Ametek INTELLIPOWER IntelliShield 3kW User Manual
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Ametek INTELLIPOWER IntelliShield 3kW User Manual

Ametek INTELLIPOWER IntelliShield 3kW User Manual

Rugged uninterruptible power supply (ups)
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USER M
IntelliShield 3kW
Rugged
Uninterruptible Power Supply (UPS)
User Manual

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Summary of Contents for Ametek INTELLIPOWER IntelliShield 3kW

  • Page 1 USER M IntelliShield 3kW Rugged Uninterruptible Power Supply (UPS) User Manual...
  • Page 2 USER MAN...
  • Page 3 About IntelliPower USER M AMETEK IntelliPower Inc., a Business Unit of AMETEK, Inc., is a global leader in the design and manufacture of Rugged Uninterruptable Power Supplies, Power Conditioners and Power Distribution Units across diverse military and industrial segments. From rack-mounted rugged UPS...
  • Page 4 USER MAN This page intentionally left blank.

  • Page 5: Table Of Contents

    Contents USER M General Description ....................1 1.1. Introduction.......................... 1 1.2. General Description ......................1 1.3. Specifications ........................1 Installation ....................... 11 2.1. Introduction........................11 2.2. Unpacking ......................... 11 2.3. Pre-Installation Inspection ....................11 2.4. Installation ......................... 12 2.5. Air Intake and Exhaust ...................... 12 2.6.
  • Page 6 4.1.2. Charging Procedure Options During and After Storage ..........28 USER MAN 4.1.3. Battery Maintenance During UPS Service ..............29 4.2. Battery Run-time Test ....................... 29 4.3. Battery Charging Modes ....................30 4.3.1. Fast Charging Mode ....................30 4.3.2. Float/Final Charging Mode ..................30 4.4.

  • Page 7: Important Safeguards

    Important Safeguards USER M Read all information and instructions in this manual. • The equipment is heavy. Use proper lifting techniques and seek assistance or use lifting aids to avoid injury. • Do not operate unit if it has been damaged, including chassis, internal components, connectors, and power cords.
  • Page 8 USER MAN This Page Intentionally Left Blank...

  • Page 9: Warranty Terms

    IntelliPower Customer Service should be notified at the phone number or email below. An RMA request may also be initiated on the AMETEK IntelliPower, Inc. website. Upon receipt of this notification, the Customer Service Department will provide the assistance required to obtain repair or replacement of the equipment.

  • Page 10: Battery Warranty

    shipment. If the product is heavy (greater than 95 lbs.), it must be secured to a pallet for shipment. If questions arise, call IntelliPower for details in addition to using IntelliPower’s USER MAN engineered packaging materials. The warranty is expressly in lieu of all other warranties, expressed or implied, including, without limitation, any implied warranty or merchantability or fitness for a particular purpose, and/or any other obligation or liability on the part of IntelliPower Inc.

  • Page 11: General Description

    1. Provide proof of purchase, including the original sales PO and date of purchase. 2. Submit the completed maintenance records for the battery. 3. Return the defective battery to AMETEK IntelliPower Remedies: If a covered defect is found, the manufacturer will, at its option, repair or replace the defective battery at no charge.

