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Summary of Contents for MEI UPS10000
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MESTA ELECTRONICS, INC. ninterruptible ower ystem Owner's Manual MODELS: UPS10000, UPS15000, UPS20000, UPS25000, UPS30000, UPS50000 SAVE THESE IMPORTANT SAFETY INSTRUCTIONS 11020 Parker Drive N. Huntingdon, PA 15642 412/754-3000...
1. INTRODUCTION As computers become increasingly fundamental to today’s businesses, protection against power disruptions has never been more critical; and since vital data and hardware are threatened by routine sags, surges, spikes, and transients – as well as major blackouts – protection must be constant and instantaneous.
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Once the AC power returns, the system’s microcontroller employs optimum charging techniques to extend battery life while minimizing charging time. The microcontroller follows a unique algorithm by which it regulates the charging process and enables a minimal recharging time. WARNING Your UPS may contains up to twenty (depending on model) 12 volt batteries wired in series providing a total nominal DC voltage of up to 240 volts.
2. INSTALLATION Cabinets – The Mesta Electronics UPS system and optional auxiliary battery cabinets are supplied in cabinets of several sizes, which are indicated by the last digit in the model number. Please reference Appendix A for dimensions of enclosures. If UPS system is configured with internal batteries, Appendix A contains their quantity and capacity.
Unpacking: Before unpacking your unit, examine the shipping carton for damage. If there is any obvious damage, report it immediately to the dealer or carrier. If no damage is found, unpack the unit and inspect it for shipping damage. Again, in case of any damage, report it directly to the dealer or the carrier.
connected to the W terminal. If the phase relationship is incorrect (see BAD ROTATION below), the problem is easily corrected by swapping any two of the X, Y, and Z wires. Refer to Figure 3, UPS External Wiring, and Figure 4, AC Wiring Terminal Block. A copper lug marked “GND”...
WARNING Extreme caution must again be exercised so that the polarity of the batteries is preserved as it is presented to the breaker. The "+" and "-" lugs on the breaker are indicated with "+" on the left and "-" on the right.
WARNING Risk of Electric Shock and Fire. The battery circuit is grounded at the UPS. Do not attempt to additionally ground the battery circuit. Otherwise, maintenance personnel may be exposed to an electrical shock hazard that could result in death or injury, or damage to the UPS or its electrical loads may occur.
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MODEM COMMUNICATION: "DTE" CONNECTOR SIGNAL SIG GND MODEM TELEPHONE LINE <100 feet "DTE" CONNECTOR (female - as seen on back panel): CURRENT LOOP TRANSMITTED 1 - Earth Ground DATA RETURN/ - 2 - TX / TRANSMITTED DATA/ 3 - RX / RECEIVED DATA/ 4 - RTS / REQUEST TO SEND/ 5 - CTS / CLEAR TO SEND/ 7 - Signal Ground/CURRENT LOOP TRANSMITTED/...
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LARGE RELAY CONTACTS: CONTACTS RELAY NC - Normally closed contact NO - Normally open contact - Common side of contact Purchase mating AMP socket 1-480708-0 with suitable pins Maximum rating of contacts = 120V/10A See Appendix B for function of relay contacts. SMALL RELAY CONTACTS: CONTACTS RELAY...
3. SYSTEM DESCRIPTION This section points out the main components of the Uninterruptible Power System and discusses the theory of operation of the unit. 3.1 PRINCIPAL COMPONENTS The principal components in the Mesta Electronics UPS system are identified in Figure 6. On the front panel, the 16 key keypad and the LCD readout are found, along with two locks for securing access to the system.
Front Panel – The front panel (see illustration below) provides real time information about the system operation on the liquid crystal display (LCD) screen. The keypad enables the system operator to command the various functions and view a number of informational screens on the 8 line by 40 character LCD display.
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Mesta's inverter uses a unique pulse-width-modulation (PWM) design that results in a sine wave output while being able to power non-linear loads without derating. The unit delivers 300% peak transient overload current (with or without the utility present) for any commonly occurring transient load conditions (such as load equipment being powered up).
