Attachment 6 Mitsubishi UPS.pdf

Revision 2.2: April 2, 2001

ALN-H0355

MITSUBISHI ELECTRIC AUTOMATION, INC.

UNINTERRUPTIBLE POWER SUPPLY SYSTEM

2033C SERIES

OWNERS / TECHNICAL MANUAL

MITSUBISHI

ELECTRIC

2033C SERIES UPS

OWNERS / TECHNICAL MANUAL

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i

MITSUBISHI ELECTRIC 2033C SERIES UPS

Preface

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TABLE OF CONTENTS

LIST OF TABLES ................................................................................................ iii LIST OF FIGURES .............................................................................................. iv HOW TO USE THIS MANUAL ............................................................................ v

1.0 INTRODUCTION .......................................................................................... 1-1

1.1 GENERAL..................................................................................................... 1-3

1.2 DEFINITIONS ............................................................................................. 1-4

1.3 OVERVIEW ................................................................................................. 1-5

1.4 SPECIFICATIONS ...................................................................................... 1-12

2.0 OPERATION CONTROLS AND INDICATORS ..................... 2-1

2.1 LED DISPLAY AND KEYPAD .................................................................... 2-2

2.2 EXTERNAL SIGNAL TERMINAL BLOCK .................................................. 2-3

2.3 EXTERNAL COMMUNICATION CONNECTOR ...................................... 2-6

3.0 INSTALLATION AND OPERATION ............................... 3-1

3.1 TRANSPORTATION AND INSTALLATION .............................................. 3-1

3.2 HANDLING ................................................................................................. 3-1

3.3 INSTALLATION PROCEDURE .................................................................. 3-2

3.4 PROCEDURE FOR CABLE CONNECTIONS ........................................... 3-3

3.5 OPERATING PROCEDURES ................................................................... 3-9

3.6 MAINTENANCE BYPASS SET-UP PROCEDURES ................................ 3-10

4.0 RESPONSE TO UPS FAILURE .................................. 4-1

5.0 PARTS REPLACEMENT ........................................ 5-1

6.0 FAULT CODES ................................................ 6-1

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List of Tables

Table 1.1 Power Specifications .................................................................. 1-12 Table 1.2 UPS Module Information ............................................................. 1-12 Table 1.3 Detail of Specifications ............................................................... 1-13 Table 1.4 Rating of Conductor and Fuses .................................................. 1-14 Table 3.1 How to Transport and Install the System .................................... 3-1 Table 3.2 List of UPS Weights (lb.) ............................................................ 3-2 Table 3.3 Type and Number of Internal Battery ......................................... 3-2 Table 3.4 Recommended Cable Size and Torque Requirements ............. 3-4 Table 3.5 Crimp Type Compression Lug .................................................... 3-4

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List of Figures

Figure 1.1 Single Line Diagram- Normal Operation .................................... 1-5 Figure 1.2 Single Line Diagram- Bypass Operation .................................... 1-6 Figure 1.3 Single Line Diagram- Battery Operation ..................................... 1-7 Figure 1.4 Single Line Diagram- UPS on Maintenance Bypass Operation. . 1-7 Figure 1.5a UPS Parts Location (7.5-20kVA) ................................................ 1-9 Figure 1.5b UPS Parts Location (30kVA) ...................................................... 1-10 Figure 1.5c UPS Parts Location (40,50kVA) ................................................. 1-11 Figure 1.6 Display PCB DPAU-57/DPAU-58 ............................................... 1-11 Figure 1.7 External I/F PCB RYDR-O/RYDR-X ........................................... 1-11 Figure 1.8a Main Control PCB UPFR-Y ......................................................... 1-12 Figure 1.8b Main Control PCB UPFR-K ........................................................ 1-12 Figure 2.1 Operation/Display Panel ............................................................. 2-1 Figure 2.2 Normal operation on 7 Segment LED Display ........................... 2-2 Figure 2.3 External Signal Terminal Block .................................................. 2-3 Figure 2.4 Control Wiring for External Contacts .......................................... 2-4 Figure 2.5 Remote "Start" Contact Connections ......................................... 2-5 Figure 2.6 External communication connector ............................................ 2-6 Figure 3.1 Handling ...................................................................................... 3-1 Figure 3.2 UPS Terminal Designation ......................................................... 3-5 Figure 3.3 Input / Output Power Terminals (7.5-20kVA) ............................. 3-6 Figure 3.4 Input / Output Power Terminals (30kVA) .................................... 3-7 Figure 3.5 Input / Output Power Terminals (40,50kVA) ............................... 3-8 Figure 3.6 EPO Button ................................................................................. 3-9

