Keor MOD Table of Contents 1 Introduction Purpose of the manual Symbols in the manual Where and how to keep the manual Update of the manual Manufacturer’s liability and guarantee 1.5.1 Guarantee terms 1.5.2 Extension of the guarantee and maintenance contracts Copyright 2.
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Table of Contents 5. Configuration and start-up Pre-start-up checks Start-up procedure Switching off the UPS 6. Maintenance Preventive maintenance Periodical checks Ordinary maintenance 6.3.1 Hot-swap procedure for the replacement of power modules 6.3.2 Installation/replacement of power modules with the UPS in maintenance bypass mode 6.3.2.1 Setting the UPS in maintenance bypass mode 6.3.2.2 Installation/replacement of power modules 6.3.2.3 Exit the UPS from the maintenance bypass mode...
The purpose of this manual is to provide the skilled technician (see paragraph 2.2.1) with instructions for safely installing the Keor MOD UPS, also called “equipment” in the rest of the manual and carry out ordinary maintenance procedures. Extraordinary maintenance operations are not dealt with because they are the sole preserve of the LEGRAND Technical Support Service.
The guarantee terms may vary depending on the country where the UPS is sold. Check the validity and duration with LEGRAND’s local sale representative. If there should be a fault in the product, contact the LEGRAND Technical Support Service which will provide all the in- structions on what to do.
1.5.2 Extension of the guarantee and maintenance contracts The standard guarantee can be consolidated in a single extension contract (maintenance contract). Once the guarantee period has passed, LEGRAND is available for giving a technical assistance service able to meet all requirements, maintenance agreements, 24/7 availability and monitoring.
The figure that will carry out the installation, start up and ordinary maintenance is called “Skilled Technician”. This definition refers to people qualified by LEGRAND who have the specific technical qualification and are aware of the method of installing, assembling, repairing, bringing online and using the equipment safely.
Keor MOD The following list sum up the minimum Personal Protective Equipment to wear always. Additional requirements may be needed according to national safety standards. Anti-accident and non-sparking shoes with rubber sole and reinforced toe Protective gloves for handling operations Isolated rubber gloves for operations of connection and work under hazardous voltage Protective garments for electrical work...
General warnings DANGER The UPS works with dangerous voltages. Only skilled technicians qualified and authorized by LEGRAND must perform the installation and ordinary maintenance operations. No part of the UPS can be repaired by the operator. Extraordinary maintenance operations must be carried out by LEGRAND Technical Support Service personnel.
When the UPS is used for special applications such as life support systems or any other application where a product failure is likely to cause substantial harm to people, it is mandatory to contact LEGRAND to confirm the possibility of the equip- ment to meet the requested level of safety, performance, reliability and compliance with applicable laws, regulations and specifications.
- 1 accessory box; - user manual; - installation and maintenance manual. In case of defects and/or missing items, immediately inform the LEGRAND Technical Support Service before commission- ing the equipment. INDICATION The installation manual must be used and consulted only by Skilled Technicians.
Keor MOD Transportation WARNING The UPS must be placed and stand in a vertical position throughout the transportation. It shall also be packed properly. Move the UPS very carefully, lifting it as little as possible and avoiding dangerous swings or falls. Follow always the directions indicated in the symbols present on the packaging.
3. Unpacking and moving Unpacking To remove the packaging material, two people are required and they must comply comply with the following procedure: - bring the UPS to the installation site using a forklift and/or a transpallet with suitable characteristics (see fig. 1); - remove the plastic film and cardboards protecting the UPS;...
Keor MOD Placement When the UPS is in the final position for the installation, unscrew counterclockwise the feet on the front and rear of the cabinet to position it. Make sure that all the wheels and feet adhere to the floor. (all the dimensions are in mm)
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3. Unpacking and moving The UPS must be positioned respecting the following conditions: - do not cover the cooling vents of the power modules and keep a clearance of 20 cm beyond the cabinets real panels; - keep a clearance of 160 cm on the front to allow the opening of the door; - temperature and humidity must be within permitted limits;...
