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Tescom MTW User Manual

Modular ups 10-150 kva
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MODULAR UPS
MTW 10-150 KVA
USER MANUAL

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  • Page 1 MODULAR UPS MTW 10-150 KVA USER MANUAL...

  • Page 2: Safety Precautions

    Safety Precautions Safety Precautions This manual contains information concerning the installation and operation of modular UPS. Please carefully read this manual prior to installation. The modular UPS cannot be put into operation until it is commissioned by engineers approved by the manufacturer (or its agent).

  • Page 3: Maintenance & Replacement

    Safety Precautions Move & Installation Keep the equipment away from heat source or air outlets.  In case of fire, use dry powder extinguisher only, any liquid  DANGER extinguisher can result in electric shock. Don't start the system if any damage or abnormal parts are ...

  • Page 4: Battery Safety

    Safety Precautions following the recommended operating procedures in this manual. Battery Safety All the battery maintenance and servicing procedures  involving internal access need special tools or keys and DANGER should be carried out only by trained personnel. When connected, the battery terminal voltage will exceed ...
  • Page 5 Safety Precautions be damaged by the acid. At the end of battery life, the battery may have internal  short circuit, drain of electrolytic and erosion of positive/negative plates. If this condition continues, the battery may have temperature out of control, swell or leak. Be sure to replace the battery before these phenomena happen.
  • Page 6 1 Installation Contents Safety Precautions ..........................I Safety Information Definition ...................... I Warning Label ..........................I Safety Instruction ........................I Move & Installation ........................II Debug & Operate ........................II Maintenance & Replacement ....................II Battery Safety ........................... III Disposal ........................... IV Note ............................
  • Page 7 1 Installation 5.2 1+1 Parallel System ......................30 5.2.1 Features of Parallel System ..................30 5.2.2 Parallel Requirements of UPS Modules..............30 5.3 Operating Mode ......................... 31 5.3.1 Normal Mode ......................31 5.3.2 Battery Mode ......................31 5.3.3 Auto-Restart Mode ....................31 5.3.4 Bypass Mode ......................

  • Page 8: Installation

    1 Installation 1 Installation 1.1 Introduction This chapter introduces the relevant requirements for positioning and cabling of the UPS and related equipment. WARNING: installation can only be done by authorized engineers Do not apply electrical power to the UPS equipment before the commissioning engineer arrives at the installation site.
  • Page 9 1 Installation carrier. 1.3 Location 1.3.1 UPS Location The UPS is intended for indoor installation and should be located in a cool, dry and clean environment with adequate ventilation to keep the environmental parameters within the specified operating range (see Table.9-2). The Modular series UPS uses forced convection cooling by internal fans.
  • Page 10 1 Installation Protection against dust and other particulate matter.  Compliance with the fire prevention regulations and practices.  Operating environment temperature of 74 °F-80 °F (23 °C-27 °C) for maximum battery life.  1.4.1 System Cabinet A UPS system comprises an UPS rack system, external battery cabinet, depending on the specific system requirement.
  • Page 11 1 Installation Manual bypass Bypass module Power module Fig.1- 1: UPS Structure (b)6 modules cabinet, 150/25E,120/20E, 60/10E Table.1- 1: UPS Con�iguration List Item Component Quantity Remarks Requisite, factory installed Bypass module Requisite, factory installed Bypass/maintenance Requisite, factory installed bypass breakers Power module Requisite 1.4.5 Installing Power Modules...
  • Page 12 1 Installation Fig.1- 2: rack mounted installation fasten cabinet into rack enclosure and insert power modules WARNING Service rack enclosure within side doors should be chosen to cover side panel of UPS cabinet, otherwise the connector for power modules might be touched with tools like screwdriver.
  • Page 13 1 Installation Power cable entry (a) 2 modules cabinet, 050/25E,040/20E,020/10E power cable entry (b) 6 modules cabinet, 150/25E,120/20E, 60/10E Fig.1- 3: power cable entry Note Cables connection should be followed as diagram on rear panel or appendix B. Fix cables in 6-module cabinet as Fig.1-3 to make sure best ventilation. Enter through reserved entry cover if ellipse holes are not big enough, and block the remained space to protect UPS from rats.

  • Page 14: External Protective Devices

    1 Installation 1.5 External Protective Devices For safety concerns, it is necessary to install external circuit breakers or other protective devices for the input AC supply of the UPS system. This section provides generic practical information for qualified installation engineers. The installation engineers should have the knowledge of the regulatory wiring standards, and of the equipment to be installed.
  • Page 15 1 Installation power Main input current Output current at full Battery discharging current at (KVA) 1，2 load 2 E.O.D=1.75V/cell, no overload/fuse 32Batt./str 38Batt./str 40Batt./str 380V 400V 415V 380V 400V 415V (DC Fuse (DC Fuse (DC Fuse recomme recomme recomme nded) nded) nded) 446(500A...

