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ZGR SCALABLE 60 KVA Operation Manual

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Operation Manual
ZGR SCALABLE 60
300 KVA
Online Three-phase UPS
www.zigor.com

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Summary of Contents for ZGR SCALABLE 60 KVA

  • Page 1 Operation Manual ZGR SCALABLE 60 300 KVA Online Three-phase UPS www.zigor.com...

  • Page 3: Table Of Contents

    ZGR SCALABLE 60 – 300 KVA INDEX PRECAUTIONS ..............................3 General precautions ............................. 3 Storage precautions ............................. 4 Environmental precautions .......................... 5 Precautions on receiving the unit ......................... 6 Precautions on the transportation of the unit ....................6 Symbol Description ............................6 GENERAL DESCRIPTION .............................
  • Page 4 ZGR SCALABLE 60 – 300 KVA Connection of Power Cables ........................48 Recommended cross-sectional areas for power cables ............... 49 Power cable connector requirements ....................50 Recommended input front-end and output back-end circuit breakers ..........51 Power cable connection ..........................51 Battery connection .............................

  • Page 5: Precautions

    Only expert and duly authorised personnel may operate our units. Danger warnings. When handling or accessing the interior of the ZGR SCALABLE 60 300 KVA, please remember that some parts may be live. Pay special attention to soldering points, printed circuits, connecting terminals, relay contacts, etc.

  • Page 6: Storage Precautions

    ZGR SCALABLE 60 – 300 KVA measures to be applied and the specific technical characteristics of the unit. • Even though all the safety systems are in place, before touching any working parts, you must check that they are not live.

  • Page 7: Environmental Precautions

    ZGR SCALABLE 60 – 300 KVA WARNING Any failure to respect these precautions may render the product warranty null and void. 1.3 Environmental precautions Dispose of the packaging in an ecological way: ZIGOR, based on the exceptions detailed in the First Additional Provision of Law 11/1997 on commercial or industrial packaging,...

  • Page 8: Precautions On Receiving The Unit

    ZGR SCALABLE 60 – 300 KVA 1.4 Precautions on receiving the unit Visually check that the warehouse location is adequate by checking its characteristics (clean, free of leaks with good ventilation); the floor must be level and have sufficient load resistance for the equipment.

  • Page 9: General Description

    Optional Accessories available such as Isolation transformer, distribution Panel, SNMP Card, Relay Contact Board, etc... 2.3 Construction of ZGR SCALABLE 60 – 300 KVA Below are the different views of the ZGR SCALABLE 60 300 KVA in all its formats and available powers (Fig. 2-1 to Fig. 2-11): Manual de operaciones www.zigor.com...
  • Page 10 SCALABLE 30-60 kVA 30-60 kVA 30-60 kVA Fig. 2-4 Front view of ZGR SCALABLE 30-60 kVA (redundant power module and bypass module are optional) Fig. 2-5 Front view of ZGR SCALABLE 40-120 kVA (redundant power module and bypass module are optional) Fig.
  • Page 11 Fig. 2-9 Rear view of ZGR SCALABLE SCALABLE 90-300 kVA 90-300 kVA 90-300 kVA Fig. 2-10 Front view of ZGR SCALABLE 90-270 kVA Fig. 2-11 Front view of ZGR SCALABLE 100-300 kVA (Redundant power module and bypass module are optional)
  • Page 12 ZGR SCALABLE 60 – 300 KVA 3. Bypass module 4. Control unit 5. Mains switch 6. Bypass switch 7. Maintenance switch 8. Output switch 9. Intelligent Slot (SNMP card/ Relay card) 10. Mains-A input copper bar 11. Mains-B input copper bar 12.
  • Page 13 ZGR SCALABLE 60 – 300 KVA 3. Monitor unit 4. Intelligent slot • ECU unit Fig. 2-13 ECU unit The elements that compose the ECU unit (Fig. 2-13) are: 1. PARALLEL port 2. LBS port 3. LED • Dry-contact unit Fig.
  • Page 14 ZGR SCALABLE 60 – 300 KVA • Monitor unit Fig. 2-15 Monitor unit The elements that compose the monitor unit (Fig. 2-15) are: 1. BAT_T: NTC temperature sensor port 2. R-CAN: CAN communication resistor adjust 3. USB port: for software update and history download 4.

