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AEG Protect 5.31 Series Operating Instructions Manual

10 kva-120 kva
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Uninterruptible
Power Supply UPS
Protect 5.31/xxx-480-220-120
10 kVA - 120 kVA
AEG Power Supply Systems GmbH
Department: PSS TED
Name:
Schenuit/Bögge
Revision:
02
Date:
09.05.2008
Operating Instructions
8000020680 BAL, en

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  Summary of Contents for AEG Protect 5.31 Series

  • Page 1 Uninterruptible Power Supply UPS Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA AEG Power Supply Systems GmbH Department: PSS TED Name: Schenuit/Bögge Revision: Date: 09.05.2008 Operating Instructions 8000020680 BAL, en...
  • Page 2: Notes On These Operating Instructions

    Power Supply Systems GmbH or its representatives without prior notice if maintenance and repair work is carried out using anything other than original AEG Power Supply Systems GmbH spare parts or spare parts purchased from AEG Power Supply Systems GmbH.
  • Page 3 Copyright No part of these operating instructions may be transmitted, reproduced and/or copied by any electronic or mechanical means without the express prior written permission of AEG Power Supply Systems GmbH. © Copyright AEG Power Supply Systems GmbH 2007. All rights reserved.
  • Page 4: Table Of Contents

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Table of Contents Notes on these Operating Instructions ...........2 Safety Regulations..............6 Important Instructions and Explanations ........6 Accident Prevention Regulations ..........6 Danger during Maintenance and Repair Work......7 Fire Protection................7 Qualified Personnel..............7 Safety Awareness ..............8 Application ................8...
  • Page 5 Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Operation ................32 Disconnecting the UPS (Individual Unit) ........32 8.1.1 Restarting after Disconnection (Individual Unit) .....33 Shutting Down the UPS ............33 Emergency Shutdown ............34 UPS Fuses ................34 Graphical Display and Operation Unit .......35 General Information ...............35 9.1.1 Signalling ................35...
  • Page 6: Safety Regulations

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Safety Regulations Important Instructions and Explanations The instructions for operation and maintenance, as well as the following safety regulations must be complied with to ensure the safety of personnel as well as the continued availability of the unit.
  • Page 7: Danger During Maintenance And Repair Work

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Danger during Maintenance and Repair Work CAUTION: The voltage applied to the UPS can be fatal. Prior to start-up and/or maintenance work always disconnect the UPS from the power supply and secure the unit against reclosing. The capacitors must be discharged.
  • Page 8: Safety Awareness

    It is not permitted to make any unauthorised modifications to the UPS or to use any spare parts and replacement parts not approved by AEG Power Supply Systems GmbH or to use the UPS for any other purpose. The person responsible for the installation must ensure that •...
  • Page 9: Liability

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Liability No liability is accepted if the UPS is used for applications not intended by the manufacturer. Any measures necessary for the prevention of injury or damage to equipment are the responsibility of the owner or user.
  • Page 10: Technical Data

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Technical Data Please refer to the enclosed technical data sheet for optional and unit-specific setting values. Type 3 x 480 V ± 15 % Rated connection voltages Voltage range in V Frequency on rectifier input in Hz...
  • Page 11: General Information

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA General Information One application of Protect 5. 31/xxx systems is to ensure an uninterruptible power supply to computers, IT systems, process control systems and their periphery in production and administration systems. The Protect 5. 31/xxx range covers a power range of 10 kVA to 80 kVA.
  • Page 12 Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The information exchange between the individual modules is carried out using the CAN bus (Controller Area Network). This CAN bus has high interference immunity and is frequently used for industrial applications. Mains SBS-Mains...
  • Page 13: Operating Elements Of The Ups

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The rectifier (REC) supplies the inverter and the battery with DC voltage. The inverter (INV) converts this DC voltage into a 1-phase AC voltage. In the event of a mains fault (such as a power failure), the power supply to the load is maintained from the battery without any interruption.
  • Page 14: Transport, Storage And Installation