The master controller monitors internal and external battery currents, which enables the microcontroller to determine: a) that the external batteries or battery breakers, if used, are functioning, and b) proper charging current is sent to the battery systems. The heat sink, inside ambient and room temperatures are monitored for the protection of the equipment itself.
Power Inverter). 1 Wye Output. Front of Cabinet Green White AC SIDE POWER DC SIDE POWER Black Blue TITLE TITLE POWER WIRING DIAGRAM UPS10000-UPS30000 POWER WIRING DIAGRAM UPS10000-UPS30000 MESTA ELECTRONICS, INC. MESTA ELECTRONICS, INC. SIZE ENGR DWG NO 10 ALLEGHENY SQUARE SIZE ENGR...
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9c) DC Power Wiring w/o Internal Batteries 9d) AC Power Wiring w/o Internal Batteries From Utility To External Battery Cabinet(s) Distribution Panel Precharge Resistor (P/O PC-I) White (Must be protected with 3 To Critical Blue phase breaker as instructed White Loads Black by Owner's Manual)
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System Circuit Boards - The system circuit boards are shown in Figure 10. The circuitry represented here is primarily located on the left side of the UPS and consists of all PC-boards in the unit (except the IGBT drivers that are located on the heat sink) and power circuitry located in the same vicinity. The external battery breaker BR2 (included only in units requiring external battery cabinets) and the main battery breaker BR1 are shown in the top of this diagram.
Figure 10 System Circuit Boards Figure 10a) System with Internal Batteries Figure 10b) System without Internal Batteries External Batteries External Batteries Chassis Chassis DC Contactor DC Contactor Power Power Circuitry Circuitry Power Power Circuitry Circuitry Power Power Circuitry Circuitry Temp Sensor of Temp Sensor of Internal Batteries Room Ambient...
4. OPERATING PROCEDURE This section outlines the procedure to turn on and off your UPS and perform a transfer from UPS to Bypass and vice-versa. All of the power controls are conveniently located on the front of the UPS. The Main battery breaker controls the connection of the UPS to all batteries (internal or external).
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IDLE position for any period of time). Make sure the breakers are not in the tripped position. If they are, turn the breakers all the way off, then turn them on. The breakers and transfer switch may be turned on in any order.
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0 1 / 1 1 / 9 9 M E S T A E L E C T R O N I C S 1 6 : 5 2 : 1 1 I N P U T O F F O U T P U T O F F B A T T E R Y...
Once the loads are turned ON, a typical screen will appear as: 0 1 / 1 1 / 9 9 M E S T A E L E C T R O N I C S 1 6 : 5 2 : 1 1 I N P U T O F F O U T P U T...
pressed, the display will indicate a UPS to BYPASS transfer has been requested. If the AC utility is not present at the time, the UPS will not allow such a transfer to take place, as doing so would switch the critical load to a non-existent utility, which would crash the critical load.
4.4 DIAGNOSING PROBLEMS The three front panel lights along with the LCD display will indicate any problems that exist in the UPS. When the transfer switch is first turned from the OFF to the OFF IDLE position, the lights will all be lit as a lamp test.
5. FRONT PANEL KEYPAD & LCD OPERATION 5.1 SYSTEM SOFTWARE COMMANDS (via the front panel) The keypad on the front panel of the UPS can be used by the operator to select the information displayed on the LCD display, as well as to input various set-up parameters. A.
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0 1 / 1 1 / 9 9 _ _ _ M A I N M E N U ( 1 . 1 6 ) _ _ _ 1 6 : 5 2 : 1 1 D I S P L A Y M A N B A T T E R Y T E S T...
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5) SYSTEM HELP -- Displays the same information that the HELP key displays. Use the SELECT key to return to the MAIN MENU display. 6) MAN BATTERY TEST -- Displays the manual battery test that can be performed by the operator on the UPS batteries.
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entered correctly, no error message will be displayed and the time in the upper right corner of the display will change to the time that you entered. A new weekday is entered as a number 1 through 7, representing Sunday through Saturday. Enter 1 for Sunday, 2 for Monday, 3 for Tuesday, 4 for Wednesday, 5 for Thursday, 6 for Friday, or 7 for Saturday.
