Gamatronic MEGA V2 250 Installation Manual
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Gamatronic MEGA V2 250 Installation Manual

Modular ups system up to 250 kw
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Cat. no. 101SMD6x-405
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Release 2.2, December 2013
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AMATRONIC
17 Hartom St., PO Box 45029, Jerusalem 91450, Israel
Tel: +972-2-588-8222
Email: info@gamatronic.co.il
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Fax: +972-2-582-8875
Website: www.gamatronic.com
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  • Page 1 Cat. no. 101SMD6x-405 Release 2.2, December 2013 AMATRONIC LECTRONIC NDUSTRIES 17 Hartom St., PO Box 45029, Jerusalem 91450, Israel Tel: +972-2-588-8222 Fax: +972-2-582-8875 Email: info@gamatronic.co.il Website: www.gamatronic.com 2MUM-MPP/16...
  • Page 2 Gamatronic is not liable for and the Purchaser waives any right of action it has or may have against Gamatronic for any consequential or special damages arising out of any breach of warranty, and for any damages that the Purchaser may claim for damage to any property or injury or death to any person arising out of its purchase or the use, operation or maintenance of the subject product.

  • Page 3: Table Of Contents

    AMATRONIC LECTRONIC NDUSTRIES TABLE OF CONTENTS 1. I ........................... 1 NSTALLATION 1.1 Installation Checklist ......................1 1.2 Installation Procedure ...................... 3 1.2.1 Visual Inspection ....................3 1.2.2 Site Preparation – Physical ..................3 1.2.3 Site Preparation – Electrical ................... 5 1.2.4 Cabling ........................
  • Page 4 AMATRONIC LECTRONIC NDUSTRIES LIST OF FIGURES Figure 1: Recommended clearances around the MegaV2 250 UPS ........... 4 Figure 2: The cable guard (without and with its rear panel) ..............5 Figure 3: Attaching the cable guard ..................... 6 Figure 4: Recommended standard system connections ..............9 Figure 5: Recommended system connections, with input isolation transformer ........
  • Page 5 AMATRONIC LECTRONIC NDUSTRIES Figure 51: Two screws on the front of the computer ................47 Figure 52: A UPS's bypass circuit ...................... 48 LIST OF TABLES Table 1: Recommended clearances ....................4 Table 2: Battery lifetime vs environmental temp. (illustrative, as per Eurobat) ........8 Table 3: Maximum input currents .......................
  • Page 6 AMATRONIC LECTRONIC NDUSTRIES AFETY ONSIDERATIONS The MegaV2 250 UPS system is designed for industrial applications and harsh environments. Nevertheless the MegaV2 250 UPS system is a sophisticated power system and should be handled with appropriate care, following these guidelines. WARNING! HIGH TOUCH CURRENT! EARTH CONNECTION ESSENTIAL BEFORE CONNECTING SUPPLY.
  • Page 7 AMATRONIC LECTRONIC NDUSTRIES Don’ts • Do not open the cover of the UPS or the battery cabinets under any circumstances. All UPS panels and doors should be closed. • Do not insert any objects through the ventilation holes. • Do not put objects on the UPS. •...
  • Page 8 AMATRONIC LECTRONIC NDUSTRIES viii MegaV2 250 Installation Guide, Release 2.2...

  • Page 9: Installation

    Complete the following checklist as you perform the installation, initialization, configuration, and testing procedures. Refer to the appropriate sections (specified in the Reference column) for detailed information about each checklist item. When the checklist is complete, fax it to Gamatronic at +972-2-582-8875. UPS model and configuration Customer...
  • Page 10 S i t e P r e p a r a t i o n – E l e c t r i c a l Check size of circuit breakers on electrical boards Meet local code and Gamatronic supplying the MegaV2 250. Refer to Chapter 5 in 1.2.3 Step 1...

  • Page 11: Installation Procedure

    Perform the following procedures before connecting any external cables to MegaV2 250. Ensure that the ambient temperature in the immediate vicinity of MegaV2 250 complies with Gamatronic requirements: Minimum/maximum operating temperatures: –10 °C / +40 °C (+14 °F / +104 °F).

