in 7/8- FUSE...

  • Page 39: Figure 12. Wiring An Rim To The Ups

    DB---9 CONNECTOR (ON COMMUNICATIONS PANEL OF THE UPS) TB1 TB2 Figure 12. Wiring an RIM to the UPS Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
  • Page 40 From RIM A TB1---4 TB1---5 TB1---6 TB1---7 From RIM B (if used) TB1---4 TB1---5 TB1---6 TB1---7 Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Table E. RIM Wire Terminations To UPS TB3---1 TB3---2 TB3---3 TB3---4 To UPS TB3---5 TB3---6...

  • Page 41: Installing A Supervisory Contact

    (RMPs, RIMs, or SCMs) can be installed. Refer to Chapter 4, Table C for the number of accessories permitted. See Drawing 164201261---9 in Appendix A for enclosure dimensions, side views, and knockout patterns. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Installing a Supervisory Figure 13.

  • Page 42: Figure 14. Terminal Block Bracket

    Figure 15). Use two screws from the spare parts kit to secure the terminal block bracket to the Communications Panel. Connect to Port 1 (DB---9) on Communications Panel Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Figure 14. Terminal Block Bracket in. knockout in 7/8- FUSE...

  • Page 43: Figure 13. Supervisory Contact Module

    TB1---7 From SCM B (if used) TB1---4 TB1---5 TB1---6 TB1---7 Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 DB---9 CONNECTOR (ON COMMUNICATIONS PANEL OF THE UPS) TB1 TB2 Figure 15. Wiring an SCM to the UPS...

  • Page 44: Figure 16. Supervisory Contact Module Tb2

    Note: Supervisory contacts are rated at 2.0 amps at 28 Vdc or 120 Vac and 0.15 amp at 115 Vdc. Supervisory contacts require external power supply. Internal 24 Vdc is not capable of supplying contact current. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Figure 16. Supervisory Contact Module TB2 164291261 Rev. F 111503...

  • Page 45: Section Ii Operation

    Section II Operation Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
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  • Page 47: Understanding Ups Operation

    An alarm is a system event that requires immediate operator intervention. System events, alarm horns, and indicator lights are described in Chapter 12 --- Responding to System Events. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Understanding UPS Operation...

  • Page 48: Looking Inside The Ups

    Looking Inside the UPS The Powerware BPIII HE is a continuous duty, solid-state UPS that supports the following equipment: process control, data processing, and telecommunications/PBX. The Powerware BPIII HE maintains power to the critical loads during commercial electrical power brownout, blackout, overvoltage, undervoltage, and out-of-tolerance frequency conditions.

  • Page 49: Normal Mode

    If the UPS suffers an internal failure, it switches automatically to Bypass mode and remains in that mode until the failure is corrected and the UPS is back in service. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 50: Bypass Mode

    Bypass mode is a normal operating mode, and not an alarm condition. However, if the UPS is unable to return to Normal mode following an automatic transfer to Bypass mode, an alarm condition will be recorded. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation BYPASS INVERTER...

  • Page 51: Battery Mode

    Normal mode and alarm indications clear. However, the process of returning to Normal mode is not instantaneous. The rectifier gradually draws increasing power from the incoming utility until Normal mode is achieved. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 BYPASS...

  • Page 52: Maintenance Bypass Mode

    This breaker is opened to isolate the UPS bypass after the load is transferred to maintenance bypass. The MBP and MIS breakers are electrically interlocked to limit the possibility of UPS system damage from improper operation. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation BYPASS INVERTER (closed)

  • Page 53: Monitoring And Controlling Ups Operation

    These control power to and from the UPS, and allow you to change the UPS mode manually. The Control Panel is discussed in Chapter 10. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
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  • Page 55: Controls And Features

    The filter also reduces input harmonic current distortion and minimizes upstream interference that can damage sensitive hardware components. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Controls and Features...