  • Page 16: Control Cabling And Communication

    1 Installation Common Input Connections 4. For common bypass and rectifier inputs, connect the AC input supply cables to the UPS input terminals (input A-B-C-N) Refer to Fig. 4-11 and tighten the connections to 5 Nm (M6 Bolt), 13Nm(M8 Bolt) or 27Nm (M10 Bolt). ENSURE CORRECT PHASE ROTATION. Split Bypass Connections(option) 5.
  • Page 17 1 Installation 2 slots system Dry contact Cold start RS232 RS485 SNMP 6 slots system Fig.1- 5: Static Bypass Assembly Features 1.7.2 Dry Contactor Interface of Battery and Environmental Temperature Detection The dry contactor detect the temperature of batteries and environment respectively, which can be used in environment monitoring and battery temperature compensation.
  • Page 18 1 Installation Table.1- 4: Description of Input Dry Contactor for Remote EPO Position Name Purpose EPO-1 EPO_NO EPO is activated when shorting with EPO-2 EPO-2 +24V, connect the common terminal of NC ＋24V EPO-3 +24V, connect the common terminal of NO ＋24V EPO-4 EPO_NC...
  • Page 19 1 Installation IP1-3 Generator Fig.1- 9: BCB Interface Table.1- 6: Description of BCB Interface Position Name Description BCB_STAT IP1-1 BCB contact status IP1-2 Common connection BCB on-line–input (normally open), BCB is on-line when the IP2-3 BCB_ONL signal is connecting with common connection IP2-4 Common connection BCB actuating signal, provide the actuating signal of +24V,...
  • Page 20 1 Installation Position Name description Battery warning relay (normally open) will be closed during OP1-2 BAT_LOW_NO warning OP1-3 Common connection 1.7.7 General Alarm Output Dry Contactor Interface OP2 is the integrated warning output dry contactor interface, when one or more than one present warning is triggered, the system will send an integrated warning information, and provide an auxiliary dry contactor signal via the isolation of a relay.
  • Page 21 1 Installation Fig.1- 12: Utility Failure Warning Dry Contactor Table.1- 9: Description of Mains failure warning dry contactor Position Name Purpose Utility failure warning relay (normally closed) will be open OP3-1 UTI_FAIL_NC during warning Utility failure warning relay (normally open) will be closed OP3-2 UTI_FAIL_NO during warning...

  • Page 22: Battery Installation And Maintenance

    2 Battery Installation 2 Battery Installation and Maintenance 2.1 General Recommendations Take special care when operating the batteries of the UPS system. When all the batteries are connected, the battery voltage can exceed 400Vdc, which is potentially lethal. Note The precautions for battery installation, use and maintenance are to be provided by the batteries manufacturers.

  • Page 23: Battery Typologies

    2 Battery Installation attached to the separation board and plate in the battery. However, when the battery case is broken, the acid will leak from the battery. Therefore, be sure to wear a pair of protective glasses, rubber gloves and skirt when operating the battery.
  • Page 24 2 Battery Installation BAT+ BATN BAT- N/2+1 Fig.2- 1: Diagram of Batteries Connection WARNING When using a traditional battery solution, always comply with the following precautions: Disconnect the charging power before connecting or disconnecting the cable of  the battery terminals. Do not connect the cables between the UPS battery terminals and the batteries ...

  • Page 25: Battery Maintenance

    2 Battery Installation pulling force or twisting force of the cable. Otherwise, the internal connection of the battery may be damaged, and in severe case, the battery may catch fire. Do not connect power until the total voltage of the battery string is verified correct ...
  • Page 26 3 Installation of UPS Rack System and Parallel System 3 Installation of UPS Rack System 3.1 Overview The single system should be installed according to the installation procedures of the UPS rack module system and the requirements in this Chapter. For single UPS installation the EPO button on the front panel of the UPS rack controls the emergency stop of UPS modules and bypass static switch and also supports remote emergency power off function that can be used to shut down the UPS rack module remotely.
  • Page 27 3 Installation of UPS Rack System and System 3.2 UPS in Parallel System The basic installation procedures of parallel system are the same with those of the UPS rack module system. In this section, only the installation procedures related to the parallel system are introduced.
  • Page 28 3 Installation of UPS Rack System and Parallel System 1+1 system Fig.3- 3: Connection of Parallel Cables of Parallel System N+1 system Modular UPS System 10-150kVA User Manual...