  • Page 12: Figure 1: Recommended Clearances Around The Megav2 250 Ups

    AMATRONIC LECTRONIC NDUSTRIES Table 1: Recommended clearances ECOMMENDED MINIMUM CLEARANCE AROUND THE Front 100 cm (39 in.) Clearance for user access and service. 30 cm (12 in.) Clearance for service; the UPS is not next to another UPS. If there is another UPS at the side of the MegaV2, the recommended clearance increases to 60 cm, due to the additional heat generated by Sides 60 cm (24 in)

  • Page 13: Site Preparation - Electrical

    Verify that circuit breakers on the electrical board that supplies MegaV2 250 are compliant with local and national codes and Gamatronic system specifications. Verify that the input and output power cable connections, GND, and neutral lines comply with local and national codes and are appropriate for the circuit breakers protecting them.

  • Page 14: Figure 3: Attaching The Cable Guard

    AMATRONIC LECTRONIC NDUSTRIES After the cables have been threaded through the cable guard rear panel and have been connected to the UPS bus bars, attach the cable guard (item 2 in Figure 3) to the static switch's rear cover (item 1.1 in Figure 3). Then attach the cable guard cover (item 2 in Figure 3) to the cable guard.

  • Page 15: Neutral Line

    AMATRONIC LECTRONIC NDUSTRIES 1.2.4.2 Neutral Line During both installation and operation of the MegaV2 250, a neutral line must always be connected to the UPS. This neutral line must be connected at all times while the UPS is working and should not be disconnected at any time. Caution: If at any time the neutral line becomes disconnected, there will be no input or output reference voltage because the input neutral line and the output neutral line are physically linked together.

  • Page 16: Assembling And Connecting The Batteries

    AMATRONIC LECTRONIC NDUSTRIES 1.2.4.4 Assembling and connecting the batteries It is recommended that the battery cabinet(s) be located as close to the UPS as is practically possible. Assemble the batteries within the battery cabinet and make necessary connections to the switch inside the battery cabinet.

  • Page 17: Figure 4: Recommended Standard System Connections

    AMATRONIC LECTRONIC NDUSTRIES Figure 4: Recommended standard system connections For recommended circuit breakers see Table 3 (page 11) and Table 4 (page 11). MegaV2 250 Installation Guide, Release 2.2...

  • Page 18: Figure 5: Recommended System Connections, With Input Isolation Transformer

    AMATRONIC LECTRONIC NDUSTRIES Figure 5: Recommended system connections, with input isolation transformer For recommended circuit breakers see Table 3 (page 11) and Table 4 (page 11). MegaV2 250 Installation Guide, Release 2.2...

  • Page 19: Table 3: Maximum Input Currents

    AMATRONIC LECTRONIC NDUSTRIES Table 3: Maximum input currents AXIMUM STEADY STATE AXIMUM OUTPUT RECTIFIER INPUT CURRENT BYPASS INPUT CAPACITY AMPS CURRENT AMPS 3x40 3x36 3x80 3x70 3x120 3x110 3x160 3x140 3x200 3x180 3x240 3x215 3x280 3x250 3x320 3x280 3x360 3x320 3x400 3x360 Table 4: Recommended circuit breaker / switch ratings...

  • Page 20: Figure 6: Alternate Battery Connection Option

    AMATRONIC LECTRONIC NDUSTRIES Figure 6: Alternate battery connection option MegaV2 250 Installation Guide, Release 2.2...

  • Page 21: Connecting The Megav2 250 To The Electrical Panel

    AMATRONIC LECTRONIC NDUSTRIES 1.2.4.5 Connecting the MegaV2 250 to the electrical panel Suitably rated circuit breakers must be installed between the MegaV2 250 and the electrical panel. See Figure 4 or Figure 5 for system connections. See Table 3 and Table 4 fpr circuit breaker recommendations.