  • Page 56: Emergency Power Off

    Customer Convenience Outlet An uninterruptible 120 VAC, 0.2 amp, fuse-protected convenience outlet is provided with the optional modem. It is located adjacent to the Communications Panel. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 57: Safety Considerations

    Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the equipment. • Always conform to the more detailed safety precautions described in “Important Safety Instructions” section of Chapter 15. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 58: Symbols, Controls, And Indicators

    Stop and refer to the Operator’s Manual for more information. RISK OF ELECTRIC SHOCK There is a risk of electric shock present, and you should observe associated warnings. The UPS contains high voltages. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 59: Using The Monitor Panel

    UPS operation. The Monitor Panel is a black rectangular area on the front of the UPS (see Figure 23). UNINTERRUPTIBLE POWER SYSTEM Figure 23. UPS Monitor Panel Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 60: Using The Lcd Screen

    Meters Events Statistics Graphics Figure 24. Parts of the LCD Screen (Typical for Powerware BPIII HE 75 480/480V Unit) The UPS status area contains three lines that display the current state of the UPS. The first line shows the present operational mode of the UPS. The second line shows the highest level of the current active alarms, and the third line shows any notices the UPS has posted.

  • Page 61: Using The Pushbuttons

    Use the pushbuttons to adjust the contrast on the LCD screen. Hold down the pushbutton, then press the pushbutton to decrease the contrast. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 pushbuttons to move through the menu titles on the...

  • Page 62: Reading The Status Indicators

    If any indicator does not light, its LED may need to be replaced. Contact Customer Service if you have a problem with the indicator lamps. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation pushbuttons simultaneously. The Alarm indicator may be lit pushbuttons pushbuttons 164291261 Rev.

  • Page 63: Using The Menu Options

    Meters Events Statistics Graphics Figure 25. System Meters Screen (Typical for Powerware BPIII HE 75 480/480V Unit) The Input area shows the phase-to-phase voltage, frequency, and phase current of the incoming utility, followed by the KVA, KW, and power factor measurements. The output area shows the same information for the power being output by the UPS.

  • Page 64: Figure 26. Load Amps Meters Screen

    Notice: None Battery Percent 100% Meters System Load Amps Meters Events Statistics Graphics Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Uninterruptible Power System Output Current 125% 100% Phase A Phase B Setup Figure 26. Load Amps Meters Screen...

  • Page 65: Figure 27. Event History Log Screen

    When the scroll bar is in the information area, you can press the to scroll through the Event History log. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Uninterruptible Power System...

  • Page 66: Figure 28. Active System Events Screen

    Battery Minutes 001.3 Events History Active Meters Events Statistics Graphics Setup Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Uninterruptible Power System Shutdown Imminent Active System Events NOTICE: Input power unavailable NOTICE: Bypass Not Available ALARM: Shutdown Imminent Figure 28.

  • Page 67: Figure 29. Unit Statistics Screen

    UPS logic has been functioning since the start date. The lower right column shows the percent of availability of the UPS and the bypass source. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 68: Figure 30. Mimic Screen

    Mimic Meters Events Statistics The Mimic screen shows the internal components of the UPS cabinet. The flow of current through the components is highlighted. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Uninterruptible Power System Bypass Rectifier Inverter...

  • Page 69: Figure 31. Time Setup Screen

    (make it a higher value), press the (make it a lower value), press the upon exit from this screen, be sure the SAVE field is set to YES. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Uninterruptible Power System Set Time &...

  • Page 70: Figure 32. Port Setup Screen

    SAVE field is set to YES. The setup screens for Port 1 and Port 2 are identical. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Uninterruptible Power System Setup Serial Port 1...