  • Page 15: Operation Of Zgr Scalable

    ZGR SCALABLE 60 – 300 KVA 3 OPERATION OF ZGR SCALABLE 60 300 KVA 3.1 Operation Modes ZGR SCALABLE 60 300 KVA is a double-conversion on-line UPS that may operate in the following alternative modes: Normal mode The rectifier/charger derives power from the AC mains and supplies DC power to the inverter while floating and boosting charge the battery simultaneously.

  • Page 16: Bypass Mode

    ZGR SCALABLE 60 – 300 KVA Bypass mode If the inverter is out of order, or if overload occurs, the static bypass will be activated to transfer the load from the inverter supply to bypass supply without interruption to the critical load (Fig. 3-3).

  • Page 17: Maintenance Mode (Manual Bypass)

    ZGR SCALABLE 60 – 300 KVA Maintenance mode (Manual Bypass) A manual bypass switch is available to ensure continuity of supply to the critical load when the UPS is out of order or in repair. This manual bypass switch is fitted for all UPS modules and bears for equivalent rated load (Fig. 3-5).

  • Page 18: Test Procedure

    ZGR SCALABLE 60 – 300 KVA Test procedure WARNING The UPS is operating normally. It may take 60 seconds to boost up the system and perform self-test completely. 1. Switch off the MAINS to simulate utility failure, the rectifier will turn off and the battery should feed the inverter without interruption.

  • Page 19: Cold Start Procedure

    ZGR SCALABLE 60 – 300 KVA 5. Switch OFF the maintenance bypass switch, then the output is supplied by the bypass of the modules. 6. Put on the maintenance switch cover (1.2m cabinet). The rectifier will operate normally after 30 seconds. If the inverter works normally, the system will be transferred from bypass mode to normal mode.

  • Page 20: Startup Procedure For Parallel System

    ZGR SCALABLE 60 – 300 KVA WARNING Wait for about 5 minutes for the internal DC bus bar capacitors to be completely discharged. Start-up procedure for parallel system 1. Connect parallel cable, input/output cable, and battery cable well; modify the parallel board jumpers correctly.

  • Page 21: Control Panel And Monitorization

    ZGR SCALABLE 60 – 300 KVA 4 CONTROL PANEL AND MONITORIZATION LCD Display 60 kVA Fig. 4-1 Distribution of the control panel areas and elements Click the main block to enter the main data display window, click return to return to the previous window, click home page to return to the main page.

  • Page 22: Status Menu

    ZGR SCALABLE 60 – 300 KVA Fig. 4-3 Datas menu detail Status menu In this window it can be viewed the voltage and current of the main, bypass, output, battery (Fig. 4-4). Moreover, it can also be entered through by real-time data block), the status of the switches, dry contacts, through clicking on the block, enter the corresponding data window.
  • Page 23 ZGR SCALABLE 60 – 300 KVA 4.1.2.2 Bypass submenu Click the bypass block to enter the bypass data display window (Fig. 4-6). Fig. 4-6 Status/Bypass submenu 4.1.2.3 Output submenu Click the output block to enter the output data display window (Fig. 4-7 and Fig. 4-8).
  • Page 24 ZGR SCALABLE 60 – 300 KVA 4.1.2.4 Battery submenu Click the battery block to enter the battery data display window (Fig. 4-9 y Fig. 4-10). Fig. 4-9 Status/Battery (1) submenu Fig. 4-10 Status/Battery (2) submenu 4.1.2.5 Status info submenu To access to the status information click the block to enter the status data display window (Fig. 4-11, Fig. 4-12 and Fig.