5.3 LCD SUB-MENU DISPLAYS This section of the manual describes in greater detail some of the menu options introduced in the previous section. 5.3.1 DISPLAY #1 Screen 0 1 / 1 1 / 9 9 M E S T A E L E C T R O N I C S 1 6 : 5 2 : 1 1 I N P U T...
charged, the normal condition, the AMPS should nominally be close to 0. CHARGE indicates an estimate of the amount of charge left in the batteries. Nominally this value will be 100% indicating the batteries are fully charged. If the utility fails and energy must be drawn from the batteries, this value will start to drop.
5.3.3 DISPLAY ALARMS Screen This screen provides access to any system alarm messages that may be active in the system. Refer to the TROUBLESHOOTING section of this manual for additional information concerning alarms. SHUTDOWN Screen - Various messages identifying the situations that have been detected which caused a system shutdown.
DIAGNOSTIC Screen - This screen will reveal various situations that have been detected and need to be corrected. See Troubleshooting, Section 7, for further information on diagnostic readouts. 0 1 / 1 1 / 9 9 D I A G N O S T I C A L A R M ! 1 6 : 5 2 : 1 1 L I N K / B A T T E R Y...
short period of time. Should you receive a “FAIL-DIAGNOST” message, you should immediately call for service. If service can not be immediately obtained, power down your loads and turn the UPS transfer switch counter-clockwise to the “ON BYPASS” position via the “OFF IDLE” and “OFF” positions. When in the “ON BYPASS”...
6. SYSTEM SOFTWARE COMMANDS (via the rear panel RS232 interface) For sophisticated applications, the Mesta UPS system provides an RS232 communications interface which can link the microcontroller with a remote computer or terminal. This two-way link allows users to 1) collect detailed information on power usage and other characteristics of the load to which the UPS is connected and 2) remotely control the UPS or the load.
This command is used to run an in-service battery check test for 60 seconds. The LCD screen on the cabinet will show that this test is being run. RQ0 will terminate this test early. After the battery test is initiated, type VG<enter> to view the battery status during the test. If your batteries are in very poor condition, the test may abort prematurely and immediately display a very low charge percentage on DISPLAY #1 for about 1 minute.
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2. The accuracy of the percentage of battery charge remaining depends on operating conditions and the present loading of the UPS. The accuracy will be much more precise at the lower percentages than it is at the higher percentages (where the performance curve flattens and a perfectly correct interpolation is more difficult - in the 92-100% range).
7. TROUBLESHOOTING WARNING Risk of Electric Shock. Do not open a UPS and attempt to repair it yourself. Personnel entering the cabinet may be exposed to an electrical shock hazard that could result in death or injury or further damage to the UPS or its electrical loads Your UPS is equipped with extensive diagnostic capabilities.
immediately, you may run them from the AC utility directly by turning the Transfer Switch counter- clockwise to the ON BYPASS position. While in the ON BYPASS position, your loads are not protected by the UPS and are subject to any outages or disturbances that may occur on the AC utility. You may remain in the ON BYPASS position until the problem with the UPS is resolved.
AC BREAKER OPEN AC breaker on unit has been Turn on the AC breaker if you want the UPS to run from turned off. the utility, otherwise it will stay on battery until energy is exhausted at which time it will shut down. AC LINE DISABLED BY An ACDIS command was Type ACEN command over serial interface to re-enable...
directly from the utility (see section 4.2). If not able to transfer to bypass, shut down all of your loads in an orderly manner, then perform an interrupted transfer to Bypass by turning the Transfer Switch counter-clockwise through the OFF IDLE and OFF positions to the ON BYPASS position. You may now power up your loads to operate from the utility directly.
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LCD OVERLOAD Alarm Comments Remedy Message LOAD CURRENT OVERLOAD One or more of the 3 output Remove the load causing the problem. phases or the neutral is presently being overloaded. UNDER VOLTAGE OVERLOAD Internal Problem Call for service INVERTER CURRENT TRIP Internal Problem Call for service OVERLOAD...
LCD WARNING Alarm Comments Remedy Message NOVRAM PROBLEM Control had a problem Unit will continue to run with default values. Call for ENCOUNTERED retrieving setup information service. from its non-volatile memory. INT/EXT BATTERY AMP-HR A mismatch is detected Make sure External Battery Breaker on UPS and breakers MISMATCH between the current drawn on all external battery cabinets are in the on position.