  • Page 29: Installation Drawing

    4 Installation Drawing 4 Installation Drawing External Output Input Bypass Batt. REPO TEMP Fig.4- 1: Wiring Diagram Modular UPS System 10-150kVA User Manual...
  • Page 30 4 Installation Drawing 24VDC BCB box Modular UPS Auxiliary Contactor Batt + Batt N Batt - Fig.4- 2: External Battery Connection External BCB interface:  BCB DRV (OP4-4): BCB drive signal BCB STATUS (IP1-1): BCB contactor status, normally opened. Shorted to GND when activated GND (IP1-2): common connection Fig.4- 3: 2 slots UPS Dimensions Modular UPS System 10-150kVA User Manual...
  • Page 31 4 Installation Drawing Fig.4- 4: 6 Slots UPS Dimensions (a) 2 slots cabinet power connection Modular UPS System 10-150kVA User Manual...
  • Page 32 4 Installation Drawing (b) 4&6 slots cabinet power connection Fig.4- 5: Power Connection of Module System UPS Notes: 1. When installing the modules, install the modules from bottom to top. When removing the modules, remove the modules from top to bottom. The purpose is to maintain the stable center of gravity.
  • Page 33 4 Installation Drawing (b) entry from rear side Fig.4- 6: Communication cables routing 1. Loose right screws of LCD panel and open it. Remove top panel too if need connect cables from rear side. 2. Connect cables and route as Fig.4-6 3.
  • Page 34 5 Operations 5 Operations WARNING: Hazardous mains voltage and/or battery voltage present(s) behind the protective cover The components that can only be accessed by opening the protective cover with tools cannot be operated by user. Only qualified service personnel are authorized to remove such covers.

  • Page 35: 1+1 Parallel System

    5 Operations 5.1.1 Split-Bypass Input Fig. 5-1 illustrates the Modular UPS in what is known as the split-bypass configuration (that is, the bypass uses a separated AC power). In this configuration, the static bypass and manual bypass share the same independent bypass power supply and connect to the power supply through a separate switch.

  • Page 36: Operating Mode

    5 Operations 2. The bypass and the main input sources must be referenced to the same neutral potential. 3. Any RCD (Residual Current detecting device), if installed, must be of an appropriate setting and located upstream of the common neutral bonding point. Alternatively, the device must monitor the protective earth currents of the system.

  • Page 37: Battery Management-Set During Commissioning

    5 Operations 12.5ms (60Hz). 5.3.5 Maintenance Mode (Manual Bypass) A manual bypass switch is available to ensure continuity of supply to the critical load when the UPS becomes unavailable e.g. during a maintenance procedure. 5.3.6 Parallel Redundancy Mode (System Expansion) For higher capacity or higher reliability or both, the outputs of several UPS modules can be programmed for direct parallel while a built-in parallel controller in each UPS ensures automatic load sharing.

  • Page 38: Battery Protection

    5 Operations 5.5 Battery Protection (Settings by Commissioning Engineer) Battery Low Pre-warning The battery undervoltage pre-warning occurs before the end of discharge. After this pre-warning, the battery should have the capacity for 3 remaining minutes discharging with full load. And the End of discharge (EOD) protection If the battery voltage is lower than the EOD, the battery converter will be shut down.
  • Page 39 6 Operating Instructions 6 Operating Instructions DANGER: Hazardous mains voltage and/or battery voltage present(s) behind the protective cover The components that can only be accessed by opening the protective cover with tools cannot be operated by user. Only qualified service personnel are authorized to remove such covers.

  • Page 40: Ups Startup

    6 Operating Instructions 6.2 UPS Startup 6.2.1 Start-Up Procedure This procedure must be followed when turning on the UPS from a fully powered down condition. The operating procedures are as follows: 1. Open the external power switch. Open the internal power switch. Connect the power supply cables and ensure the correct phase rotation.
  • Page 41 6 Operating Instructions 6.3 Procedure for Switching the UPS between Maintenance Bypass and Normal Mode 6.3.1 Procedure for Switching from Normal Mode to Maintenance Bypass Mode This procedure can transfer the load from the UPS inverter output to the maintenance bypass supply, but the precondition is that the UPS is in normal mode before the transfer.

  • Page 42: Procedure For Completely Powering Down A Ups

    6 Operating Instructions When the UPS is in maintenance bypass or manual bypass mode, the load is not protected against abnormal mains supply. 6.3.2 Procedure for Switching from Maintenance Mode to Normal Mode Close bypass breaker if available. Close manual bypass breaker. Close external output breaker.