  • Page 25: Alarm Menu

    ZGR SCALABLE 60 – 300 KVA Fig. 4-12 Status/Status Info (2) submenu Fig. 4-13 Status/Status Info (3) submenu 4.1.2.6 Module submenu Click the module block to enter the module data display window (Fig. 4-14) Fig. 4-14 Status/Module submenu Alarm menu It allows viewing the alarms and history of the UPS, and activating or deactivating the buzzer (Fig.
  • Page 26 ZGR SCALABLE 60 – 300 KVA Fig. 4-15 Alarm menu 4.1.3.1 Curr Alarm submenu Click the curr alarm to enter the current alarm display window (Fig. 4-16). Fig. 4-16 Alarm/Curr Alarm submenu 4.1.3.2 History submenu Click the history to enter the history recode display window (Fig. 4-17).

  • Page 27: Setting Menu

    ZGR SCALABLE 60 – 300 KVA 4.1.3.3 Buzzer submenu Click the buzzer mute then the buzzer will mute and the red block will change to red (Fig. 4-18); if the buzzer is on, then click the block buzzer will on and the block will change to green (Fig. 4-19).
  • Page 28 ZGR SCALABLE 60 – 300 KVA 4.1.4.1 Basic Setting submenu Click basic setting (Fig. 4-23) and enter by input the correct password (Fig. 4-21 and Fig. 4-22). The user password is «111111». Fig. 4-21 Password window Fig. 4-22 Password keyboard Fig.
  • Page 29 ZGR SCALABLE 60 – 300 KVA • Language submenu Click the language block witch you want and click the save configuration block to save (Fig. 4-24). Fig. 4-24 Settings/Basic Settings/Language submenu • Password submenu Click password block enter user password setting page, input old password and new password, then click save confirm to save the change (Fig.
  • Page 30 ZGR SCALABLE 60 – 300 KVA Fig. 4-26 Settings/Basic Settings/Brightness And Backlight Time submenu • Date and time setting submenu Click the text to select other value or input new value and click save configuration block to save (Fig. 4-27).
  • Page 31 ZGR SCALABLE 60 – 300 KVA Fig. 4-28 Settings/Basic Settings/Communications submenu 4.1.4.2 Advanced Setting submenu Click advanced setting, enter by input the correct password (Fig. 4-29). Fig. 4-29 Settings/Advanced Settings submenu • System setting submenu Click the text to select other value or input new value and click save configuration block to save (Fig. 4-30 to Fig.
  • Page 32 ZGR SCALABLE 60 – 300 KVA Fig. 4-30 Settings/Advanced Settings/System Setting (1) submenu Freq Conv Mode: Frequency conversion mode, enable: output frequency set 50Hz or 60Hz, input frequency is 60Hz or 50Hz, UPS no alarm not battery and bypass abnormal. Default is Disable.
  • Page 33 ZGR SCALABLE 60 – 300 KVA Fig. 4-32 Settings/Advanced Settings/System Setting (3) submenu Basic Unit Numb: power module number for actual configuration, if setting number no the same to actual number, UPS will alarm. Cabinet Power: cabinet power range, the same power range of bypass.
  • Page 34 ZGR SCALABLE 60 – 300 KVA Fig. 4-34 Settings/Advanced Settings/System Setting (5) submenu Output Freq: Output frequency. The value can be 50Hz or 60Hz. Output Volt Level: Output voltage level. The value can be 220V, 230V, 240V. Inverter Volt Adjust: Inverter voltage adjust. The value can be -5%~0~+5%, step is 0.5%, default value: 0.
  • Page 35 ZGR SCALABLE 60 – 300 KVA Fig. 4-36 Settings/Advanced Settings/System Setting (6) submenu Chg.cur.limiting coef.: The charging current limit is a multiple of the battery capacity. The value can be 0.05 0.15, and is 0.1 by default. Cell float voltage: The float voltage value can be 2.23-2.30 V/cell, and is 2.25 V/cell by default.
  • Page 36 ZGR SCALABLE 60 – 300 KVA Fig. 4-38 Settings/Advanced Settings/System Setting (8) submenu Cabinet Shared Battery: Tow parallel ups use common batter bank. The value can be set Disable and enable, disable by default. Generator on prohibit charging: UPS disable charge the battery if set the value to enable when the generator signal is enable.
  • Page 37 ZGR SCALABLE 60 – 300 KVA Bypass Freq Tracking Range: When the difference between the bypass input frequency and the rated frequency is greater than this value, the system determines that the bypass frequency is not normal, and that the bypass is unavailable. The value range is 1%, 2%, 4%, 5%, 10%(default).
  • Page 38 ZGR SCALABLE 60 – 300 KVA Enable or disable battery breaker connection detection. The default BATT Switch (BAT): value is Disable. Fig. 4-42 Settings/Advanced Settings/System Setting (11) submenu Output Switch: Enable or disable output breaker connection detection. The default value is Disable.
  • Page 39 ZGR SCALABLE 60 – 300 KVA Fig. 4-44 Settings/Advanced Settings/System Setting (12) submenu OUT01~OUT06: Output dry contact port, modify on the LCD, the default value is Disable. The output port can set to normally closed or normally opened. The default value is normally opened.