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How to use this Manual

This manual is designed for ease of use, giving the user easy and quick reference to information.

This manual uses notice icons to draw attention to the user important information regarding the safe operation and installation of the UPS. The notice icons used in this manual are explained below, and should be taken into account and adhered to whenever they appear in the text of this manual.

WARNING: A warning notice icon conveys information provided to protect the user and service personnel against hazards and/or possible equipment damage.

CAUTION: A caution notice icon conveys information provided to protect the user and service personnel against possible equipment damage.

NOTE: A Note notice icon indicates when the user should make a reference of information regarding the UPS operation, load status and display status.

Such information is essential if Mitsubishi field service group assistance and correspondence is required.

Safety Recommendations: If any problems are encountered while following this manual, Mitsubishi field service group assistance and correspondence is recommended.

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1.0 INTRODUCTION

The Mitsubishi Uninterruptible Power Supply (UPS) is designed to provide many years of reliable power supply and protection from power failure, brown-outs, line noise and voltage transients. To ensure optimum performance of the equipment, follow the manufacturer's instructions accordingly.

This manual contains descriptions for the installation and operation procedures of the UPS. Please read this manual carefully and retain it for future reference.

This manual contains important instructions for the 2033C Series Uninterruptible Power Supply Systems that should be adhered to during installation, operation and maintenance of the UPS and batteries.

Lethal voltages exist within the equipment during operation.

Observe all warning and cautions in this manual.

Failure to comply may result in serious injury or death.

Obtain a qualified service for this equipment as per instructions.

IMPORTANT SAFETY INSTRUCTIONS

RETAIN THESE INSTRUCTIONS

WARNING 1

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This UPS does not include an AC input circuit breaker (MCCB) to protect the bypass and main input circuit. The AC input circuit breaker (MCCB) is to be field supplied and installed. Circuit breaker (MCCB) specifications are as follows:

Capacity (kVA)

AC input Voltage (Vac)

AC input Rating (Aac)

Recommended Breaker (A)

7.5 208 23 30 10 208 30 35 15 208 45 60 20 208 61 75 30 208 91 125 40 208 121 150 50 208 151 200

AC output and DC input overcurrent protection and disconnection devices shall be field supplied and installed.

WARNING 2

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1.1 General

The Mitsubishi 2033C Series UPS is designed to provide continuous and clean electrical power to a critical load. In the event of an input power failure, the UPS will supply power to the critical load for the specified battery time.

If the input power is not restored promptly, backup power from the UPS battery permits the orderly shutdown of equipment supported by the UPS. The UPS is simple to start up, operate and maintain.

The 2033C Series UPS is available in seven (7) kVA sizes: 7.5, 10, 15, 20, 30, 40 and 50kVA.

Specifications for each kVA model appear in Section 1.4. Models up to 30kVA have batteries included in the UPS module cabinet. 40kVA and 50kVA models have external batteries. The principles of operation described herein are applicable to all models.

This manual provides an overview of the 2033C Series components and their functions. The appearance and purpose of operator controls and indicators is described with procedures for operation, start-up, shutdown and basic maintenance included.

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1.2 Definitions

UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS Module Cabinet and associated batteries which function as a system to provide continuous, conditioned AC power to a load. This is sometimes referred to as the "System".