- The energy quality of the electrical network should comply with the individual voltage harmonics compatibility levels defined by EN 61000-2-2. For more severe conditions, a power quality audit is required during the UPS commissioning by the LEGRAND Technical Support Service in orded to check the compatibility. Electrical connections The electrical hook-up of the UPS to the switchgear or to the external battery cabinets is part of the installation that is not normally performed by the UPS manufacturer.
4. Installation 4.2.1 Protective devices To ensure proper protection from overloads, output short-circuits or electrical shocks, it is necessary to install adequate automatic residual-current and thermal-magnetic breakers upstream of the UPS on the input line. In case there is a sepa- rate bypass line, the residual current earth leakage protection system must be common for the AC input and bypass lines and must be installed upstream.
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Keor MOD To insert the cables in the cabinet, it is necessary to remove the panels at the bottom of the cabinet according to the following sequence:...
Keor MOD 4.2.3 Earthing connection Before carrying out any other installation operation, connect the earthing wiring coming from the low voltage switchgear to one of the earthing bars located on the left and right side of the busbars connection system. The minimum cross-sectional area of the earthing conductor must be chosen according to the following criteria: •...
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4. Installation KEOR MOD 250 – earthing bars...
Keor MOD 4.2.4 Cable fastening In the accessory box there are two metal bars for Keor MOD 125 and three metal bars for Keor MOD 250. They are used along with the plastic supports for cable ties to fasten the installation cables. Each bar must be fixed to the cabinet using two hex M8x14 screws.
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4. Installation The fastening of the battery, input and output cables on Keor MOD 125 must be done according to the following steps: 1) Fix the first metal bar to the cabinet, behind the surge arrester and the fuse holders, using two hex M8x14 screws. 2) Fix the plastic supports for cable ties using M6 torx pan head screws.
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Keor MOD 3) Fix the cables with cable ties. The fastening of the neutral and output cables on Keor MOD 125 must be done according to the following steps: 1) Fix the second metal bar to the cabinet, close to the maintenance manual bypass switch, using two hex M8x14 screws.
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4. Installation 2) Fix the plastic support for cable ties using M6 torx pan head screws. 3) Fix the cables with cable ties.
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Keor MOD (all the dimensions are in mm) KEOR MOD 250 – view of the three metal bars for cable fastening...
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4. Installation The fastening of the battery and output cables on Keor MOD 250 must be done according to the following steps: 1) Fix the first metal bar at the bottom of the cabinet using two hex M8x14 screws. Then fix the plastic support for the cable ties using M6 torx pan head screws.
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Keor MOD The fastening of the neutral and bypass cables on Keor MOD 250 must be done according to the following steps: 1) Fix the second metal bar above the first bar using two hex M8x14 screws. Then fix the plastic support for the cable ties using M6 torx pan head screws.
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4. Installation The fastening of the input cables on Keor MOD 250 must be done according to the following steps: 1) Fix the third metal bar above the second bar using two hex M8x14 screws. Then fix the plastic support for the cable ties using M6 torx pan head screws.
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Keor MOD The tightening torque values for the cables are the following: - M8 screws: 24 Nm - M6 nuts: 15 Nm - M10 nuts: 35 Nm KEOR MOD 125 KEOR MOD 250...
Keor MOD 4.2.6 Input cables installation The default configuration has the input line in common with the bypass line through a metal jumper. Before the installation of the input cables, check the following: - the mains line must be able to provide an input voltage of 400 V + 15% - 20%; - the available mains power must be at least the same of the UPS nominal power;...
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4. Installation KEOR MOD 125 – input cables installation with input line in common with bypass line In case the input line is separated from the bypass line, follow these steps: - remove the metal jumper that connects the input line with the bypass line; - crimp the input and neutral cables with M8 eyelets;...