  • Page 43: Epo Procedure

    6 Operating Instructions Open external battery breaker  Open bypass breaker, external input breaker, external output breaker  If the mains and bypass are split, you need to open these two input breakers respectively. 6.5 EPO Procedure The EPO button is designed to switch off the UPS in emergency conditions (e.g., fire, flood, etc.). To achieve this, just press the EPO button, and the system will turn off the rectifier, inverter and stop powering the load immediately (including the inverter and bypass), and the battery stops charging or discharging.

  • Page 44: Language Selection

    6 Operating Instructions 1. Enter in function menu and press “ ” to release shutdown power module function. 2. Press “off” button on the front panel of power module to manually power off power module. 3. Loose the screws of the power module, then pull out the module after 5 minutes. If there are no redundant power modules: 1.

  • Page 45: Changing The Current Date And Time

    6 Operating Instructions 6.10 Changing the Current Date and Time To change system date and time: 1. In main menu, press “ ” to enter in function setting menu in the LCD screen. 2. Select DATE&TIME in SysFunc. 3. Enter new date and time, then enter to confirm it. Modular UPS System 10-150kVA User Manual...

  • Page 46: Control And Display Panel

    7 Control and Display Panel 7 Control and Display Panel This chapter introduces the functions and operation instructions of the UPS operator control and display panel in detail, and provides LCD display information, including LCD display types, detailed menu information, UPS alarm list. 7.1 Introduction The control and display panel is located on the front panel of the UPS.

  • Page 47: Lcd Display

    7 Control and Display Panel 7.1.1 Audible Alarm (buzzer) There are two different types of audible alarm during UPS operation as shown in table.7-3. Table.7- 2: Description of Audible Alarm Alarm Purpose Two short, one when system has general alarm (for example: main input abnormal), long this audible alarm can be heard When system has serious faults (for example: fuse or hardware...
  • Page 48 7 Control and Display Panel Menu Description Home Return to main menu page Bypass, main, output, Load, battery information Information of power module(input, output, load, information) Language, Sys Func, BAT set, Sys Set, Dry Contact History LOG, Current Alarm Mute ON/OFF, Fault clear, Manual bypass, Manual transfer to inverter, Esc Manual bypass, Module “on/off”...

  • Page 49: Detailed Description Of Menu Items

    7 Control and Display Panel Home Bypass Main Output Cabinet Load Battery Input Output UPS monitor LCD Module Load Information Function Button Control Test Command Language Sys Func Comm. Set Battery Set Sys Set Current Alarm Dry Contact History Alarm Output Current Scope Bypass Voltage...
  • Page 50 7 Control and Display Panel Fig.7- 4: cabinet menu Submenu BYPASS, MAIN, OUTPUT, LOAD, BATTERY Table.7- 6: Submenu of Cabinet The information of submenu is shown as below: Sub-menu Contents Meaning Phase voltage Phase current Bypass Input frequency Power factor Phase voltage Phase current Main...
  • Page 51 7 Control and Display Panel Enter in to enter in the menu of power module Fig.7- 5: power module information Module information menu includes submenu: Input, Output, Load, Information, Scode, software version. Table.7- 7: Submenu of Module The information of submenu is shown as below: Sub-menu Contents Meaning...
  • Page 52 7 Control and Display Panel Sub-menu Contents Meaning Air Inlet Temp.(°C) Air inlet temperature Air Outlet Temp.(°C) Air outlet temperature REC IGBT Temp.(°C) REC IGBT temperature of the phase A/B/C INV IGBT Temp.(°C) INV IGBRT temperature of the phase A/B/C S-code Fault Code For the maintenance personnel...
  • Page 53 7 Control and Display Panel Setting the boost Voltage for battery cell Boost Charge Voltage/Cell* VRLA (Cell/2V)＜2.5V;Lithium (Cell/3.2V)＞3V EOD voltage for cell battery,@0.6C current EOD Voltage(0.6C)* VRLA (Cell/2V)＜2V;Lithium (Cell/3.2V)＞2V EOD voltage for cell battery,@0.15C current EOD Voltage(0.15C)* VRLA (Cell/2V)＜2V;Lithium (Cell/3.2V)＞2V Charge Current Percent Charge current (percentage of the rated current) Limit...
  • Page 54 7 Control and Display Panel Fig.7-7: History log and current Alarm The details of all the events are shown as Chapter 7-4. Enter in to enter in UPS command menu. The function and test command are shown as below: Modular UPS System 10-150kVA User Manual...
  • Page 55 7 Control and Display Panel Fig.7- 8: Function and test command Menu of Operate includes: Function Mute off or mute on Fault clear manually Manually transfer to bypass or escape from bypass mode Transfer to inverter mode manually. The output could be interrupted. Enable the “OFF”...