  • Page 40: Maint Menu

    ZGR SCALABLE 60 – 300 KVA Fig. 4-46 Settings/Advanced Settings/System Setting (14) submenu Maint menu In this menu the History can be downloaded, the touch correction adjusted and done a battery self-test (Fig. 4-47). Fig. 4-47 Maint menu 4.1.5.1 USB Wizard submenu This submenu provides the History Output, downloads history and sets the setting record by USB (Fig.
  • Page 41 ZGR SCALABLE 60 – 300 KVA • Alarm log output submenu (Fig. 4-49) Fig. 4-49 Maint//USB Wizard/Alarm log output submenu • Setting log output submenu (Fig. 4-50) Fig. 4-50 Maint/USB Wizard/Setting log output submenu 4.1.5.2 Battery Self-Check submenu It can be selected the check by Timing Daily, Timing Weekly. The default value is Timing Self-Check Close (Fig.
  • Page 42 ZGR SCALABLE 60 – 300 KVA • Timing daily Modify the check date, time and check time (10S (default), 10min, EOD) (Fig. 4-52). Fig. 4-52 Maint/Battery Self-Check/Timing daily submenu • Timing weekly Modify the check date, time and check time (10S (default), 10min, EOD) (Fig. 4-53).

  • Page 43: Common Menu

    ZGR SCALABLE 60 – 300 KVA Common menu Through this menu the inverter can be started-up or switched off (INV ON/OFF), test the battery and clear the faults (Fig. 4-55). Fig. 4-55 Common menu 4.1.6.1 INV ON/OFF submenu In this window the inverter can be started-up or switched off (INV ON/OFF) depending on the configuration (Fig.

  • Page 44: About Menu

    ZGR SCALABLE 60 – 300 KVA Fig. 4-57 Common/Battery Test submenu 4.1.6.3 Fault Clear submenu Clear the current fault (not for all faults) (Fig. 4-58). Fig. 4-58 Common/Fault Clear submenu About Menu It shows the software version Monitor and LCD software version (Fig. 4-59).

  • Page 45: List Of Events And Alarms

    ZGR SCALABLE 60 – 300 KVA 4.1.7.1 Internal software version • Power module software version: PFC DSP, PFC CPLD, INV DSP and INV CPLD. • Center control unit (ECU) software version: DSP and PFGA. Bypass module software version: DSP and CPLD •...
  • Page 46 ZGR SCALABLE 60 – 300 KVA Rectifier Fault Beep continuously Fault LED lit Inverter Fault Beep continuously Fault LED lit INV IGBT SHORT Beep continuously Fault LED lit Inverter relay Short Beep continuously Fault LED lit Inverter relay Broken Beep continuously Fault LED lit INV par.