  • Page 71: Operating The Ups

    UPS system operates properly. BYPASS INPUT BREAKER (BIB) CONTROL PANEL MONITOR PANEL Figure 33. Location of the Operating Controls Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Operating the UPS MAINTENANCE MAINTENANCE BYPASS ISOLATION BREAKER (MBP)

  • Page 72: Using The Operating Controls

    DC to DC converter if the converter shuts down during normal operation. • The PUSH TO RESET pushbutton is described in the “Resetting UPS System after Emergency Power Off” section of this chapter. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation NORMAL PUSH TO RESET BATTERY...
  • Page 73 UPS internal bypass circuit. This breaker is opened to isolate the UPS bypass after the load is transferred to maintenance bypass. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 74: Operation

    CB2 breaker switch to OFF. Then move the CB1 breaker switch to OFF. The bypass source supplies the critical load and the power processor de-energizes. The Bypass mode indicator illuminates on the Monitor Panel. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 75: To Start The Ups In Bypass Mode

    Open MBP circuit breaker. The critical load is now on UPS bypass. To transfer the critical load to normal mode follow the procedure “To Place the UPS in Normal Mode” at the beginning of this section. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 76: To Cold Start The Ups From Battery (No Ac Input Power)

    The DC walks up to 540 VDC. The inverter starts. K3 closes. All fans and blowers are functional. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Horn sounds every 2 seconds. Load Off Converter Offline Bypass AC Under Voltage...

  • Page 77: To Shut Down The Ups From Cold Start

    Turn BATTERY switch to OFF. Wait at least four seconds. Turn BATTERY switch to NORMAL. The converter restarts. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 System Normal, On Battery On Battery more than 30 Seconds...

  • Page 78: Using The Emergency Power Off Pushbutton

    TRIPPED position. The UPS system is now reset. To restart the UPS system, follow the procedure at the beginning of this chapter. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 79: Using Features And Options

    Building Alarm 2, Building Alarm 3, etc., on the LCD screen of the Monitor Panel. You should use twisted pair wires for each alarm input and common. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 80: Summary Alarm Contacts

    UPS is located in a remote area where the UPS alarm horn may not be heard immediately. CAUTION: Contacts should not be operated in excess of 30 VAC or 42.4V peak AC or DC @ 1A maximum. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation ALARM NO ALARM NC COMMON NOTICE NO...

  • Page 81: Remote Monitor Panel

    Table 1. Optional Monitoring Accessories Number and Type of Accessories Permitted Remote Monitor Panel — — — Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Figure 37. Remote Monitor Panel Relay Interface Module Supervisory Contact Module —...
  • Page 82 The UPS is preparing to shut down because the UPS is in Battery mode and the DC voltage is approaching its low limit. This light is accompanied by an audible alarm horn. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 83: Relay Interface Module

    UPS OFF LINE • UTILITY FAILURE • BATTERY WEAK Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Figure 38. Relay Interface Module (pins 1 and 12) Contacts are closed when the UPS is offline.

  • Page 84: Rev. F

    ON BYPASS • SHUTDOWN IMMINENT See Chapter 6, “Installing a Supervisory Contact Module” for TB2 contact configurations. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Figure 39. Supervisory Contact Module TB2---1 through TB2---3 TB2---4 through TB2---6 TB2---7 through TB2---9...

  • Page 85: Responding To System Events

    For descriptions of the status indicators, see “Reading the Status Indicators” section of Chapter 9, “Using the Monitor Panel”. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Responding to System Events...

  • Page 86: System Event Messages

    Check Unit Setup Bypass Contactor (K4) Fail Battery Ground Fault 100% Overload Shutdown 125% Overload Shutdown Over Temperature Shutdown Network Sync Failure Inverter Calibration Required Inverter Setup Required Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...
  • Page 87 Check Parallel Setup Parallel System Overload On Battery more than 30 Seconds Check UPM Breaker (CBS) AUX Check Bypass Breaker (CBP) AUX Monitor Calibration Required Monitor Setup Required Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
  • Page 88 Battery DC Under Voltage Battery Disconnected Battery Not Charged Phase A Current Limit Phase B Current Limit Phase C Current Limit Battery Voltage Low Inv. Logic Power Failure Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...
  • Page 89 Input Transient DC Voltage Low DC Voltage High Equalizing Battery Testing Battery Battery Test Failed Input/Battery Current Limit Reduced Input Current Limit Rct. Logic Power Failure Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
  • Page 90 Building Alarm 6 Active Testing Battery Battery Test Aborted (load) Battery Test Aborted (utility) Battery Passed Test ##Printing Sampled Data Other UPS Bypass Not Available Loss of Redundancy Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...
  • Page 91 CONVERTER NOTICES Converter Shutdown Converter In Startup OK To Close CB2 Converter Logic Power OK CONVERTER STATUSES Converter Normal Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
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  • Page 93: Serial Communications

    The following sections describe the serial communications feature, and provide information about connecting hardware, setting up the ports, changing settings, and changing modes. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Serial Communications This chapter describes the serial communications feature of...