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Keor MOD KEOR MOD 125 – input cables installation with input line separated from the bypass line When the input line is separated from the bypass line, it is also possible to install an accessory for double cable. In this way it is possible for each terminal to use two cables with a smaller cross section than the one of a single cable.
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4. Installation KEOR MOD 250 The default configuration has the input line in common with the bypass line through a metal jumper. If no change is required, follow these steps: - unscrew the three hex M10x35 screws that fix the jumper to the input terminal of the busbar; - crimp the input and neutral cables with M10 eyelets;...
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Keor MOD In case the input line is separated from the bypass line, follow these steps: - remove the metal jumper that connects the input line with the bypass line; - crimp the input and neutral cables with M10 eyelets; - connect the input cables L1, L2, L3 to the terminals IN L1, IN L2, IN L3 of the input busbar using three hex M10x30 screws along with M10 flat washers and M10 grower washers.
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4. Installation When the input line is separated from the bypass line, it is also possible to install an accessory for double cable. In this way it is possible for each terminal to use two cables with a smaller cross section than the one of a single cable. For this installation, follow these steps: - remove the metal jumper that connects the input line with the bypass line;...
Keor MOD 4.2.7 Bypass cables installation The default configuration has the input line in common with the bypass line through a metal jumper. If no change is required, follow the steps indicated in the previous paragraph. To perform a dual input installation with a separate bypass line, the following requirements must be met: - the two lines must be supplied by the same MV/LV transformer source (same electrical potential).
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4. Installation When the input line is separated from the bypass line, it is also possible to install an accessory for double cable. In this way it is possible for each terminal to use two cables with a smaller cross section than the one of a single cable. For this installation, follow these steps: - remove the metal jumper that connects the input line with the bypass line;...
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Keor MOD KEOR MOD 250 – bypass cables installation with input line separated from the bypass line...
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4. Installation When the bypass line is separated from the input line, it is also possible to install an accessory for double cable. In this way it is possible for each terminal to use two cables with a smaller cross section than the one of a single cable. For this installation, follow these steps: - remove the metal jumper that connects the input line with the bypass line;...
Keor MOD KEOR MOD 250 – bypass cables installation with accessories for double cable and input line separated from the bypass line 4.2.8 Output cables installation Before the installation of the output cables, check the following: - the nominal power of the UPS must be at least the same of the nominal power of the load; - the cables to connect to the UPS must be isolated upstream and no voltage must be present;...
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4. Installation KEOR MOD 125 – output cables installation It is also possible to install an accessory for double cable. In this way it is possible for each terminal to use two cables with a smaller cross section than the one of a single cable. For this installation, follow these steps: - crimp the output and neutral cables with M8 eyelets;...
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Keor MOD KEOR MOD 250 Follow these steps: - crimp the output and neutral cables with M10 eyelets; - connect the output cables L1, L2, L3 to the terminals OUT L1, OUT L2, OUT L3 of the output busbar using three hex M10x30 screws along with M10 flat washers and M10 grower washers.
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4. Installation It is also possible to install an accessory for double cable. In this way it is possible for each terminal to use two cables with a smaller cross section than the one of a single cable. For this installation, follow these steps: - crimp the output and neutral cables with M10 eyelets;...
Keor MOD KEOR MOD 250 – output cables installation with accessories for double cable 4.2.9 Battery cables installation The default configuration has the strings of batteries in common. Before the installation of the input cables, check the following: - the fuse breakers of all the external battery cabinets must be open; - the cables to connect to the UPS must be isolated upstream and no voltage must be present;...
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4. Installation KEOR MOD 125 The default configuration has the strings of batteries in common. KEOR MOD 125 – battery terminals If no change is required, follow these steps: - crimp the positive, negative and neutral battery cables with M8 eyelets; - connect the positive cable of the battery cabinet to the + BATT terminal using a hex M8x20 screw along with M8 flat washer and M8 grower washer.