  • Page 22: Emergency Power Off - Epo (Manual)

    AMATRONIC LECTRONIC NDUSTRIES 1.2.5 Emergency Power Off – EPO (manual) An external Emergency Power Off (EPO) switch may be installed on the MegaV2 250 by the customer. The EPO switch cuts power to the load in emergency situations. After being switched OFF by the EPO, the MegaV2 250 must be restarted manually.

  • Page 23: Input And Output Dry Contacts

    AMATRONIC LECTRONIC NDUSTRIES 1.2.6 Input and output dry contacts The MegaV2 250 has input and output dry contacts. The input dry contacts enable the MegaV2 250 computer to monitor the state (open or closed) of a relay external to the UPS, and to generate an alarm if the state of the external relay changes. The output dry contacts enable the MegaV2 250 to trigger an external circuit in response to a system alarm.

  • Page 24: Powering-Up The System

    AMATRONIC LECTRONIC NDUSTRIES Figure 11: Pin usage in D9 alarm connector. 1.2.7 Powering-up the system There are two circuit breakers on the rear side of each power module. Verify that on each module the circuit breakers are in the OFF (down) position, then insert each power module into a MegaV2 250 power module shelf.

  • Page 25: Initial Configuration

    AMATRONIC LECTRONIC NDUSTRIES Initial configuration On the initial startup of the MegaV2 250, a series of configuration screens are presented on the display panel. Through these screens you supply the MegaV2 250 with required, basic configuration information to enable initial operation of the MegaV2 250. The initial configuration process is described here.

  • Page 26: Figure 14: Initial Config. Wizard: Set Number Of Modules

    AMATRONIC LECTRONIC NDUSTRIES On the next screen, you must indicate two things: In the lower half of the screen, indicate the number of modules that are intended to provide redundancy. ("Redundant" modules are those above and beyond the minimum number of modules required to supply the maximum expected UPS load.

  • Page 27: Figure 15: Initial Config. Wizard: Number Of Battery Cabinets

    AMATRONIC LECTRONIC NDUSTRIES Figure 15: Initial config. wizard: number of battery cabinets Indicate the total capacity of all connected battery cabinets, in ampere/hours (Ah), then press "Next". (This capacity figure is used by the UPS when in battery mode to calculate the amount of backup time remaining.) If you are not sure of your battery cabinet's Ah capacity, look at one of the batteries in the cabinet.

  • Page 28: Figure 17: Initial Config. Wizard: Set Date And Time

    AMATRONIC LECTRONIC NDUSTRIES Set the current date and time, then press "Next". Figure 17: Initial config. wizard: set date and time Indicate the appropriate time zone, then press "Next". Figure 18: Initial config. wizard: set time zone MegaV2 250 Installation Guide, Release 2.2...

  • Page 29: Figure 19: Finish Configuration Wizard

    AMATRONIC LECTRONIC NDUSTRIES Press "Finish" to exit the wizard. Figure 19: Finish configuration wizard Continue with section 1.3.1 below. MegaV2 250 Installation Guide, Release 2.2...

  • Page 30: Continuing First-Time Start-Up Process

    AMATRONIC LECTRONIC NDUSTRIES 1.3.1 Continuing first-time start-up process Turn ON the ac input and ac output circuit breakers on the rear of each power module. Turn ON the battery cabinet circuit breaker. On the MegaV2 250 main menu, choose "Operation > Turn on/off > System on". Return to the main menu by tapping on the "house"...

  • Page 31: Define The Ip Address Of Megav2 250

    AMATRONIC LECTRONIC NDUSTRIES 1.3.2 Define the IP Address of MegaV2 250 This procedure assigns an IP address to the MegaV2 250. Assigning an IP address enables you, the user, to remotely monitor and control the MegaV2 250 over an IP network. If you do not intend to remotely monitor the MegaV2 250 this step can be skipped.

  • Page 32: Testing

    AMATRONIC LECTRONIC NDUSTRIES Testing Perform the following tests on the MegaV2 250 unit. 1.4.1 Blackout Test This test is designed to verify the operation of MegaV2 250 in the event of a blackout, when no ac power is supplied to the UPS. Turn all ac input to the system OFF (turn OFF the ac input switches to both Bypass and Rectifier).