UPS MODULE CABINET - The metal enclosure which contains the Converter / Charger, Inverter, Static Transfer Switch, Internal Bypass line, operator controls, batteries (up to 30kVA models only) and internal control systems required to provide specified AC power to a load.

UPS MODULE - The Converter / Charger and Inverter assemblies which, under the direction of the internal control system and operator controls, provide specified AC power to a load.

CONVERTER / CHARGER - The UPS components which contain the equipment and controls necessary to convert input AC power to regulated DC power required for battery charging and for supplying power to the Inverter.

INVERTER - The UPS components which contain the equipment and controls necessary to convert DC power from the Converter / Charger, or the battery, to AC power required by the critical load.

STATIC TRANSFER SWITCH - The device which connects the critical load to the bypass line when the Inverter cannot supply continuous power.

BYPASS LINE - The line which conducts electricity directly from the input power source to the critical load during Maintenance or whenever the UPS is not completely operational.

AC INPUT POWER - Power provided by the electrical utility company, or auxiliary generator, which is connected to the UPS for supplying the critical load and recharging the battery.

BATTERY - The rechargeable battery strings which supply DC power to the inverter to maintain continuous AC power to the load during AC input power failure conditions.

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1.3 Overview

The UPS provides two power paths between the utility source and the critical load. Figure 1.1 shows the path for normal operation, with the load powered from the inverter. Figure 1.2 shows the path for bypass operation, with the load supplied through the static bypass line.

FIGURE 1.1 Single Line Diagram - Normal Operation. Load powered by inverter.

During normal operation, the path through the inverter is used to power the load.

Referring to Figure 1.1: Input AC power is converted to DC by the Converter. DC power is utilized to charge the UPS battery and to provide power to the Inverter. The Inverter converts the DC power to clean AC power to supply the critical load.

The conversion - inversion process eliminates any voltage transients or fluctuations existing in the input power before it reaches the critical load.

* The Input circuit breaker(MCCB) for protection of the UPS and cables are field supplied and field installed. (See WARNING 2 in section 1.0).

UPS Module

Static Transfer Switch

Power Flow

Not in Use

AC input

CB

FB

CB2

CB3

CONVERTER INVERTER

Output

52C CB1 FI FO

BATTERY

User supplied 52CS(7.5-20kVA)

52MB&52L(30-50kVA)

Maintenance Bypass Switch

40kVA, 50kVA:

External Battery

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FIGURE 1.2 Single Line Diagram - Bypass Operation. Load fed through static bypass line.

Referring to Figure 1.2, the Internal Static Bypass line is a Hard wired line through CB3 which supplies the critical load with unconditioned input power. The purpose of this line is to route power to the critical load while the UPS module is de-energized (converter and inverter), and during Start-up before the system is fully operational.

The internal control system determines the operation of the two paths, with the load powered from the inverter being the normal operation.

Referring to Figure 1.3, if the input power is interrupted, the battery will immediately supply the DC power required by the Inverter to maintain continuous AC power to the load. A fully charged battery will provide power for the specified time at the rated load, or longer at reduced load.

When power is restored after a low battery shutdown, the Converter automatically restarts operation, recharges the batteries and the Inverter is automatically restarted without operator intervention. The load is assumed by the inverter automatically without operator intervention.

In the event of a power failure, the Converter will de-energize and the batteries will discharge into the

Inverter and maintain power to the critical load until a) the battery capacity expires and the inverter turns off, or b) input power is restored after which the converter will power the inverter and

UPS Module

Power Flow

Not in Use

AC input

CB

FB

CB2

CB3

CONVERTER INVERTER

Output

52C CB1 FI FO

BATTERY

User supplied 52CS(7.5-20kVA)

52MB&52L(30-50kVA)

Maintenance Bypass Switch

40kVA, 50kVA:

External Battery

Static Transfer Switch

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1-7 simultaneously recharge the batteries. Figure 1.3 illustrates the flow diagram during battery operation.