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Keor MOD In case there is the need to use a double cable for each terminal in order to use a smaller cross section for each cable, follow the previous procedure but install two cables for each terminal. KEOR MOD 125 – battery cables installation with strings of batteries in common (double cable) It is also possible to install independent string of batteries.
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4. Installation In case of installation of independent strings of batterie, follow these steps: - remove the metal jumpers inserted in the positive and negative battery terminals. - remove the supports for the metal jumpers. - insert the positive battery cables of the battery cabinets in the positive battery terminal and the negative battery cables of the battery cabinets in the negative battery terminal.
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Keor MOD - take from the accessory box the metal support for the neutral battery cables and install it in the relative position on the neutral busbar.
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4. Installation - crimp the neutral battery cables with M5 eyelets; - connect the neutral cables of the battery cabinets to the metal support of the neutral busbar using hex M5 nuts along with M5 flat washer and M5 grower washers present in the accessory box. The grower washer must always be put on top of the flat washer.
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Keor MOD KEOR MOD 250 The default configuration has the strings of batteries in common. KEOR MOD 250 – battery terminals If no change is required, follow these steps: - crimp the positive, negative and neutral battery cables with M8 eyelets; - connect the positive cable of the battery cabinet to the + BATT terminal using a hex M8x20 screw along with M8 flat washer and M8 grower washer.
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4. Installation In case there is the need to use a double cable for each terminal in order to use a smaller cross section for each cable, follow the previous procedure but install two cables for each terminal. KEOR MOD 250 – battery cables installation with strings of batteries in common (double cable) It is also possible to install independent string of batteries.
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Keor MOD In case of installation of independent strings of batterie, follow these steps: - remove the metal jumpers inserted in the battery terminals. - insert the positive battery cables of the battery cabinets in the positive battery terminal, the negative battery cables of the battery cabinets in the negative battery terminal and the neutral battery cables of the battery cabinets in the neutral battery terminal.
4. Installation Power modules installation Once all the electrical connections have been made, close the distribution panels and fix them by screwing all the hex socket M6x16 screws along with M6 toothed washers. It is then possible to move onto the insertion of the power modules into the UPS. During the installation it is necessary to use the appropriate Personal Protective Equipment like protective gloves and anti-accident shoes (see paragraph 2.3).
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Keor MOD Insert the power module in the free slot, making sure that its switch in the front is open. Make sure that the power module is abut and then close its front switch. Fix the module to the cabinet with the four screws that were previously saved.
4. Installation Battery drawers installation The cabinet for Keor MOD 125 may include two to ten internal battery drawers. Each battery string is made up of two drawers, therefore it is necessary to install them two by two. The battery drawers have a specific order in the cabinet that must be kept, especially if the UPS has to work in a configu- ration with indipendent strings of batteries.
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Keor MOD Starting from the top of the cabinet, unscrew the four screws that fix the slot cover where the battery drawers must be installed and save them. Insert the empty battery drawers in the free slots and push them till the ‘click’ of the safety block is heard. The battery blocks must be added to the drawers only after the activation of the safety block.
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4. Installation Remove the terminal covers of the batteries at the extremes. Add two battery blocks on a drawer and connect in series the two blocks using the cable provided and respecting the polarity (connect a positive terminal to a negative terminal).
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Keor MOD Once the connection is done, insert the terminal covers on the two batteries and push the blocks at the bottom of the drawer. Add other two battery blocks on the drawer...
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4. Installation Connect in series the two new blocks to the ones already in the drawer using the cable provided and respecting the po- larity (connect a positive terminal to a negative terminal). Connect the free terminals of the two batteries located close to the handle of the drawer to the cables that go to the back of the drawer.
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Keor MOD Fill the second drawer in the same way. After the two drawers are ready, push them inside the UPS cabinet till they are abut and fix them with the four screws that were previously saved.