  • Page 33: Figure 22: Network Connections Screen

    AMATRONIC LECTRONIC NDUSTRIES Figure 22: Network Connections screen b. When the Network Connections screen appears, right-click on Local Area Connection and select Properties. Figure 23: Local Area Connection Properties screen c. When the Local Area Connection Properties screen appears, in the This connection uses the following items window scroll down to Internet Protocol (TCP/IP) and double click on it.

  • Page 34: Figure 24: Internet Protocol (Tcp/Ip) Properties Screen

    AMATRONIC LECTRONIC NDUSTRIES Figure 24: Internet Protocol (TCP/IP) Properties screen d. When the Internet Protocol (TCP/IP Properties screen appears, click the Use the following IP address button and enter IP address and Subnet mask in the appropriate fields. Leave Default gateway blank. Make sure that the first three groups of numbers in the IP address (192.212.118 in the above example) are the same as those of the domain in which the UPS is installed, and that the last number (31 in the above example) is different (it can be any number from 0 to 255, other than the one...

  • Page 35: Inserting And Removing Power Modules

    AMATRONIC LECTRONIC NDUSTRIES NSERTING AND REMOVING POWER MODULES This chapter discusses the physical insertion and addition of modules to the system, the physical removal of power modules from the system, and the related changes to the system configuration. There are four basic operations that can be performed in this respect: •...

  • Page 36: First-Time Insertion Of Power Modules At System Installation

    AMATRONIC LECTRONIC NDUSTRIES First-time insertion of power modules at system installation When the installation instructions in section 1.2 call for it, insert the power modules into the module shelf. For each module: Before inserting the power module, verify that the two circuit breakers on the module's rear panel are in the OFF (down) position.

  • Page 37: Figure 27: Left Side Of Module Shelves

    AMATRONIC LECTRONIC NDUSTRIES Figure 27: Left side of module shelves Table 6: Key to Figure 27 ESCRIPTION Power module shelf. Guide rail for module pin (item 2 in Figure 26). Lever for locking module in place. MegaV2 250 Installation Guide, Release 2.2...

  • Page 38: Figure 28: Communication Cable On Right Side Of Module

    AMATRONIC LECTRONIC NDUSTRIES Figure 28: Communication cable on right side of module MegaV2 250 Installation Guide, Release 2.2...

  • Page 39: Replacement Of A Module In An Installed System

    AMATRONIC LECTRONIC NDUSTRIES Replacement of a module in an installed system To replace a module in an operational system: From the system main menu, choose "Operation > Turn on/off > Modules off". On the screen, choose the module to be replaced. The modules are numbered from bottom to top.
  • Page 40 AMATRONIC LECTRONIC NDUSTRIES Turn off the input and output circuit breakers on the rear panel of the module to be removed. Disconnect the flat cable (module communication cable) from the right side of the module (see Figure 28). If the LCD screen happens to be connected to the module to be removed, you must also disconnect the LCD communication cable from the right side of the screen, and remove the LCD screen itself to avoid accidental damage to it.

  • Page 41: Figure 31: Verifying Status Of Replacement Module

    AMATRONIC LECTRONIC NDUSTRIES Figure 31: Verifying status of replacement module On the same screen ("Status > Modules"), press the Output button, select the replacement module and verify that the output frequency matches the system nominal value, and that the output voltage of each phase is within 2 % of the system nominal value. Figure 32: Status >...
  • Page 42 AMATRONIC LECTRONIC NDUSTRIES Navigate to the main menu screen. If the yellow, triangular alarm indicator is visible, check the alarms and see if any of them are related to the new module. If there are no alarms, you have successfully replaced the module. MegaV2 250 Installation Guide, Release 2.2...

  • Page 43: Addition Of A Module In An Installed System

    AMATRONIC LECTRONIC NDUSTRIES Addition of a module in an installed system To add a module to an operational system: First, you must verify that the shelf where the module is to be added is "OFF". To switch off (power down) the shelf: From the system main menu, choose "Operation >...