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The Power On/Off database contains information as to each time the UPS output is powered on or powered off. Information recorded includes date & time when the event occurred. “Powered off” recordings will also include a reference to shutdown if the UPS output was powered off in any way other than the transfer switch being rotated to the OFF IDLE or OFF positions.
8. MAINTENANCE 8.1 SYSTEM STORAGE Battery Life: The MESTA UPS should be stored with the batteries fully charged and all breakers in the off position. MESTA Battery Cabinets should also be stored with the batteries fully charged. Storage temperature should be maintained between -20°C and 40°C. The life of the batteries may be greatly reduced if stored at temperatures exceeding 30°C for extended periods of time.
WARNING The UPS should only be entered after all breakers on the unit and breakers on all external battery cabinets connected to the unit have been turned off. For maximum safety, the AC source feeding the UPS should also be turned off. If the load connected to the UPS must remain powered while maintenance is performed, the UPS may be entered while the AC source feeding the UPS remains energized and the Bypass Switch is in the ON BYPASS position.
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WARNING Risk of Electric Shock – Batteries are energy storage devices, and even though all breakers are off, there still exists the potential of high current flow. For this reason extreme caution should be exercised at all times during operation or maintenance of the UPS and its external battery cabinets. Otherwise, maintenance personnel may be exposed to an electrical shock hazard that could result in death or injury, or damage to the UPS or its electrical loads may occur.
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The battery trays on the top shelf are disconnected and removed in a similar way to those on the bottom shelf. When the last tray is reached, the wire connected to the rearmost terminal of the back battery, marked with white tape, can be disconnected from the battery and placed aside. The last battery tray can be removed.
8.4 BATTERY TESTING The batteries are by far the most likely component in any UPS to fail. Loss of the batteries results in a power outage to your load as soon as the next power failure occurs. With most UPS’s you don’t know you have bad batteries until such a power outage occurs, which is too late.
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battery test LCD page or by typing RQ0 over the serial port. BAD AC LINE Test had to be terminated because AC utility went bad. TRANS REQUEST Test was terminated because operator asked to perform a transfer request during the test. SYS TURNED OFF Test was terminated because operator turned the transfer switch to either the “OFF IDLE”...
performed, current is drawn from the batteries. This action results in the unit annunciating that the batteries are being discharged. At the unit, this is accompanied by the yellow “BATTERY DISCHARGING” light turning on and an audible alarm sounding. Remote annunciation panels will also indicate that the battery is discharging.
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Check Heat sink, ambient, and room temperatures. Room temperature should be below 30°C for optimum battery life. Heat sink temperatures should be below 50°C (may be slightly higher if the UPS, within the last few minutes, ran off batteries with a fairly high load for several minutes). Ambient temperature on the control PC board should be below 40°C.
9. EXTERNAL BATTERY CABINETS This section describes all of Mesta’s available battery cabinets that are designed to work with a Mesta UPS covered by this manual. Make sure to read and understand all warnings and instructions in this section of the manual before any work is begun. WARNING Only qualified technicians or supervised personnel should attempt to connect/disconnect external battery cabinets to/from the UPS models covered by this manual.
Procedure: To connect one or more external battery cabinets to a UPS, perform the following steps: 1) Verify that the breaker inside each battery cabinet is turned off. Verify that the UPS is off, and verify that all battery breakers, as well as the AC breaker, on the front of the UPS are off. No power must be present during the installation procedure.
8) Once the above steps are accomplished, turn on the external battery cabinet breaker, and then turn on the External Battery Breaker as well as the Main Battery Breaker on the UPS. Should the breakers trip a) check wiring for wiring errors, b) check breakers for possible defective breaker.
cabinet's intended use. The breaker current ratings and maximum current that the UPS will pull from the batteries while supporting the rated UPS load are shown in Table 11: Table 11 Battery Cabinet Amp Ratings vs. UPS KVA Rating UPS KVA Breaker current trip rating on UPS Max Current from batteries while Rating...