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Transport, Storage and Installation Packing The UPS units are packed at the works to withstand both rail and road transport. The housing is fixed to the transport pallet using four bolts. The unit is packed in plastic film to prevent any damage to the surface paint and protect the unit against moisture.
  • Page 15: Transporting The Unit Using A Forklift Or Lowlift Truck

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The length of the ropes is calculated so that an angle of 45° is given between the rope and the top edge of the cabinet (DIN 580). The minimum load capacity of each rope must be ≥ 0.5 times the weight of the cabinet (DIN 580).
  • Page 16: Site Requirements

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Preparation: Leave the UPS on the transport pallet. Transport with lowlift truck Transport with forklift truck Figure 6 Transport with lowlift and forklift truck ATTENTION: Observe the centre of gravity of the unit!
  • Page 17: Floor Mounting

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA ATTENTION: The waste heat of the UPS must be dissipated! The ventilation of the battery compartments must be carried out in accordance with DIN/VDE 0510, Part 2. The following general rule is applicable for ventilation requirements (for lead-acid batteries): Q = 0.05 x n x I / 2...
  • Page 18: Storage

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Storage UPS units may only be stored for a maximum period of six months in the original packaging in dry, ventilated rooms with a permanent roof. The permissible ambient temperature range is between -35 °C and +70 °C with a relative humidity of ≤...
  • Page 19: Operation With Faulty Mains Supply

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.1.2 Operation with Faulty Mains Supply Secured Mains circuit busbar Loads Q29 option Figure 9 Power circuit with a faulty mains supply The mains does not sufficiently maintain the supply of the rectifier of the UPS system.
  • Page 20: Operation With A Faulty Inverter

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.1.3 Operation with a Faulty Inverter Secured busbar Mains circuit Loads Q29 option Figure 10 Power circuit with a faulty inverter If an inverter is defective, power is supplied to the loads by the SBS circuit.
  • Page 21: Function Of The Circuit Breakers

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Function of the Circuit Breakers Load interrupter switch Q1: The rectifier is switched over to the REC circuit using load interrupter switch Q1 (Figure 2). The open-circuit shunt release of Q1 reacts in the event of a fault (e.g.
  • Page 22: Static Bypass Switch (Sbs)

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Static Bypass Switch (SBS) SBS circuit Loads SBS trigger circuit SBS interface SBS control unit Figure 12 Functional principle of the SBS control unit The SBS control unit monitors the voltages of the load circuit and the...
  • Page 23: Charging The Battery

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA ATTENTION: If the SBS is blocked, there is no switchover to the SBS circuit! This means that if the INV fails or is switched off by the operator, the load circuit is no longer connected to the power supply. The loads must then be manually reconnected by switching the INV back on or activating the SBS (switch Q28 off and back on).
  • Page 24: Capacity Check

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Test of the battery charging circuit: This brief test checks the connected battery by lowering the voltage and carrying out a current analysis. Line interruptions or defective fuses in the battery circuit are also detected. With a battery present, the test takes approx.
  • Page 25: Capacity Test

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 5.6.2 Capacity Test The capacity test allows the availability of the battery to be tested using the currently available inverter load. In this process, the regulator lowers the DC voltage setpoint to approx. 1.9 V/cell.
  • Page 26: Connection

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Connection CAUTION: Prior to commencing work, ensure that the connection cables are disconnected from the power supply and that it is not possible to activate the power supply. NOTE: In order to avoid deformation of the supporting rail and to protect...
  • Page 27: Connection Of The Mains, Load And Battery Cables

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Connection of the Mains, Load and Battery Cables Figure 14 Connection panel of the Protect 5. 31/10-40 kVA U V W Figure 15 Connection panel of the Protect 5. 31/60-120 kVA ATTENTION: Ensure correct polarity when connecting the cables!
  • Page 28: Connection Of The Control And Signal Lines