  • Page 47: Alarm Information

    ZGR SCALABLE 60 – 300 KVA Bypass Fan Fault Beep continuously Fault LED lit Table 4-2 Faults list Alarm Information ALARM UPS ALARM WARNING BUZZER CODE Battery Over Voltage Once per second Alarm LED lit BAT Low Pre-warning Once per second...
  • Page 48 ZGR SCALABLE 60 – 300 KVA Once per 2 seconds Alarm LED lit BPS Not Available Once per second Alarm LED lit Once per second Alarm LED lit Ecu Set Data Err Once per 2 seconds Alarm LED lit BPS Par.cable abnormal...

  • Page 49: Installation

    ZGR SCALABLE 60 – 300 KVA 5 INSTALLATION 5.1 Unpack checking Check the appearance to see if the UPS is damaged during transportation, do not switch on the UPS if any damaged is found and please contact the dealer. Check the accessories according to the packing list and contact the dealer if any parts missing.

  • Page 50: Electrical Installation

    ZGR SCALABLE 60 – 300 KVA WARNING Typical battery performance data are quoted for an operating temperature between 20°C and 25°C. Operating it above this range will reduce the battery life while operation below this range will reduce the battery capacity.
  • Page 51 ZGR SCALABLE 60 – 300 KVA WARNING Upon starting, please ensure that you are aware of the location and operation of the external isolators which are connected to the UPS input/bypass supply of the mains distribution panel. Check to see if these supplies are electrically isolated.
  • Page 52 ZGR SCALABLE 60 – 300 KVA • When the mains input and bypass input share a power source, configure both types of input power cables as mains input power cables. The cables listed in Table are used only when the following requirements...
  • Page 53 ZGR SCALABLE 60 – 300 KVA Recommended input front-end and output back-end circuit breakers BYPASS MAINS INPUT MAINTENANCE OUTPUT BATTERY INPUT CIRCUIT CIRCUIT CIRCUIT CIRCUIT CABINET CIRCUIT (KVA) BREAKER BREAKER BREAKER BREAKER BREAKER 63A 3P 63A 3P 63A 4P 63A 3P...
  • Page 54 ZGR SCALABLE 60 – 300 KVA Fig. 5-2 Power cable connection Choose appropriate power cable. (Refer to the table above) and pay attention to the diameter of the connection terminal of the cable that should be greater than or equal to that of the connection poles.
  • Page 55 ZGR SCALABLE 60 – 300 KVA WARNING If the load equipment is not ready to accept power on the arrival of the commissioning engineer then ensure that the system output cables are safely isolated at their ends Connect the safety earth and any necessary bonding earth cables to the copper earth screw located on the floor of the equipment below the power connections.
  • Page 56 ZGR SCALABLE 60 – 300 KVA Factory setting of the long-run unit is battery quantity---36pcs, battery capacity---12V 100AH. When connecting 30/32/34/38/40/42/44/46/48/50 batteries, please re-set desired battery quantity and its capacity after UPS starts at AC mode. Charger current could be adjusted automatically according to battery capacity selected. All related settings can be done through LCD panel or monitoring software.
  • Page 57 ZGR SCALABLE 60 – 300 KVA WARNING Before start the module, the module_ON switch must on the "ON" status and the red indicator must flash or off. Before remove the module, the module_ON switch must on the "OFF" status and the red indicator must light.
  • Page 58 ZGR SCALABLE 60 – 300 KVA UPS modules as shown below (Fig. 5-7). The parallel control board is mounted on each UPS module. The ring configuration ensures high reliability of the control. Fig. 5-7 Ring configuration LBS installation (Load Bus Synchronisation) The LBS system is a module to keep the outputs of two completely independent UPSs synchronized, even if they come from two different power supplies.