  • Page 94: Locating The Communications Panel

    Connection COMMUNICATIONS PANEL PORT 2 (DB---25F) RS---232 Connection (Optional) Figure 40. Location of Communications Ports on the Powerware BPIII HE UPS (shown without the Environmental Cabinet) Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 95: Connecting Equipment To A Serial Port

    Table 3 describes them. Table 2. Pin Assignments for Port 1 (DB---9) Pin # Symbol +24V 485+ 485--- Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 PORT 1 (DB- -9) +24V NOT USED RS232 TXD 485 +...

  • Page 96: Figure 42. Port 2 Pin Assignments

    Table 3. Pin Assignments for Port 2 (DB---25) Pin # Symbol +12V ---12V NOTE: Pins 5 and 6 are tied together internally. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation PORT 2 (DB- -25) RS232 TXD RS232 RXD RS232 RTS RS232 CTS...

  • Page 97: Configuring The Serial Ports

    To save the settings upon exit from this screen, be sure the Save field is set to YES. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 98: Mode

    300 baud is not recommended for any mode except Remote Monitor. You can select a baud rate of 300, 1200, 2400, 4800, 9600, or 19,200. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Options Terminal Mode...

  • Page 99: Data/Stop

    Each communications port on the UPS operates in one of five modes which you select when configuring the port using the Setup Port screen. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 300 baud...

  • Page 100: Terminal Mode

    Prints all system information Ctrl+B Prints Battery Test Log To use a key combination, hold down the Control key and press the letter key. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation :::: Description Month (3 letters) Day (2 digits)

  • Page 101: Entire Log (Ctrl + P)

    16:42:05.5 16:42:46.8 16:43:15.8 16:43:42.4 16:44:29.1 12 16:44:36.6 STATUS: JUN 04 12:16:35.9 Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Uninterruptible Power System None Event History Log Event Description COMMAND: Keyswitch On STATUS: Auto Mode...

  • Page 102: Meters Printout (Ctrl + M)

    This key sequence prints a listing of all available serial data. This printout contains the information shown on the Event History Log and Meters screens of the UPS (both Figures 44 and 45). Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Uninterruptible Power System Input...

  • Page 103: Battery Test Printout (Ctrl + B)

    Aborted (Load), or Battery Test Aborted (Utility). If the test ran to completion, Battery Passed Test will appear in the UPS Event History Log. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 UPS # 1...

  • Page 104: System Configuration

    If 1 is entered at the prompt, you can program the building alarm functions: Program Building Alarms 1. Enable/Disable Default Functions 2. Customize Alarm Messages 3. Return to Main Menu Enter Selection: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 105: Enable/Disable Default Functions

    The line following the Enabled Building Alarm Number(s) label indicates which building alarms are currently enabled. (In this example, Building Alarms 1 and 4 are enabled.) Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 106: Customize Alarm Messages

    If the user wants to center the text portion of the name, the appropriate number of leading spaces should be included when entered. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 107: Adjust Output Voltage

    NOTE: Password must be six characters in length. <CR> to return with no change. The password will be changed if the user enters and verifies the password. The entry must be six characters. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 108: Battery Test Setup

    No Battery Test Scheduled Enter <CR> to return to Battery Test Setup Menu NOTE: The unit will only perform one battery test in any 24 hour period. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 109: Modify Low Battery Time

    For a list of products available, contact your sales representative. Remote Monitor Mode This mode provides the interface for the RMP , RIM, or SCM described earlier. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...
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  • Page 111: Remote Notification

    UPS to call a paging service and send numeric messages. The Housekeeping function maintains the link between the UPS and modem. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Optional Remote Notification...

  • Page 112: Remote Notification Features

    Remote and local ability to clear Call Out alarms and events. • Error detection and correction for misconfigured and disconnected modems. • Uses standard modems and cables available at your local computer supply center. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 113: Description Of Operation

    (phone numbers) required. The command sent to the modem for group one is “ATDTS0” and “ATDTS1” for group two. This allows the user to program the phone numbers into the modem. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 114: Housekeeping

    UPS logs a modem failure event into the event log. When the modem link is confirmed, the UPS communications resume normal operation and Call Out is enabled. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 115: Hardware Requirements

    An alternative to purchasing a cable is to build your own serial cable using the following pin out description: Male DB25 pin 7 pin 2 pin 3 Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Male DB25 pin 7 pin 2 pin 2...

  • Page 116: Configuring The Modem

    The modem should be a plug and play type. All setup is configured by the UPS. Only the initial phone number needs to be entered by the user. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 117: Configuring The Modem To Call A Remote Computer

    NOTE: To set up a group one or group two pager number, refer to “Configuring the Modem to Call a Numeric Pager” section of this chapter. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 118: Configuring The Modem To Call A Numeric Pager

    NOTE: To set up a group one or group two number to call a computer, refer to “Configuring the Modem to Call a Remote Computer” section of this chapter. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Keying in the “#”...

  • Page 119: Configuring The Modem To Answer Incoming Calls

    The final step in configuring the PC modem for use with the UPS is to turn off the echo feature of the modem. This procedure is performed automatically by the UPS. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503...

  • Page 120: Ups Setup Configuration

    Chapter 13, “Serial Communications”). If using a standard serial cable, a null modem adapter is required for the connection to the modem. The Powerware BP III HE UPS can only use optional serial Port 2, DB---25F, for the Remote Notification option. This connection is located in the serial communications panel at the base of the UPS cabinet, behind the front door.

  • Page 121: User-Selected Events

    Failed Bypass Control Failed Bypass Phase Rotation Go To Bypass Active Battery Contactor (K2) Failed Battery Ground Fault Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Group Group INVERTER MESSAGES -- NOTICES Inv. Logic Power Failed...
  • Page 122 Rectifier DC Over Voltage Rectifier DC Under Voltage Rectifier Failure Rectifier Setup Required Temperature Sensor Failure Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation RECTIFIER Group Group MESSAGES -- NOTICES Battery Test Failed DC Voltage High DC Voltage Low...
  • Page 123 Load Over 100% Load Over 125% Monitor Calibration Required Monitor Setup Required Overload Warning Power Supply Failure Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 MONITOR Group Group MESSAGES -- NOTICES Battery Passed Test...
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  • Page 125: Maintaining The Ups System

    Battery maintenance or battery replacement should be performed by authorized service personnel only. Keep unauthorized personnel away from battery room. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Maintaining the UPS System The components inside the UPS cabinet are secured to a...

  • Page 126: Performing Preventive Maintenance

    ASHRAE rating of 52.2. An AmAir 62 Plus meet these requirements. To remove filters: Loosen captive screw at left side of filter grill. Open grill. Remove and replace filter. Close filter grill and secure with captive screw. Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 164291261 Rev. F 111503...

  • Page 127: Maintenance Training

    Maintenance Training A basic training course, available from Powerware, gives you a competent working knowledge of UPS operation and teaches you how to perform first level corrective maintenance. For more information about training and other services, contact the Powerware Training Coordinator in Raleigh, North Carolina, or call Powerware field service at 1 -- 800 -- 843 -- 9433.
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  • Page 129: Product Specifications

    Current Input Current Harmonic Content Power Walk-In Power Factor Line Surges Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Product Specifications The following sections detail the input, output and Models 50 kVA, 40kW 62.5 kVA, 50kW...

  • Page 130: System Output

    Synchronous to Bypass Frequency Slew Rate Overload Capability Maximum Output Capability Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 135% + 6 Kw Ripple voltage less than 0.5% peak to peak 100% current at 0.8 power factor 1% (10% to 100% load)

  • Page 131: Environmental Specifications

    Float Charging Initialize Charge Battery Charge Current Limit Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 0 to 50˚C without derating. However, operating at or near 50˚C will adversely affect battery life (refer to your battery specifications for more information).
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  • Page 133: Appendix A

    164201261---7 • 164201261---8 • 164201261---9 Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 The information in this appendix will help you plan for and install Installation Notes Typical UPS System Oneline Drawings of UPS System...
  • Page 134 Table A. Powerware BPIII HE 50---75 kVA (208, 480, and 600 Volt) Ratings Basic unit rating at 0.8 lagging PF load gg g AC Input to UPS Rectifier Full Load Full Load + Batt. Chg.(max) (.95min.PF) 3  , (1) gnd Minimum conductor size (number per  )
  • Page 135 Non-linear loads can create neutral currents that are greater than 100%. This product can accommodate double-sized neutral terminations if needed. NOTE: Callout letter map to drawing #164201261---3 Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 OUTPUT Ratings & External Wiring Requirements for Units...
  • Page 136 Callout letter map to drawing #164201261---3 A ---4 Ratings & External Wiring Requirements for Ratings DESCRIPTION: DRAWING NO: REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Rating Units 50 Hz 62.5 INPUT/OUTPUT VOLTAGE Amps (max) AWG or...
  • Page 137 AC Output to Environmental e tal Cabinet Cabinet DC Input from Environmental Environmental Cabinet Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Cable Size of Function Termination Number Phase ‘A’ 1 --- 1 bolt mounting Phase ‘B’...
  • Page 138 Air Conditioning or Ventilation Heat Rejection BTU/hr (Kg---cal/hr) 23,000 (5796) DESCRIPTION: INSTALLATION NOTES DRAWING NO: REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Tightening Int Hex Torque Size N ---M (lb ---in ) (In.) 42.4 (375) 42.4 (375) 42.4 (375)
  • Page 139 Table H. Maximum Output Circuit Breaker Ratings Balanced Power System Balanced Power System Balanced Power 75 Balanced Power 62.5 Balanced Power 50 Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Input Voltage Rating 208V 400V 480V...
  • Page 140 A ---8 Weight Kg (lb) 1878 (4140) DESCRIPTION: INSTALLATION NOTES DRAWING NO: 164201261---1 REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation All Voltage Ratings Point Loading Kg (lb) 8 at 235 (518) SHEET: 7 of 11 DATE: 011500...
  • Page 141 Not all building alarms are available for customer use. For remote EPO, use an isolated normally open contactor switch (24VDC, 20ma minimum) connected at TB2-1 and TB2-2. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Communications Panel...
  • Page 142 Contacts used to indicate UPS Battery Contactor is closed. General purpose NO and NC relay contacts. General purpose NO and NC relay contacts. DESCRIPTION: DRAWING NO: REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Description INSTALLATION NOTES SHEET: 164201261---1 DATE: 053099 164291261 Rev.
  • Page 143 Refer to Tables L, M, and N, and to applicable chapters for information about installing control wiring for options and accessories. Terminal CONTACT RATING: Maximum Switched Voltage Maximum Carrying Current Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Table L. Control Wiring Terminations Description Terminal Function Terminal Block...
  • Page 144 NOTE: This switch must be a dedicated switch not tied into any other circuits. DESCRIPTION: INSTALLATION NOTES DRAWING NO: REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation SHEET: 164201261---1 11 of 11 DATE: 053099 164291261 Rev. F 111503...
  • Page 145 UPS CABINET Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 ENVIRONMENTAL CABINET DESCRIPTION: TYPICAL UPS SYSTEM DRAWING NO: REVISION: SHEET: 164201261---2 DATE: 053099 1 of 1 A ---13...
  • Page 146 UPS SYSTEM WITH 480/480 OR 400/400 VOLT INPUT/OUTPUT DESCRIPTION: ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO: SHEET: 164201261---3 1 of 4 REVISION: DATE: 053099 Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation A ---14 164291261 Rev. F 111503...
  • Page 147 UPS SYSTEM WITH 480/208 VOLT INPUT/OUTPUT Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 DESCRIPTION: ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO: 164201261---3 REVISION: DATE: SHEET: 2 of 4 053099 A ---15...
  • Page 148 UPS SYSTEM WITH 208/208 VOLT INPUT/OUTPUT DESCRIPTION: ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO: SHEET: 164201261---3 3 of 4 REVISION: DATE: 053099 Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation A ---16 164291261 Rev. F 111503...
  • Page 149 UPS SYSTEM WITH 600/208 VOLT INPUT/OUTPUT Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 DESCRIPTION: ONELINE DRAWINGS OF UPS SYSTEM DRAWING NO: 164201261---3 REVISION: DATE: SHEET: 4 of 4 053099 A ---17...

  • Page 150: External Wiring

    Input Switch (MIS) Source ENVIRONMENTAL CABINET EXTERNAL WIRING DESCRIPTION: LOCATION OF UPS POWER TERMINALS DRAWING NO: REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation Output Critical Load AC Input To UPS Rectifier Neutral Rectifier Input Breaker (CB1)
  • Page 151 Jumper NOTE: Connections shown are between the UPS cabinet and Environmental cabinet. External connections are shown on sheet 1. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 Ground INTERCABINET WIRING DESCRIPTION: DRAWING NO: REVISION:...
  • Page 152 DESCRIPTION: UPS CABINET DRAWING NO: SHEET: 164201261---5 1 of 1 Dimensions are in millimeters (inches) REVISION: DATE: 053099 Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation A ---20 164291261 Rev. F 111503...
  • Page 153 115.8 (4.56) 114.3 (4.50) TO UPS Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 (0.47) TO OTHER Dimensions are in millimeters (inches) EQUIPMENT DESCRIPTION: DRAWING NO: REVISION: 11.9 88.9 (3.50) (3.75) SQUARE Knockout pattern typ.
  • Page 154 EXCEED 500 FEET. A ---22 197.47 (7.75) 88.9 (3.50) DESCRIPTION: DRAWING NO: REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 285.7 (11.25) MAX. WIRE SIZE: NO. 14 AWG MIN. WIRE SIZE: NO. 18 AWG 216.58 (8.50) SURFACE MOUNT...
  • Page 155 28.6 (1.12) 41.1 (1.62) 190.5 88.9 (7.50) (3.50) EXISTING INTERNAL WIRING Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 215.9 (8.5) 196.8 (7.75) 19.0 Relay Interface Module CONDUIT AND WIRING SUPPLIED BY CUSTOMER. Maximum distance between RIM and UPS not to exceed 500 feet.
  • Page 156 A ---24 CONNECTORS 171.5 (6.75) KNOCKOUTS PROVIDED ON FIVE SURFACES Dimensions are in millimeters (inches) DESCRIPTION: DRAWING NO: REVISION: Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation 285.7 (11.25) 273.1 (10.75) RELAY INTERFACE MODULE SHEET: 164201261---8 DATE: 053099 164291261 Rev.
  • Page 157 (1.62) 190.5 (7.50) CONDUIT AND WIRING SUPPLIED BY CUSTOMER. MAX. DISTANCE BETWEEN REMOTE MONITOR AND UPS NOT TO EXCEED 500 FEET. Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operatio 164201261 Rev. F 111503 197.47 (7.75) 88.9 (3.50) DESCRIPTION:...
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  • Page 159 All parts requiring replacement for the Factory Warranty period. If, in the opinion of Powerware, the Unit fails to meet published specifications and the defect is within the terms of this warranty, the Unit will be repaired or replaced at the option of Powerware with no charge for replacement parts. Labor required, to make...
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  • Page 162 *164201261F* 164201261 Rev F...

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