  • Page 44: Figure 34: Turning On A Module

    AMATRONIC LECTRONIC NDUSTRIES Figure 34: Turning on a module To verify that the new module is operating normally, navigate to the module status screen ("Main screen > Status > Modules"), press on the icon of the module that was just switched on, and verify that the status is "ON"...

  • Page 45: Figure 36: Status > Modules > Output

    AMATRONIC LECTRONIC NDUSTRIES Figure 36: Status > Modules > Output If the output voltage of one or more phases is not within 2 % of the system nominal output voltage, then: 10.1 Navigate to "Setup > Modules > Ac output voltage adjustment". 10.2 Select the replacement module, and adjust the problematic phases up or down as required.

  • Page 46: Removing A Module From An Installed System

    AMATRONIC LECTRONIC NDUSTRIES Removing a module from an installed system To remove a module in an operational system: From the system main menu, choose "Operation > Turn on/off > Modules off". On the screen, choose the module to be replaced. The modules are numbered from bottom to top.
  • Page 47 AMATRONIC LECTRONIC NDUSTRIES Turn off the input and output circuit breakers on the rear panel of the module to be removed. Disconnect the flat cable (module communication cable) from the right side of the module. If the LCD screen happens to be connected to the module to be removed, you must also disconnect the screen’s power/communication cable and remove the LCD screen itself to avoid accidental damage to it.

  • Page 48: Installing The Lcd Screen

    AMATRONIC LECTRONIC NDUSTRIES NSTALLING THE SCREEN This chapter explains how to install the LCD display screen. The LCD screen can be installed on the front of any of the power modules that are at about eye-level. (The only limitation is that the module must be within reaching distance of the communication/power cable which must be connected to the right side of the LCD screen –...

  • Page 49: Figure 41: Attaching The Clamp To The Mounting Post, Part 1

    AMATRONIC LECTRONIC NDUSTRIES Figure 41: Attaching the clamp to the mounting post, part 1 Figure 42: Attaching the clamp to the mounting post, part 2 Slide the LCD screen onto the mounting clamp. See Figure 43. MegaV2 250 Installation Guide, Release 2.2...

  • Page 50: Figure 43: Slide Lcd Screen Onto The Mounting Clamp

    AMATRONIC LECTRONIC NDUSTRIES Figure 43: Slide LCD screen onto the mounting clamp Now attach the communication/power cable to the right rear side of the screen. The cable should be visible, projecting from the right side of the UPS’s frame. If not, you will find it behind the second, third, or fourth hinged doors from the top, on the right side of the frame (Figure 44).

  • Page 51: Figure 44: The Screen's Cable Projects From Right Side Of Ups Frame

    AMATRONIC LECTRONIC NDUSTRIES Figure 44: The screen’s cable projects from right side of UPS frame There is a spring-loaded catch on each side of the cable-head. Squeeze the catches, press the cable head firmly and gently onto the LCD screen's cable socket, and then release the catches to lock the cable into place.

  • Page 52: Figure 45: Attach Comm. Cable To The Lcd Screen

    AMATRONIC LECTRONIC NDUSTRIES Figure 45: Attach comm. cable to the LCD screen Press the screen's "power" button to power-on the screen. MegaV2 250 Installation Guide, Release 2.2...

  • Page 53: Replacing The Computer

    AMATRONIC LECTRONIC NDUSTRIES EPLACING THE COMPUTER The MegaV2 250's computer is built to provide trouble-free service for many years. However, if it does at some point become necessary to replace the computer, the following steps explain how to do so. The process begins at the lower left of the MegaV2 250, when looking at the MegaV2 250 from the front.

  • Page 54: Figure 48: The Flat Cables

    AMATRONIC LECTRONIC NDUSTRIES Figure 49: The power cord Figure 48: The flat cables Figure 50: The left side of the computer MegaV2 250 Installation Guide, Release 2.2...

  • Page 55: Figure 51: Two Screws On The Front Of The Computer

    AMATRONIC LECTRONIC NDUSTRIES On the right side of the computer is another metal panel. Remove it, and carefully disconnect all the cables from the right side of the computer. Remove the two screws from the front of the computer. See Figure 51. Figure 51: Two screws on the front of the computer Slide the old computer box out of the MegaV2 250.