Keor MOD 4.5.1 Emergency Power Off (EPO) The UPS has a contact that can be used to activate the immediate stop of the equipment. It can be set as normally closed (NC) or normally open (NO) from the user interface. The default configuration is NC. The EPO terminal is found on pins 1 and 2 of contact N13 of the SSS interface.
5. Configuration and start-up DANGER All the configurations and start-up operations must be carried out exclusively by a SKILLED TECHNICIAN (para- graph 2.2.1). Pre-start-up checks Before powering the equipment, carry out the following checks: 1. Close all the distribution panels on the UPS cabinet. 2.
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Keor MOD 6. Set the desired voltage and frequency output in the tab “System” by tapping on the pencil icon on the items “Voltage” and “Frequency”. 7. Set the correct number of KB (Battery Kits) installed in the tab “System”...
5. Configuration and start-up INDICATION 1 KB (Battery Kit) represents a string of 48 batteries in series. In case of models with internal battery drawers, 1 KB is made up of 2 drawers. 8. Set the correct battery capacity in Ah of the single KB in the tab “System” INDICATION The UPS calculates the total battery capacity as produced by the total KB * Capacity.
2.2.1). EXTRAORDINARY MAINTENANCE operations must be carried out only by LEGRAND TECHNICAL SUPPORT SER- VICE. LEGRAND declines all liability for any injury or damage caused by activities carried out differently from the instructions written in this manual. Preventive maintenance The UPS does not contain parts for preventative maintenance by the operator.
6. Maintenance Ordinary maintenance After the removal of power from the UPS, the capacitors discharge time inside the power modules is 40 minutes. It is forbidden to operate inside the power modules before this time has elapsed. 6.3.1 Hot-swap procedure for the replacement of power modules The hot-swap procedure makes it possible to replace a faulty power module while the load is powered by the UPS in on-line mode.
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Keor MOD During the hot-swap procedure the maximum active power available is indicated in the following table: MAXIMUM ACTIVE POWER AVAILABLE KEOR MOD 50 25 kW (50%) KEOR MOD 75 50 kW (66%) KEOR MOD 100 75 kW (75%) KEOR MOD 125 100 kW (80%) KEOR MOD 150 125 kW (84%)
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6. Maintenance 3. Choose the PM to replace by tapping on it or scrolling it with the ARROWS UP and DOWN icons. Then, tap on the SWITCH icon and confirm to turn off the module once the pop-up appears. 4. Initially, the LED on the PM turns blue. Wait until it turns white: the PM is ready to be replaced. 5.
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Keor MOD 8. Push the safety hook located on the top right of the PM to unlock the block and pull the PM to finalize the extraction. 9. Insert the new PM on the free slot making sure that the frontal switch is open and that the module is in abutment. 10.
6. Maintenance 6.3.2 Installation/replacement of power modules with the UPS in maintenance bypass mode If the hot-swap procedure explained in the previous paragraph is not applicable, it is possible to replace or even to add PM with the UPS in maintenance bypass mode. INDICATION During this procedure, the load is not protected by the UPS because it is powered from the bypass input line.
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Keor MOD 3. Extract the PM until the safety block prevents to continue the extraction. 4. Push the safety hook located on the top right of the PM to unlock the block and pull the PM to finalize the extraction. 5.
6. Maintenance 7. Close the frontal switch of the PM. To add a PM: 1. Unscrew the screws of the protective cover of a free slot starting from the top of the cabinet. 2. Insert the new PM on the free slot making sure that the frontal switch is open and that the module is in abutment. 3.
6. Maintenance Battery drawers replacement WARNING A battery can present a risk of electrical shock and high short circuit current. Read and apply the safety instructions in chapter 2 before operating on batteries INDICATION The battery drawers must always be added/removed in multiples of two (1 KB consists of two battery drawers). Always replace just one KB at a time.