  • Page 13: General Description

    General Description 1.1. Introduction The IntelliShield 3kW is a 3kW Rugged Uninterruptable Power Supply (RUPS) that provides regulated voltage at up to 25 Amps RMS load current. The IntelliShield 3kW RUPS accepts input voltages from 108 Volts to 264 Volts at frequencies from 47 to 440 Hz. A battery backup of up to 6.7 minutes at 3000 Watts is also provided by a removeable battery pack drawer.
  • Page 14 OUTPUT RATINGS 3000 VA, 3000 W Output Power Rating 120VAC, 220VAC, 230VAC, or 240VAC (+/- Output AC Voltage 50 or 60 Hz, (±1 %), Follows input frequency, Frequency Frequency change (optional) Galvanic Isolation Isolation Switch. Factory default switch position is Neutral Bonded to Ground Bonded.
  • Page 15 Fan Filters EMI Metal Honeycomb Grid, Dust Filter (EMI/Dust/Combination/Grill): Mounting Ears JES slides for Defense applications, GD slides for other applications. Use GD hole Rack Slides pattern for both. INTERFACE COMMUNICATIONS Serial Data Stream SNMP, Ver 3 (SNMP2/SNMP3/RS232, type): EPO (Optional) Discrete (Relay/Opto, Description): ADDITIONAL ELECTRICAL FEATURES and CONTROLS/INTERFACE Output Power Loading %;...
  • Page 16 CONNECTORS MS3452L20-19P (Pin A = High, Pin B = Connector(s) AC Input Neutral, Pin C = GND) Connector(s) DC Input MS3452L20-19S (Pin A = High, Pin B = Connector(s) AC Output Neutral, Pin C = GND) Connector(s) DC Output 2x2 Anderson, Rear Panel Connector(s) EBP/Charger SNMP SNMP/Ethernet...
  • Page 17 LEAD ACID BATTERY 12V 8AH Battery Rating 168VDC(Nominal) Battery String Voltage: 2 minutes at 3000Watt (See External Battery Battery Minimum Run Time Module Section) Internal Hot Swap Drawer Battery Mounting (Hot Swap/Fixed): FB00093 Hot Swap Drawer PN LITHIUM IRON PHOSPHATE BATTERY 3.2V 2.5A Battery Cell Rating 172.8VDC(Nominal)
  • Page 18 External Battery Pack (EBP) – Lead Acid 12VDC 8AH Battery Rating Battery Total Quantity: 168VDC(Nominal) Battery String Voltage: Battery Minimum Run Time (UPS 5 minutes at 3000W Internal Battery + 1 EBM) Battery Minimum Run Time (UPS 10 minutes at 3000W Internal Battery + 2 EBM) MECHANICAL Rack Mountable, 2U, 3.5"H, 17"W, 18.195"D;...
  • Page 19 External Battery Pack (EBP) - LFP 2.5Ah Battery Rating 172.8VDC(Nominal) Battery String Voltage: Battery Minimum Run Time (UPS 13.6 minutes at 3000W Internal Battery + 1 EBM) Battery Minimum Run Time (UPS 20.4minutes at 3000W Internal Battery + 2 EBM) MECHANICAL Rack Mountable, 2U, 3.5"H, 17"W, 18.195"D;...
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  • Page 21: Installation

    Installation 2.1. Introduction The IntelliShield 3kW rugged UPS has been aligned, calibrated, and tested prior to shipment. Therefore, the RUPS is ready for immediate use upon receipt. However, the following checks should be made to ensure that the rugged Uninterruptable Power Supply was not damaged during shipment.

  • Page 22: Installation

    connectors, and displays, for dents, cracks, or deformities. Ensure that all MIL-DTL 5015 connectors are securely attached and free of dust or debris. Verify that the LED indicators and control buttons are intact and functional. Additionally, confirm that the unit’s model and serial number labels are legible.
  • Page 23 7. Connect Input cables. It is recommended to use shielded input and output cables 8. Double check all connections.

  • Page 24: Input/Output Connectors

    2.8. Input/Output Connectors Table 2-1 provides details of the IntelliShield 3kW input and output connectors. Table 2-1 IntelliShield AC Input Connector Details AC Input Connector Panel Connector MS3452L20-19P Mating Connector MS3452L20-19S Function Drawing Line Neutral Ground AC Output Connector Panel Connector MS3452L20-19S Mating Connector MS3452L20-19P...
  • Page 25 When specifying wire gauge, the operating temperature must be considered. Wire gauge current capability and insulation performance drops with the increased temperature developed within a cable bundle and with increased environmental temperature. Thus, short cables with generously derated gauge and insulation properties are recommended for power source applications.
  • Page 26 2. Determine which wire gauge for the application by knowing the expected peak loa current (I ), the maximum tolerated voltage loss (V ) within peak loss the cable, and the one way cable length. The formula below determines which ohms/100 feet entry is required from Column 3. Read the corresponding wire gauge from Column 1.

  • Page 27: 2.10. Load Devices

    Safety margins to accommodate degradations due to age, mechanical abrasion, and insulation migration caused by bending and temperature. 7. As frequency increases, the magnetic field of the current carrying conductors becomes more significant in terms of adverse coupling to adjacent electrical circuits. Use twisted pairs to help cancel these effects. Shielded twisted pairs are even better.