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Figure 12 Battery Cabinet Wiring Diagrams Figure 12a) BC20-38 and BC40-38 Wiring Diagram Figure 12b) BC60-38, BC80-38, and BC100-38 Wiring Diagram To UPS Cabinet To UPS Cabinet White White Black Shelf of Batteries White Shelf of Batteries (Top View) (Top View) Rear of Cabinet Rear of Cabinet WHITE...
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Figure 12c BC20-65 and BC40-65 Wiring Diagram To UPS Cabinet White Shelf of Batteries (Top View) Rear of Cabinet 250 VDC BREAKER Front of Cabinet Shelf of Batteries (Top View) Rear of Cabinet Front of Cabinet Black White Shelf of Batteries NOTE: Only top two cabinet shelves shown in detail.
APPENDIX A. UPS SPECIFICATIONS BY MODEL This section of the Mesta Electronics Owner's Manual contains the full set of operating specifications for the models covered herein. Standard UPS Models UPS10000/3-20-1 • 10KVA/KW 3Φ UPS15000/3-20-1 • 15KVA/KW 3Φ UPS20000/3-20-1 • 20KVA/KW 3Φ UPS25000/3-20-1 • 25KVA/KW 3Φ...
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UPS10000/3-20-1 - 10KVA/KW 3Φ ON LINE UPS SPECIFICATIONS INPUT INDICATORS AND CONTROLS Voltage • 208/120VAC 3Φ Nominal Keypad • to address several data screens, Current • 35 amps max at rated load. command UPS control, set parameters LCD Screen • to provide full system operating Frequency •...
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UPS15000/3-20-1 - 15KVA/KW 3Φ ON LINE UPS SPECIFICATIONS INPUT INDICATORS AND CONTROLS Voltage • 208/120VAC 3Φ Nominal Keypad • to address several data screens, Current • 50 amps max at rated load. command UPS control, set parameters LCD Screen • to provide full system operating Frequency •...
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UPS20000/3-20-1 - 20KVA/KW 3Φ ON LINE UPS SPECIFICATIONS INPUT INDICATORS AND CONTROLS Voltage • 208/120VAC 3Φ Nominal Keypad • to address several data screens, Current • 67 amps max at rated load. command UPS control, set parameters LCD Screen • to provide full system operating Frequency •...
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UPS25000/3-20-1(or 2) - 25KVA/KW 3Φ ON LINE UPS SPECIFICATIONS INPUT INDICATORS AND CONTROLS Voltage • 208/120VAC 3Φ Nominal Keypad • to address several data screens, Current • 85 amps max at rated load. command UPS control, set parameters LCD Screen • to provide full system operating Frequency •...
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UPS30000/3-20-2 – 30KVA/KW 3Φ ON LINE UPS SPECIFICATIONS INPUT INDICATORS AND CONTROLS Voltage • 208/120VAC 3Φ Nominal Keypad • to address several data screens, Current • 100 amps max at rated load. command UPS control, set parameters LCD Screen • to provide full system operating Frequency •...
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UPS50000/3-20-2 – 50KVA/KW 3Φ ON LINE UPS SPECIFICATIONS INPUT INDICATORS AND CONTROLS Voltage • 208/120VAC 3Φ Nominal Keypad • to address several data screens, Current • 160 amps max at rated load. command UPS control, set parameters LCD Screen • to provide full system operating Frequency •...
APPENDIX B: REAR PANEL RELAY CONTACT FUNCTIONAL OPERATION The UPS has status relay contacts accessible from the rear of the unit. The status of these contacts (open or closed) is controlled by the internal microcontroller to reflect operational conditions of the UPS. Section 2.2 of this manual defines the electrical operation of these relay contacts.
MODE 3: Relay Normally Open Contacts Closed if These Conditions Exist UPS is producing output power AND battery has been discharging for at least 10 seconds. UPS has either shut down due to an abnormal condition, is in overload or over-temperature condition, or has detected a diagnostic or warning condition (UPS needs attention).
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Mesta Electronics, Inc. The foremost name in power protection! REV 6.6 (6-03)
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MESTA ELECTRONICS, INC. 11020 Parker Drive N. Huntingdon, PA 15642 412/754-3000...
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