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The cables are connected as follows: • Open the control cabinet door. • Remove the connection cover from the terminals. • Insert the cables to be connected into the UPS from below or from the rear.
  • Page 29: Connection Cross Sections And Fuse Protection

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Connection Cross Sections and Fuse Protection Layout of cross sections in acc. with Type rating in kVA DIN 0298, Part 4, Table 3 Laying type B1/B2 Rectifiers, input Rectifier fusing in A Cross section in mm²/pole *1 2x50 min.
  • Page 30: Start-Up

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Start-Up The start-up procedure is the same for the various UPS versions from 10 kVA to 80 kVA. Prior to start-up, ensure that the preset unit specifications match the battery specifications. For parallel systems, see description of "Parallel Operation"!
  • Page 31: Starting Up The Ups (Individual Unit)

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Starting up the UPS (Individual Unit) Step Action Display Q1 and battery isolator (external) to the "OFF" position. Q29 (internal option) to position "2" service mode. Switch on mains voltage for rectifier and SBS circuits. Wait...
  • Page 32: Operation

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Operation Disconnecting the UPS (Individual Unit) ATTENTION: Only switch off the UPS in an absolute emergency by switching off the rectifier circuit and SBS circuit in their distribution! In addition, the inverter must be switched off using the remote OFF contact.
  • Page 33: Restarting After Disconnection (Individual Unit)

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 8.1.1 Restarting after Disconnection (Individual Unit) Proceed as described in the following table to restart the UPS after it has been disconnected from the power supply. Step Action Display Q1 and battery isolator (external) set to "OFF" position.
  • Page 34: Emergency Shutdown

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA To restart the UPS after shutdown, proceed as described in Chapter 7. Emergency Shutdown Emergency shutdown is available as an option and mainly serves to disconnect the loads from the power supply via an external contact.
  • Page 35: Graphical Display And Operation Unit

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Graphical Display and Operation Unit General Information The graphical display and operation unit (DOU) is integrated in the front of the UPS housing. It serves to signal and display UPS unit data and to control and parameterise the UPS system. The DOU consists of a display unit with 3 LEDs, a graphical LCD and an operating panel with 5 keys.
  • Page 36: Keyboard Operation

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9.1.2 Keyboard Operation You can use the ENTER key to open and close submenus and to acknowledge control functions and parameters. The 4 display keys are assigned to different functions. The current key functions are represented as symbols which can be found in a small framed area on the right-hand side of the LCD.
  • Page 37 Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Possible symbol keys and their function: Switch off inverter Switch on inverter Switch off rectifier Switch on rectifier Switch off booster Switch on booster Switch off charger Switch on charger Acknowledge acoustic signal generator...
  • Page 38: Start-Up

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Start-Up Following the power-up reset, the DOU performs a self-test. Data is loaded from the power converters after the test has been completed successfully. The LEDs light up sequentially during this phase. A start screen appears on the LCD, and a status bar indicates the duration of the start-up process.
  • Page 39: Main Menu

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9.3.2 Main Menu Current cursor position Operating display Blocking Settings Fault history Service Information 00:00 Thu 01-Jan-04 Fig. 18 Main menu After start-up, the “main menu” represents the highest menu level, which means that you can open further submenus from here, and you can always return to this level.
  • Page 40: Status/Measured Values

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA The operating display consists of 3 parts: On the left-hand side, the unit status is shown in a pictogram. The individual components of the unit are represented here as symbols. The respective symbol flashes in the event of messages or faults in a component.
  • Page 41: Blocking

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 9.3.5 Blocking You can call up the “Blocking” menu from the “main menu”. After you have entered the current password, you can “block operation” of the control systems (switching on/off and fault acknowledgement). The password must be entered digit by digit and then acknowledged using the ENTER key.
  • Page 42: Help