  • Page 29: Operation

    Operation 3.1. Introduction The controls and display for the IntelliShield 3kW rugged UPS are easily understood after a brief overview. 3.2. Control and Indicator Panel Refer to figure 3-1 for the location of the indicators and controls described in this section. All controls and indicators for the IntelliShield 3kW rugged UPS are located on the Control and Indicator Panel.
  • Page 30 BATT CAP 0 to 100% – Battery Capacity LED Meter Each of the five positions on the LED meter indicates a different level of battery capacity. If the LED is flashing, the unit is on battery. Position LED Other Indication Status Condition 1 (0%+)
  • Page 31 FAULT – LED Units with an auto bypass will go into bypass to power the load and allow time for graceful shutdown. Other Indication Status Condition The inverter has malfunctioned due to an internal fault. Normal mode. FLASHING ON – LED Indicates inverter output status.
  • Page 32 OUT LOAD 0 to 100% – Output Load LED Meter Each of the 4 green LEDs within the bar represents approximately 25% of rated output power in terms of RMS VA or Watts, whichever is greater. Positions 1 through 4 each represents 25% of load.
  • Page 33 F3 SILENCE – BUTTON Press this button to loop through buzzer modes. F4 TEST - BUTTON Push this button once to run a local panel LED test. This will help to pinpoint any faulty LEDs. This test can be performed while the unit is in normal operation without effecting power to the load devices.
  • Page 34 F2 AND F4 – BUTTON – Advanced Users Only – Auto/Manual Start This section outlines steps to enable Auto Start or Manual Start. See also “F2 AND F4 – BUTTON – Advanced Users Only – Overview”. Warning! Do not access this mode without proper training, documentation, and instructions.

  • Page 35: Normal Start

    3.3. Normal Start 3.3.1. Unit Startup 1. Turn ON the unit Input Circuit Breaker. 2. Local Panel LEDs will turn ON for approximately 5 seconds before running LED startup test. If the unit is set to Auto start, the inverter will begin to output power in 5-10 seconds;...

  • Page 36: Cold Start

    3.3.4.3. Configuration 1. Press F3 and F4 at the same time. To initiate, press F3 briefly before pressing F4. Before releasing both F3 and F4 should be pressed at the same time. Allow UPS to charge for 10 hours. 3.4. Cold Start When AC power is not available, the rugged UPS can be started from the internal battery by performing the Cold Start procedure.

  • Page 37: Battery Care And Handling

    Battery Care and Handling Your rugged UPS is designed to support two different battery configurations: VRLA (Valve- Regulated Lead-Acid) and LFP (Lithium Iron Phosphate). Both configurations offer reliable backup power, but each has distinct characteristics and care requirements. Proper handling and maintenance of your UPS batteries are essential for ensuring optimal performance and extending battery life.

  • Page 38: Charging Procedure Options During And After Storage

    5. To avoid full battery discharge after 40-60% partial or 100% full charging, the UPS can be completely shut down. First remove input power. Then press F2 and F3 in the front control panel and hold for at least 1 second. This will initiate UPS shut down in battery mode.

  • Page 39: Battery Maintenance During Ups Service

    4.1.2.2. Lithium Iron Phosphate: Removal from Storage; Short-Term Storage - Less than 3 months 1. Perform a battery runtime test described in section 3.1.3.1. 2. Follow this with at least 12 hours of normal AC line powered operation to restore the battery charge level from a complete discharge to 100% charge.

  • Page 40: Battery Charging Modes

    100%, the unit has transitioned from fast-charge mode to float charge mode. The UPS is now top charging batteries the last few percent at a slower, safer rate. 2. With AC power applied, apply a 3KW load for battery runtime testing. 3.

  • Page 41: Open Cell Damage

    of the missing voltage from the shorted cell. The UPS will thus remain in “Fast Charge” mode. If battery charging continues with a shorted cell, the remaining cells in series may eventually be damaged from overcharging, resulting in swelling, outgassing or venting of the battery. To help prevent this, the UPS microprocessor monitors the battery charger operating mode.
  • Page 42 4. Do not remove any screws used to hold the tray assembly together. 5. The power connection is internal to the UPS and uses self-aligning dagger pins that do not require any tools or actions from the operator to disconnect the battery drawer. 6.