  • Page 56: Ups Event Log

    7 Control and Display Panel Battery test command . UPS transfer to battery mode to test the condition of battery. If battery voltage is low or battery is failure, UPS will alarm and transfer back to normal mode or transfer to bypass mode. Make sure there is not any warns or alarm, make sure that battery voltage is higher than 90% of float voltage.
  • Page 57 7 Control and Display Panel Table.7- 5: UPS Event List window and current record window. UPS events Description Fault Clear Manually clear fault Log Clear Manually clear History log Load On UPS Inverter feeds load Load On Bypass Bypass feeds load No Load No load Battery Boost...
  • Page 58 7 Control and Display Panel Byp Freq Over This alarm is triggered by an inverter software routine when the Track frequency of bypass voltage exceeds the limit. The alarm will automatically reset if the bypass voltage becomes normal. First check if relevant alarm exists, such as “Byp Sequence Err” and “Input Neutral Lost”.
  • Page 59 7 Control and Display Panel displayed in LCD so as to confirm if this alarm is true. 2. If this alarm is true, measure the actual output current to confirm if the displayed value is correct. Disconnect non-critical load. In parallel system, this alarm will be triggered if the load is severely imbalanced.
  • Page 60 7 Control and Display Panel Charge Manual Float Manually force the charger work in float charge mode. Charge UPS Locked Forbidden to shutdown UPS power module manually. Parallel Cable Parallel cables error. Check: Error If one or more parallel cables are disconnected or not connected correctly If parallel cable round is disconnected If parallel cable is OK...
  • Page 61 7 Control and Display Panel Please check if input voltage is abnormal. DC Bus Over Voltage of DC bus capacitors is over limitation. UPS shutdown Volt rectifier and inverter. REC Soft Start While soft start procedures are finished, DC bus voltage is lower Fail than the limitation of calculation according utility voltage.
  • Page 62 7 Control and Display Panel be activated via software. INV IGBT Driver Inverter IGBTs are shutdown. Block Please check if power modules are inserted in the cabinet correctly. Please check if fuses between rectifier and inverter are broken. Battery Expired Working life of batteries is expired, and it’s recommended that batteries are replaced with new batteries.

  • Page 63: Product Specification

    8 Product Specification 8 Product Specification This chapter provides UPS product specifications. 8.1 Applicable Standards The UPS has been designed to conform to the following European and international Table.8- 1: Compliance with European and International Standards standards: Item Normative reference General safety requirements for UPS used in operator access EN50091-1-1/IEC62040-1-1/AS 62040-1-1...

  • Page 64: Input Characteristics

    8 Product Specification Protection Level, IP20 IEC(60529) Note Wheels or holders of cabinets are not included in dimension. Please refer to Chapter 4 to get detailed dimension. 8.4 Input Characteristics Table.8- 4: Mains input Items Unit Parameter 380/400/415(three-phase and sharing neutral with Rated AC Input the bypass input) Voltage...

  • Page 65: Output Characteristics

    8 Product Specification 8.6 Output Characteristics Table.8- 6: Inverter Output (to Critical Load) Rated capacity Unit 10~150 (kVA) 380/400/415(three-phase four-wire and sharing neutral with the bypass) Rated AC voltage 220/230/240(single-phase and sharing neutral with the bypass input) Frequency 50/60 110% load, 1 hour 125% load, 10min overload 150% load, 1min...
  • Page 66 8 Product Specification Frequency 50/60 Switch time (between bypass and inverter) Synchronized switch: 0ms Upper limit: +10,+15,+20, +25, default: +15 Bypass Lower limit: -10, -20, -30 or -40, default:-20 voltage tolerance (acceptable stable bypass voltage delay: 10s) Bypass frequency tolerance ±2.5, ±5, ±10 or ±20, default: ±10 Synchronizati Rated frequency±2Hz (selectable from ±0.5Hz～±5Hz)
  • Page 67 Appendix A Guide for Ordering and Selection of UPS Rack System Annex A Guide for Ordering and Selection of UPS System The UPS system includes two parts: cabinet and power modules. The model of cabinet is shown as following: XX 040/20 Cabinet power/ power module System Model...
  • Page 68 Annex A Guide for Ordering and Selection of UPS System Annex C. Parallel Setting If finish connecting all parallel cables and connection, set each unit in parallel system via software: Enter in “ SysSet” to set “system Mode” as parallel. Set “Unit Number”...

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