Keor MOD 5. Push up the safety hook located on the left side of the battery drawer to unlock the block and pull the drawer to fina- lize the extraction. 6. Follow the procedure shown at paragraph 4.4 to insert a new battery drawer INDICATION If the UPS turns to battery mode during these operations, do not continue the installation/replacement.
6. Maintenance 3. Remove all the battery blocks from the drawer 4. Push up the safety hook located on the left side of the battery drawer to unlock the block and pull the drawer to fina- lize the extraction. 5. Follow the procedure shown at paragraph 4.4 to insert a new battery drawer 6.
Keor MOD KEOR MOD 125 KEOR MOD 250 Extraordinary maintenance Contact the LEGRAND Technical Support Service if there are failures that require the access to internal parts of the UPS.
- up to 2 months if the temperature is over +40°C (+104°F). CAUTION Batteries must never be stored if partially or totally discharged. LEGRAND is not liable for any damage or bad functioning caused to the UPS by wrong warehousing of the batteries.
Keor MOD 8. Dismantling DANGER Dismantling and disposal operations must be carried out only by a SKILLED TECHNICIAN (paragraph 2.2.1). The instructions in this chapter are to be considered indicative: in every country there are different regulations regarding the disposal of electronic or hazardous waste such as batteries. It is necessary to strictly adhere to the standards in force in the country where the equipment is used.
9. Mechanical characteristics The UPSs Keor MOD are sold as empty power cabinets. It is necessary to purchase the power modules separately. Cabinets (all the dimensions are in mm) (all the dimensions are in mm) 3 104 80 KEOR MOD 25-125 kVA 3 104 81 KEOR MOD 25-250 kVA...
10. Technical data Main features Keor Keor Keor Keor Keor Keor Keor Keor Keor Keor Nominal Power (kVA) Active Power (kW) Number of power modules online, double conversion Technology VFI-SS-111 (EN62040-3) IN/OUT configuration Three-phase / Three-phase Dual Input Available UPS system Modular, expandable and redundant Neutral system Neutral passing straight from input to output (not isolated)
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Keor MOD Output electrical characteristics (normal mode) Keor Keor Keor Keor Keor Keor Keor Keor Keor Keor Maximum output current (A) Output voltage 380/400/415 ± 1% Output frequency 50 / 60 (Hz) (selectable by the user) Range of the output If synchronized with the bypass frequency: adjustable range from ±1% to ±14% frequency If not synchronized (free run): ±...
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10. Technical data Batteries and battery charger characteristics Keor Keor Keor Keor Keor Keor Keor Keor Keor Keor Nominal battery ± 288 (48 blocks) voltage (V) Battery voltage ± 264 to ± 312 (44-52 blocks) range (V) Internal batteries: string made up of 2 drawers Battery wiring (composed by 4 blocks of 6 batteries) Only external batteries...
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Keor MOD Mechanical characteristics Keor Keor Keor Keor Keor Keor Keor Keor Keor Keor Empty power cabinet 3 104 80 3 104 81 Net weight (kg) Dimensions H x W x D (mm) 1990 x 600 x 970 Installable Power up to 5 up to 10 modules PM25 3 106 75...
11. Tables CAUTION The choice of the type and section of the power cables must be done according to the voltage and rated current as well as the local wiring standards and regulations. It is a responsibility of the installation engineer. The input current and the output power of the UPS are indicated in chapter 10 and the battery current in table 4 of this chapter.
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Keor MOD TABLE 4 Maximum current absorbed by the batteries at full load and minimum wire cross sections recommended for con- necting the UPS to the external battery units POWER MAXIMUM BATTERY CURRENT MINIMUM WIRE CROSS SECTION 125 kVA 5 x 65 A 5 x 16 mm 250 kVA 5 x 130 A...
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Pro and Consumer Service BP 30076 - 87002 LIMOGES CEDEX FRANCE www.legrand.com Installer stamp Legrand reserves at any time the right to modify the contents of this booklet and to communicate, in any form and modality, the changes brought to the same.
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