  • Page 56: Circuit Breaker Selectivity

    AMATRONIC LECTRONIC NDUSTRIES IRCUIT BREAKER SELECTIVITY When discussing power distribution, selectivity (also referred to as "discrimination") is the selection and arrangement of circuit breakers such that in the event of a short circuit or overload in the line, the circuit breaker closest to the short will be tripped and the upstream circuit breakers remain unaffected.
  • Page 57 AMATRONIC LECTRONIC NDUSTRIES In order to protect the UPS's bypass contactor and also the main input of the UPS, for all scenarios including short circuit, the following recommendations apply: • The circuit breaker that feeds the bypass input line and the circuit breaker feeding the main input of UPS shall have no magnetic protection delay, or a maximum magnetic protection delay of 50 msec.

  • Page 58: Periodic Preventive Maintenance

    It is important that the UPS owner continue to arrange regular preventive maintenance inspections even after the expiration of the initial warrantee period. Gamatronic bears no liability for damage caused to the UPS due to improper maintenance by third parties, in particular after the expiration of the warrantee or service agreement.

  • Page 59: Objectives

    AMATRONIC LECTRONIC NDUSTRIES These preventive maintenance procedures shall be performed only by a trained and qualified technician! Objectives Periodic preventive maintenance is performed on the MegaV2 to verify the following: • The MegaV2 UPS and batteries are in proper electrical and physical condition •...

  • Page 60: Maintenance Procedures And Report

    NDUSTRIES Maintenance Procedures and Report Record the values of all parameters checked and of measurements taken during the periodic maintenance in the form below. Fax the completed form to Gamatronic at +972-2-582-8875. UPS model and configuration Company ______________________ Address _______________________________________...
  • Page 61 AMATRONIC LECTRONIC NDUSTRIES Al a r m s Use Alarm Log to display the alarms. List the names of any active alarms: ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ List the names of recent alarms: ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ B y p a s s T e s t a n d M o d u l e M a i n t e n a n c e Connect an oscilloscope to MegaV2 output terminals L1 and N.
  • Page 62 AMATRONIC LECTRONIC NDUSTRIES B a t t e r y C h e c k s Turn the battery circuit breaker to Off and disconnect all Anderson connectors in the battery set. Record the battery serial number, type, and number of cells in the table below: Battery manufacturer Battery model Rating (Ah)

  • Page 63: Service And Repairs

    Without a written agreement, Gamatronic is under no obligation to provide service after expiration of the initial warrantee period. Gamatronic will not be responsible for maintenance or changes to the UPS that are performed by an agent without written authorization from Gamatronic.

  • Page 64: Ega Specifications

    AMATRONIC LECTRONIC NDUSTRIES V2 250 SPECIFICATIONS Table 7: Technical specifications MEGA.V2 250 T ECHNICAL Topology True on-line, double-conversion, VFI Construction Modular, parallel hot-swapped modules Operation Continuous Input Voltage 3×400 Vac + N Voltage range –20 % and +15 % Current 3x42 A per module –...
  • Page 65 AMATRONIC LECTRONIC NDUSTRIES MEGA.V2 250: TECHNICAL SPECIFICATIONS FOR THE SYSTEM CONTROLLER Display LCD flat panel, touch-sensitive Other indicators Audible alarm Analog input channels 4 input dry contacts (N.O. / N.C.) Real-time clock (RTC) Yes, with backup Power meter kVA, kW, PF Volt-free outputs (dry contacts) 6 outputs, rated 48 V / 1 A Ac failure...
  • Page 66 Headquarters and Factory: 17 Hartom Street, POB 45029, Jerusalem 91450, Israel Gamatronic Singapore Sales Office: email: singapore@gamatronic.co.il Gamatronic (UK) Ltd.15 Chester Road, Eaton Socon, St. Neots, Cambridgeshire PE19 8YT United Kingdom Tel: +44 (0)1480 479 889 Fax: +44 (0)1480 407 865 email: info@gamatronic.net...

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