  • Page 59 ZGR SCALABLE 60 – 300 KVA Fig. 5-8 LBS cable installation 5.8.3.3 UPS installation The whole systems are showed below (Fig. 5-9). Fig. 5-9 Installation of the whole system Manual de operaciones www.zigor.com...
  • Page 60 ZGR SCALABLE 60 – 300 KVA 5.9 Communication CAN communication port definition Definition of port (Fig. 5-9): Fig. 5-10 Puerto CAN (Table 5-5). SAI (RJ45) DESCRIPTION PIN 1 PIN 1 CAN_H PIN 2 PIN 2 CAN_L PIN 3/7 PIN 3/7...
  • Page 61 ZGR SCALABLE 60 – 300 KVA RS485 communication data format • Baud rate: 9600 bps • Byte length: 8 bit • End bit: 1 bit • Parity check: None BAT_T communication port definition Definition of port (Fig. 5-12): Fig. 5-12 BAT_T port Table 5-7).
  • Page 62 ZGR SCALABLE 60 – 300 KVA Connection between the button and UPS REPO port (Table 5-8): BUTTON UPS REPO DESCRIPTION Pin 1 Pin 1 EPO-NA Pin 2 Pin 2 EPO-12 V Pin 1 Pin 3 EPO-NC Pin 2 Pin 4...
  • Page 63 ZGR SCALABLE 60 – 300 KVA 6 OPTIONS 6.1 SNMP card WARNING For network management configuration and use, refer to the separate user manual - Network Management Card with Environmental Monitor - shipped with the CARD. Internal SNMP / external SNMP optional: 1.
  • Page 64 ZGR SCALABLE 60 – 300 KVA 7 TROUBLESHOOTING 7.1 Problems and Solution ZGR SCALABLE 60 – 300 KVA ZIGOR recommends that, in case of any anomaly, strange noise or supposed malfunction, the equipment should be shut down and ZIGOR customer service should be contacted.
  • Page 65 ZGR SCALABLE 60 – 300 KVA Buzzer beeps every 0,5 seconds and LCD Overload Remove some load Buzzer long beeps, The UPS output is in short Make sure the load is not in short circuit, and circuit then restart the UPS.
  • Page 66 You can ask for an offer to ZIGOR in order to perform a basic maintenance of this equipment, so that it can prolong the life of the system. In order to guarantee the correct operation of the ZGR SCALABLE 60 300 KVA, it is necessary to carry out a number of maintenance tasks.
  • Page 67 ZGR SCALABLE 60 – 300 KVA The rest of the installation must also be maintained adequately. The maintenance tasks to be carried out shall depend on the different elements that make up the installation, emergency generator and cabling. The battery requires special attention.
  • Page 68 ZGR SCALABLE 60 – 300 KVA TECHNICAL SPECIFICATIONS CABINET (30 KVA MODULE) 60 KVA 150 KVA 300 KVA 30 ~ 60 kVA 30 k ~ 150 kVA 30 ~ 300 kVA UPS cabinet 30 k ~ 60 kW 30 k ~ 150 kW...
  • Page 69 ZGR SCALABLE 60 – 300 KVA Line Mode:±1 % / ± 2 % / ± 4 % / ± 5 % of the rated frequency(optional) Output frequency Battery Mode: 50 / 60 ± 0,1 % Hz Crest factor Efficiency 95,8 %...
  • Page 70 ZGR SCALABLE 60 – 300 KVA 10 STANDARDS ZGR SCALABLE 60 300 KVA model described in this manual comply with the following European regulations: European electromagnetic compatibility directive (EMC) Standard: EN 62040-1:2008/A1:2013 IEC/EN 62040-3:2011 Uninterruptible power supply (UPS) Standard: IEC/EN 62040-2:2016 III.
  • Page 71 ZGR SCALABLE 60 – 300 KVA 11 WARRANTY Unless otherwise agreed, ZIGOR guarantees that ZGR SCALABLE 60 300 KVA units leave the factory in perfect working order and free of any defects for a period of 12 months to be counted as of the date of sale of the apparatus, shown in the delivery note and/or invoice.
  • Page 72 31268900MAOP Zigor Corporación Portal de Gamarra 28- 01013 Vitoria-Gasteiz Álava/Spain +34 945 21 46 00 www.zigor.com Consulte nuestra web para contactar con la red de delegaciones comerciales Refer to our website in order to contact the commercial branches network Veuillez consulter notre page web pour contacter nos délégations commerciales Consulte a nossa web para contatar com a rede de degaçoes comerciais...

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Scalable 150 kvaScalable 300 kva

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