FIGURE 1.3 Single Line Diagram - Battery Operation

The UPS is equipped with an internal rotary type Maintenance Bypass Switch (MBS) that can be used to divert utility power to the load during maintenance sessions. Figure 1.4 illustrates the power path when the MBS is in the BYPASS mode.

FIGURE 1.4 Single Line Diagram - UPS on Maintenance Bypass Operation.

UPS Module

FB

BATTERY

CB2

CB3

Static Transfer Switch

Power Flow

Not in Use

Output

52C CB1 FI FO

AC input

CB

User supplied

CONVERTER INVERTER

Maintenance Bypass Switch

40kVA, 50kVA:

External Battery

52CS(7.5-20kVA) 52MB&52L(30-50kVA)

UPS Module

FB

BATTERY

CB2

CB3

Static Transfer Switch

Power Flow

Not in Use

52C FO

CONVERTER INVERTER

Output AC input

CB

User supplied

Maintenance Bypass Switch

CB1 FI

40kVA, 50kVA:

External Battery

52CS(7.5-20kVA) 52MB&52L(30-50kVA)

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(7.5/10/15/20kVA)

The rotary maintenance bypass switch is shown as 52CS in Figure 1.4. 52CS is a two position three point make-before-break transfer switch.

(30/40/50kVA)

Two contactors (52MB, 52L) are used instead of the 52CS. A rotary switch(SWM) is used for control of the two contactors.

The two positions are identified as NORMAL and BYPASS. In the NORMAL position the load is fed by the UPS - either through the inverter or through the static bypass line. In the BYPASS position the load is powered by an external source such as the utility or a generator. This transfer operation must be made while the UPS is in the static bypass mode.

The transfer procedure to place the UPS in maintenance bypass mode, or from bypass mode to normal operation mode is outlined below:

A) Transfer of load from inverter to maintenance bypass

1. On the front panel, press the "STOP" button. The “BYP.OP.” LED illuminates within 3 seconds.

2. After confirming that the “BYP.OP.” LED is illuminated, Rotate MBS(52CS/SWM) clockwise to the

“TRANSFER” position (Do not rotate 52CS/SWM if the “BYP.OP.” LED is NOT illuminated).

3. After 3 seconds, rotate 52CS/SWM clockwise to the “BYPASS” position.

4. Transfer complete. Load is now powered from the external source. UPS can be shutdown.

B) Transfer of load from maintenance bypass to inverter

1. Rotate 52CS/SWM counterclockwise from the “BYPASS” position to the “TRANSFER” position, wait 5 seconds.

2. On the UPS, confirm the “BYP.OP.” LED is illuminated. If not, press the “STOP” button.

3. Rotate 52CS/SWM counterclockwise to the “NORMAL” position.

4. On the UPS, press the “START” button. The “INV.OP.” LED should illuminate.

5. Transfer complete. Load now powered by the inverter.

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FIGURE 1.5a UPS Parts Location(7.5-20kVA)

3.Main PCB

UPER-Y/UPFR-K

2.Relay PCB

RYDR-O/RYDR-X

UPS module

FRONT VIEW

Converter & Inverter Unit

6.Maintenance bypass transfer switch

52CS

Battery

4.AC input, AC output terminal

Cooling fan

1.Display PCB

DPAU-57/DPAU-58

5.Grounding bar

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FIGURE 1.5b UPS Parts Location(30kVA)

3.Main PCB

UPFR-K

2.Relay PCB

RYDR-X

UPS module

FRONT VIEW

Converter & Inverter Unit

6.Maintenance bypass transfer switch

SWM

Battery

4.AC input, AC output terminal

Cooling fan

1.Display PCB

DPAU-58

5.Grounding bar

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FIGURE 1.5c UPS Parts Location(40,50kVA)

FIGURE 1.6 Display PCB DPAU-57/DPAU-58

FIGURE 1.7 External I/F PCB RYDR-O/ RYDR-X

DPAU-57

DPAU-57/58

7.SW5

TEST switch

3.Main PCB

UPFR-K

UPS module

FRONT VIEW

Converter & