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CertaUPS PowerControl C500R-060-B UPS Installation Manual

Powercontrol c500r series. rack/tower 6-10kva
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Summary of Contents for CertaUPS PowerControl C500R-060-B UPS

  • Page 1 C500R 6-10kVA (B) Rack/Tower 6-10kVA Installation/Manual Service and support WWW.CERTAUPS.COM INFO@CERTAUPS.COM T: +44 (0)1246 431 431...

  • Page 2: Table Of Contents

    Contents 1. INTRODUCTION ....................1 2. SAFETY WARNINGS ..................4 2.1 I ..................... 4 NSTALLATION C500R-100-B ....................... 5 2.2 O ....................... 6 PERATION 2.3 M ..............6 AINTENANCE SERVICING AND FAULTS 2.4 T ....................... 7 RANSPORT 2.5 S ......................7 TORAGE 2.6 S .......................
  • Page 3 6.2 T UPS ................... 55 RANSPORTING THE 6.3 S ............... 55 TORING THE ATTERIES 6.4 T ................... 56 ESTING ATTERIES 6.5 R UPS ..............56 ECYCLING THE ATTERY OR 7. SPECIFICATIONS .................... 57 7.1 E .................. 57 LECTRICAL SPECIFICATION 7.2 D ..................

  • Page 4: Introduction

    1. Introduction The PowerControl C500R Series is an uninterruptible power supply incorporating double-conversion technology. It provides protection specifically tailored towards computer equipment, communication systems and computerized instruments. It protects your sensitive electronic equipment from power problems such as power failures, power sags, power surges, brownout, and line noise.
  • Page 5 Figure.1-2.Online C500R-100-B UPS Online R/T UPS as Tower installation. Figure.1-3.Online C500R-060-B UPS Figure.1-4.Online C500R-100-B UPS Providing outstanding performance and reliability, the C500R benefits...
  • Page 6 include:  Online UPS design with pure sine wave output.  True online double-conversion technology with high power density, utility frequency independence, and generator compatibility.  Intelligent Battery Management technology that uses advanced battery management to increase battery service life and optimize recharge time.

  • Page 7: Safety Warnings

    2. Safety Warnings CAUTION: Before performing the procedures in this document, read and follow the safety instructions and important regulatory information in your Safety, Environmental, and Regulatory Information document. IMPORTANT SAFETY INSTRUCTIONS PLEASE RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE. 2.1 Installation ...

  • Page 8: C500R-100-B

     For model C500R-100-B, use minimum 10mm for Equipment input and grounding Wire, 75C copper wire and 22.1 lb-in torque force when connecting to input terminal block.  For model C500R-060-B, Use minimum 6mm for Equipment input and grounding Wire, 75C copper wire and 18 lb-in torque force when connecting to input terminal block.

  • Page 9: Operation

    2.2 Operation  Do not disconnect the earth conductor cable from the UPS or the building wiring terminals at any time since this will affect the protective earthing of the UPS system and of all connected loads.  The UPS output terminal block may be electrically active even if the UPS system is not connected to the building wiring terminal.

  • Page 10: Transport

    1） Remove all jewellery, wristwatches, rings and other metal objects 2） Use only tools with insulated grips and handles. 3） When changing batteries, replace with the same quantity and the same type of batteries. 4） Do not attempt to dispose of batteries by burning them. It can cause explosion.

  • Page 11: Standards

    2.6 Standards * Safety IEC/EN 62040-1 * EMI Conducted Emission......:IEC/EN 62040-2 Category C2 Radiated Emission......:IEC/EN 62040-2 Category C2 *EMS ESD..........:IEC/EN 61000-4-2 Level 4 RS...........:IEC/EN61000-4-3 Level 3 EFT..........:IEC/EN 61000-4-4 Level 4 SURGE......... :IEC/EN 61000-4-5 Level 4 CS..........:IEC/EN 61000-4-6 Level 3 Power-frequency Magnetic field..

  • Page 12: Installation

    3. Installation This chapter explains:  Equipment inspection  Unpacking the cabinet  Checking the Accessories  UPS setup and installation  Connecting the internal battery  Connecting the EBM(Extended Battery Modules)  Installation requirements 3.1 Inspecting the Equipment If any equipment has been damaged during shipment, keep the shipping cartons and packing materials for the carrier or place of purchase and file a claim for shipping damage.
  • Page 13 Step 1: Open the outer carton and remove the accessories package in the cabinet (see Figure 3.1&3.2). C500R-060-B UPS: Figure 3.1: Unpacking the Carton of C500R-060-B UPS C500R-100-B UPS...
  • Page 14 Figure 3.2: Unpacking the Carton of C500R-100-B UPS CAUTION: The cabinet is heavy. Lifting the cabinets out of the carton requires two persons at least. Step 2: With one person on each side, carefully lift the cabinet out of the outer carton using the handles on the cardboard and set it on a flat, stable surface (see Figure 3.3&3.4).

  • Page 15: Ups Rear Panel

    Figure 3.3: Lifting the Cabinet out of C500R-060-B carton Figure 3.4: Lifting the Cabinet out of C500R-100-B carton Step 3: Discard or recycle the packaging in a responsible manner, or store it for future use. 3.3 UPS Rear Panel This section shows the rear panel of the C500R models. C500R-060-B model:...

  • Page 16: Ups Front Panel

    Figure 3.5: Online C500R-060-B Rear Panel C500R-100-B model: Figure 3.6: Online C500R-100-B Rear Panel 3.4 UPS Front Panel This section shows the front panel of the Online R/T UPS. The Online series have the same LCD panel and the same control button. LCD panel On/Off Button Select Button...

  • Page 17: Rack Mount Setup

    Figure 3.7: The Online R/T UPS Front Panel 3.5 Rack Mount Setup CAUTION: The cabinet is heavy, so: 1) Remove the battery packs from the UPS before lifting. 2) Lifting the cabinets into the rack requires a minimum of two people. CAUTION: removal or replacement of the batteries should be performed or supervised by authorised personnel with knowledge of batteries .
  • Page 18 Figure 3.9. Removing the Battery Protection Plate 3. Pull the battery tray out using the plastic tabs and then remove the battery tray.(see Figure 3.10) Figure 3.10: Removing the Battery Packs terminal box 4. Install the UPS and ’s ears to the UPS Figure 3.11: Install the UPS and terminal box’s ears to the UPS 5.
  • Page 19 Figure 3.12: Install the sliding rails 7. For 10K---Install the battery pack and battery protection plate, then replace the front panel. Figure 3.13: Install the UPS to the rail, then replace the front panel 8. For 6K---Replace the battery tray, and connect the internal battery connector, then replace the protection plate and the front panel.
  • Page 20 3.5.2 Installing the EBMs To install EBMs: C500R-060-B Model: 1. Plug the EBM cable into the UPS battery connector Figure 3.14. Plug the EBM cable into the UPS battery connector 2. Replace UPS’s front panel and EBM’s front panel.
  • Page 21 Figure 3.15. Replace UPS’s front panel and EBM’s front panel. CAUTION: Please connect the EBM to protective ground with 10mm wire for B500-R100-B model firstly. C500R-100-B Model: Figure 3.16. Plug the EBM cable into the UPS battery connector...

  • Page 22: Tower Setup

    3.6 Tower Setup Tower setup as below: Figure 3.17. Tower setup 3.7 Installation of UPS with AC inputs CAUTION: Online C500R-060-B/ C500R-100-B series support that the UPS can have separate AC inputs. So before connecting wires of seperate AC inputs, you should confirm that their earthing systems are identical. Otherwise, a transformer is necessary.
  • Page 23 UPS with common Normal and Bypass AC inputs UPS with separate Normal and Bypass AC inputs  Earthing systems are identical:  Earthing systems are separate: Three different installations can be choosen: 1) Transformer in the Normal AC input.
  • Page 24 2) Transformer in the Bypass AC input. 3) Both of them have transformer Frequency converter (without Bypass AC input)

  • Page 25: Power Cables Connection & Startup

    4. Power cables connection & Startup This section explains:  Access to the terminal block  Common input sources connection  Separate input sources connection  Frequency converter connection  UPS initial startup 4.1 Access to terminal block Access to terminal block: remove the 2 screws of the terminal block cover Figure 4.1.

  • Page 26: Common Input Sources Connection

    4.2 Common input sources connection CAUTION: This type of connection must be carried out by qualified electrical personnel. CAUTION: Always connect the earth wire first. Figure 4.2. Common input sources connection 4.3 Separate input sources connection CAUTION: This type of connection must be carried out by qualified electrical personnel.

  • Page 27: Frequency Converter Connection

    CAUTION: Always connect the earth wire first. Figure 4.3. Separate input sources connection 4.4 Frequency converter connection CAUTION: This type of connection must be carried out by qualified electrical personnel. CAUTION: Always connect the earth wire first.
  • Page 28 Figure 4.4. Frequency converter connection Use cable cross section and protective device specification Model C500R-060-B C500R-100-B Protective earth conductor (10AWG) 6mm2(8AWG) Min cross section Input L, N, G (10AWG) (8AWG) Min conductor cross section Input fuse Output L,N, (10AWG) (8AWG) Min conductor cross section External Battery Cabinet Positive Pole(+), Negative pole(-),...

  • Page 29: Ups Initial Startup

    The UPS does not have an automatic protection device against current backfeed. Installation of an external isolation device is recommended, as shown in the following illustration. Check for hazardous voltage between all terminals before operating this circuit. 4.5 UPS Initial Startup To start up the UPS: Verify that the total equipment ratings do not exceed the UPS capacity to prevent an overload alarm.

  • Page 30: Parallel Operation

    5. Press the button on the UPS front panel for at least 1 second. 6. Check the UPS display for active alarms or notices. Resolve any active alarms before continuing. See “troubleshooting”. 7. Verify that the UPS is operating normally and any loads are powered. 8.
  • Page 31 Figure 4-5 and ensure all breakers are open.
  • Page 32 Figure 4-5.a: Parallel systerm wiring diagram of 6K/10K Figure 4-5.b: Parallel System Installation Diagram Turn on the mains Breakers and the input breakers for the two parallel UPS.
  • Page 33 Press the button continuously for more than 1 second on one UPS in the system, then the system will start to turn on and enter line mode. Regulate the output voltage of the each UPS separately, and check if the output voltage difference between the two UPS is less than 0.5V. If the difference is more than 0.5V, the UPS need to be regulated.
  • Page 34 How to remove a single UPS from a parallel system: Firstly a main maintenance mechanical switch or static switch should be installed for the parallel system. 2) Ensure the bypass is normal and the bypass setting is “enable”, press button to turn off the UPS system, and the UPS system will work in bypass mode.

  • Page 35: Operation

    5. Operation 5.1 Display Panel The UPS has a four-button graphical LCD with dual colour backlight. Standard back-light is used to light up the display with white text and a blue background. When the UPS has a critical alarm, the backlight changes the text to dark amber and the background to red.
  • Page 36 Table 5-1 Control Button Functions The Button Function Illustration When the unit has no power and is connected Power on with battery, press this button for >100ms&<1s to power on When the unit is powered on and in Bypass Turn on mode, press this button for >1s to turn on When the unit has been turned on, press this Turn off...
  • Page 37 UPS condition Buzzer status Fault active Continuous Warning active Beep every second Battery output Beep every 4 seconds, if battery low, buzzer beeps every second Bypass output Beep every 2 minutes The UPS provides useful information about itself: Load status, events, measurements, identification, and settings through the front panel display.

  • Page 38: Operating Mode

    Figure.5-2. The default LCD display More operation details for LCD are illustrated in chapter 5.4 5.2 Operating mode Different graphic symbols could be displayed according to current operating mode or status. 5.2.1 Line mode An example of the LCD display in Line mode is shown in the following diagram: Figure.5-3.
  • Page 39 5.2.2 Battery mode An example of the LCD display in battery mode is shown in the following diagram: Figure.5-4. Battery mode When the UPS is running in battery mode, the buzzer beeps once every 4 seconds. 5.2.3 Bypass with output The LCD display in bypass mode with output is shown in the following diagram.
  • Page 40 Figure. 5-5 Bypass mode with output 5.2.4 Bypass without output The LCD display in bypass mode without output is shown in the following diagram: Figure. 5-6 Bypass mode without output mode 5.2.5 HE mode (High Efficiency When the UPS is turned on, the power is supplied from the utility power via the internal filter while the utility power is in normal range, so the high efficiency can be gained in the HE mode.
  • Page 41 Figure. 5-7 HE mode...
  • Page 42 The function could be enabled through the LCD setting or the software (Winpower, etc.). It should be noted that the transfer time of UPS output from HE mode to battery mode is about 10ms. But this is still too long for some sensitive loads.
  • Page 43 Figure. 5-9 Warning 5.2.8 Fault When a fault occurs, the UPS will directly cut off the output or transfer to bypass, and keep alarming. The backlight of LCD will also turn to red. Figure. 5-10 Fault...
  • Page 44 5.2.9 Other status When the UPS is overloaded, the alarm will beep twice every second. Some unnecessary loads should be removed one by one to decrease the loads connected to the UPS. Figure. 5-11 Overload While doing the battery test, LEDs will be illuminated and the battery test will be shown on the display.

  • Page 45: Turning On And Turning Off Ups

    alarm. Figure. 5-13 Battery Fails 5.3 Turning on and Turning off UPS Attention: The UPS can only be turning on when connected with the utility, for the first time. Attention: Connected loads should be switched off before turning on the UPS. Loads should then be switched on one by one after the UPS is turned on wherever possible.
  • Page 46 5.3.2 Turning on the UPS without utility Check all the connections are correct. Press button continuously for more than 100ms and the UPS will power on. The fan begins to rotate and the LCD will show the logo. Then LCD will show the default UPS status summary screen after the UPS finishes the self-test.

  • Page 47: Lcd Operation

    5.4 LCD operation The user can get more useful information about UPS: current status, detailed various measurements, previous event records which ever occurred, UPS own identification, and could change the settings to fit the user own requirements, optimize the function of UPS 5.4.1 The main menu In the default UPS status summary screen, when pressing <1...
  • Page 48 Figure. 5-14 Main menu tree...
  • Page 49 5.4.2 The UPS status menu By pressing on the menu of “UPS status”, the display will enter the next UPS status menu tree. The content of UPS status menu tree is the same as the default UPS status summary menu. By pressing >1 second, the display will return the last main menu tree.
  • Page 50 5.4.3 The event log menu By pressing on the menu of “Event log”, the display will enter the next event menu tree. All previous events, alarms and faults have been recorded here. This information includes the illustration, the event code, and the precise time when the event happened.
  • Page 51 Figure. 5-16 Event menu tree 5.4.4 The measurement menu By pressing on the menu of “Measurement”, the display will enter the next measurement menu tree. A lot of detailed useful information can be checked here, for example. the output voltage and frequency, the output current, the load capacity, the input voltage and frequency, etc.
  • Page 52 Figure. 5-17 Measurement menu tree 5.4.5 The control menu By pressing on the menu “Control”, the display will enter the next control menu tree. Start Battery Test: this instructs the UPS to do the battery test. Clear EPO status: once the EPO status is enabled, the UPS output will be cut off.
  • Page 53 By press >1s Control By press >1s Buzzer Mute Buzzer Mute:no Parallel UPS Identification Hold enter key to Single UPS turn off Single UPS turn off UPS Status: Battery test Settings Single UPS Battery Test Schedule battery test:no Parallel UPS Status: Battery test Parallel UPS Battery Single UPS...
  • Page 54 Figure. 5-18 Control menu tree 5.4.6 The identification menu By pressing on the menu of “Identification”, the display will enter the next identification menu tree. The identification information includes the UPS serial number, firmware serial number, model type, will be shown here. By pressing >1 second, the display will return the last main menu tree.
  • Page 55 load, battery or UPS. Most of settings could only be changed while UPS is in Bypass mode. Password:0000 HE voltage high User password Auto Restart limit <disabled> <enabled > <5% (230V ) > enabled/disabled enabled/disabled 1%-10% HE frequency Audio Alarm Automatic overload Low Limit restart...
  • Page 56 Figure 5-19:Setting menu tree...

  • Page 57: Ups Maintenance

    Example: set rated output voltage value Setting menu tree By press <1s The option would flash Output voltage Output voltage <230V> <230V> By press <1s By press <1s, to select the wanted option Output voltage <220V> By press >1s, to confirm the setting The option would stop flashing Output voltage after being confirmed...

  • Page 58: Transporting The Ups

    Note: The batteries in the UPS are rated for a 3-5 year service life. The length of service life depends on the frequency of usage and ambient temperature. Batteries used beyond expected service life will often have severely reduced runtimes. Replace batteries at least every 5 years to keep units running at peak efficiency.

  • Page 59: Testing Batteries

    Battery” alarm and the audible alarm sounds continuously, the batteries may need replacing. Contact your service representative to order new batteries. 6.4 Testing Batteries For a battery test, please check:  The batteries must be fully charged.  The UPS must be in Normal mode with no active alarms. ...

  • Page 60: Specifications

    7. Specifications This chapter provides the following specifications:  Model list  General Specification  Electrical Performance  Environmental and Safety 7.1 Electrical specification Model C500R-060-B model C500R-100-B model Output Power Capacity 6KVA/5.4KW 10KVA/9KW 208VAC/220VAC/ 208VAC/220VAC/ Voltage Range 230VAC/ 240VAC 230VAC/ 240VAC Frequency 50/60Hz...

  • Page 61: Dimension And Weight

    Voltage Range 176-276Vac (45~55)/(54~66)Hz Frequency Range 26.4A@230Vac 44.0A@230Vac Current  0,99 @100% Nominal Load  0,98 @50% Nominal Load Power Factor  0,95 @25% Nominal Load < 5 %@Full load and battery full charged THDI Battery & Charger Battery 180VDC/5Ah 240VDC/9Ah Current Charger current...

  • Page 62: Troubleshooting

    8. Troubleshooting The online series UPS is designed for durable, automatic operation and issues alarms to alert you whenever potential operating problems occur. Usually the alarms shown by the control panel do not mean that the output power is affected. Instead, they are preventive alarms intended to alert the user.
  • Page 63 Site Fault detection is supported on all models anytime there is a Site Fault detection should be Grounding Neutral enabled by default. It can still Site Wiring Fault connection. be enabled / disabled from the Alarm Code: 04 LCD settings menu. Alarm triggers when the difference between ground Reconnect all input wires...
  • Page 64 Alarm Code:41 equipment from the UPS. The UPS continues to operate, but may switch to Bypass mode or shutdown if the load increases. The alarm resets when the condition becomes inactive. UPS has transferred to The UPS transfers to Battery Inv Overload Fault bypass or fault mode mode if supporting the load.
  • Page 65 BUS Under Voltage Indicates that the UPS get The UPS transfers to Bypass BUS under voltage fault mode if supporting the load Alarm Code:22 Indicates that the positive BUS Unbalance BUS voltage and negative The UPS transfers to Bypass BUS voltage are too mode if supporting the load Alarm Code:23 lopsided to fault...

  • Page 66: Communication

    Parallel cable loss In parallel system，parallel Disconnect parallel cable one cable disconnect turn to fault mode Alarm Code: E2 Parallel system battery UPS1 connect battery， status Check battery connect status UPS2 without battery Alarm Code: E6 Line input different Parallel system，UPS1 line Check the line input ok，UPS2 line loss Alarm Code: E7...

  • Page 67: Rs-232 Interface

    9.2 RS-232 Interface The RS-232 port is available for UPS monitoring, control, and firmware updates. The cable pins for the RS-232 communication port are identified in the following illustration. RS-232 communication port pin assignments Direction from Signal name Function the UPS Unused Not applicable Transmit to external device...
  • Page 68 Normally open Activated closed Dry out contact schematic Dry in contact schematic The following table shows the options for the dry out/in contacts Dry out signal Description Summary Alarm Activated when any warning happens On Battery Activated when the UPS operates on battery Battery Low Activated with the battery low alarm UPS ok...

  • Page 69: Intelligent Slot

    Maintain bypass Activated by >100ms pulse, the UPS will turn to bypass mode and warning when it is activated, just like maintain switch action. The warning would disappear if the trigger pulse disappeared for one second. 9.4 Intelligent slot This series is equipped with an intelligent slot for other optional card to achieve remote management of the UPS through internet / intranet.

  • Page 70: Software

    UPSs. Installation procedure: 1. Go to the website: http://www.certaups.com/software 2. Choose the operation system you need and follow the instructions described on the website to download the software. 3. When downloading all required files from the internet, enter the product key: 511C1-01220-0100-478DF2A to install the software.

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Powercontrol c500r-100-b ups

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