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Menus for changing the operating statuses: • In the “Rectifier operating mode” menu, you can change the charge status of the rectifier (charger). The current charge status is displayed. • In the “Battery test” menu, you can initiate different battery tests, depending on the test implemented.
  • Page 43: Annex

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Annex 10.1 Battery Handling using the Graphical DOU 10.1.1 Charging the Battery The battery is charged according to DIN 41772 in accordance with a CVCC curve. This ensures that the battery is charged in the shortest possible time and also prevents overcharging.
  • Page 44: Battery Data

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 10.1.2 Battery Data Depending on the system configuration, different battery parameters can be set in the "SERVICE / BATTERY VALUES" menu. The parameters for the individual battery tests are also set in this menu.
  • Page 45: Battery Tests

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Protect-5: The standby time is determined by calculating the balance of the battery currents. Parameters to be set and their setting ranges: Discharge currents Corresponding discharge times I1: 1 – 9999 A t1: 1 – 999 min I2: 1 –...
  • Page 46: Possible Battery Tests

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 10.1.4 Possible Battery Tests Test of the battery charging circuit: This brief test checks the connected battery by lowering the voltage and carrying out a current analysis. Line interruptions or defective fuses in the battery circuit are also detected. With a battery present, the test takes approx.
  • Page 47: Interfaces

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Interfaces 11.1 Remote Signalling The remote signalling PCB consists of a remote signalling master board A12 and an expansion board A13, the contacts of which are connected to terminal block X12. The remote signalling boards have the following inputs and outputs: Inputs (via optocoupler): •...
  • Page 48: Serial Interface

    Two separate potential-free serial interfaces are provided to establish IT connections. These are occupied with the AEG protocol CBSER. Optionally, various protocols can be selected for the second interface. These are enabled upon purchase of a licence. A selection of the available protocols can be obtained from your UPS supplier.
  • Page 49: Maintenance And Repairs

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Maintenance and Repairs 12.1 Diagnostic Functions The comprehensive diagnostic functions implemented in the UPS not only increase its operational reliability considerably, but also reduce the time required for maintenance work and troubleshooting to a minimum.
  • Page 50: Fault Table

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 12.2.1 Fault Table Faults that occur are displayed on the DOU in plain text. Some faults can be located and eliminated quickly using the following table. Fault Possible cause Remedy Q1 triggered. Earth fault or short circuit Repair the system (renew on the battery side.
  • Page 51: Removing And Installing The Fan

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA 12.2.2 Removing and Installing the Fan CAUTION: The fan can only be removed and installed by trained and qualified personnel when the UPS is switched on. Always observe the safety regulations! Figure 22 Installing and removing the fan (sample model 60 kVA) Figure 23 Fan distribution (example model 60 kVA) –...
  • Page 52: Visual Checks

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA visual checks and functional tests of the unit to maintain its high availability and operational reliability and also to check the battery charge. It is only possible for the UPS to reach its high degree of availability of approx.
  • Page 53: Checking The Battery

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA • Activate the manual bypass via Q29 in accordance with Chapter 8 Disconnect the UPS in accordance with Chapter 8 and check the following functions when restarting the system: • LEDs of the DOU •...
  • Page 54: Spare Parts And Customer Service

    When ordering spare parts, please always state the designation (item / component) and the unit number. If the battery for the UPS system has been supplied by AEG Power Supply Systems GmbH, the battery has been specially designed for the Protect model. Use a comparable battery type when replacing the...
  • Page 55: Annex

    Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Annex Optional equipment is available for the Protect 5. 31/xxx: X1 X2 X3 X4 Figure 24 PCBs on the control unit pivot plate (sample model 40 kVA) Options: Slot Designation Remote signalling expansion board 1...
  • Page 56 Protect 5.31/xxx-480-220-120 10 kVA - 120 kVA Figure 25 shows all the PCBs included in the scope of supply. These are mounted on the control unit pivot plate behind a cover which can be opened by loosening the fixing bolts.