  • Page 43: Battery Runtime Specification

    4.7. Battery Runtime Specification _____________of runtime at _____________Watts 4.8. Battery Runtime Test Results Log Receiving/ Initial Test – Battery Runtime Results Date Runtime Wattage Quarterly Test – Battery Runtime Results Date Runtime Wattage...
  • Page 44 This Page Intentionally Left Blank...

  • Page 45: Maintenance

    Maintenance 5.1. Introduction This section includes information on maintaining the IntelliShield 3kW rugged UPS. There are no adjustments accessible to the user. This section will deal with mechanical or general operational details only. WARNING! Hazardous voltages are present when operating this equipment. Read the Important Safeguards on page vi prior to performing installation, operation, or maintenance.

  • Page 46: Troubleshooting

    1. Check the fan/grill intake and exhaust periodically to establish an appropriate cleaning frequency. Environments with high amounts of debris will require more frequent fan/grill filter cleanings. 2. Before each cleaning, shut down the UPS completely (input breaker off, followed by F2/F3 shutdown) so that fan blades are not turning during this operation.
  • Page 47 BATT CAP 0 to 100% – Battery Capacity LED Meter Observation Position 1 (bottom) is flashing red. Continuous tone audible alarm. Low battery. Shutdown imminent. The unit has been without input Cause power and has reached the end of its battery run time. If safe-shutdown software is running, no action is required.
  • Page 48 FAULT – LED Observation FAULT – LED is ON. Continuous tone audible alarm. ON – LED is OFF. The unit inverter may have failed. Cause Check that load is OFF. Completely shut down and restart the Action system. In order to not overwrite system error log, do not attempt more than one restart.
  • Page 49 Continuous Tone Audible Alarm Observation Continuous audible alarm. If configured, BYPASS-LED is ON. If enabled, red top position on the Output Load LED meter is ON. Unit may have been overloaded. Cause Reduce load. If enabled (new models), push ON – Button to return to Action normal mode.
  • Page 50 This Page Intentionally Left Blank...

  • Page 51: Glossary Of Terms

    Glossary of Terms This glossary provides definitions for key terms and concepts related to the operation and maintenance of all rugged UPS products offered by IntelliPower. Some terms may not apply specifically to the product described in this user manual but are included to offer a broader understanding of our product line and technologies.
  • Page 52 Battery Minimum Run Time: Under specified operating conditions the battery array will support a given output power level for a specified minimum amount of time. Battery Safety Disconnect Switch: Disconnects power to the battery cables to prevent arcing when the cables are removed. Battery String: Batteries connected in series.
  • Page 53 The front panel Input Power Switch or Circuit Breaker should only be turned off when the unit is unplugged or is not going to be used for an extended period. Circuit Breaker – Output Push to Reset: In the event of a fault on the output, this breaker will isolate the circuit.
  • Page 54 External Battery Charger (EBC): External enclosure that houses a large battery charger. These modules are typically utilized for fast charging of large battery banks. External Battery Module (EBM): External enclosure containing a battery array. These modules are used to increase system runtime. External enclosure containing a battery array.
  • Page 55 The unit will operate without batteries while input Input Voltage AC and Tolerance: alternating current (AC) remains within this range. In many cases input line voltages are not constant. Voltage will dip below and rise above designated ratings. IntelliPower systems will operate utilizing line power so long as it remains within input tolerances.
  • Page 56 Output Neutral Bonding Switch: In one position the switch will bond the output neutral to ground for land-based applications or land-based lab testing. The other position switches the output to an un-bonded configuration for shipboard based applications. This switch can be locked in either position.
  • Page 57 Rack Unit: A fundamental unit of height regarding rack mountable equipment. 1U is equal to 1.75”. Remote Power Management and Communications Protocol: Power management, alarm monitoring, automation, and control of multiple IntelliPower Inc. devices are available through IntelliPower communications. Supported protocols include SNMPv1, SNMPv2, SNMPv3, RS-232 and common industrial protocol (CIP) –...
  • Page 58 unit conditions to build logs, reports, and charts. Managing software can initiate safe operating system shutdown in the event of a power failure or other event. Remote operators can shut down and restart unit inverter output. SNMP Agent Module: Hardware that facilitates translation of the unit’s RS-232 protocol to SNMP for availability on an SNMP compatible network and facilitates the translation of management device queries to the node.
  • Page 59 Wall Mount. An enclosure designed for mounting on a vertical surface. See also bulkhead mount.

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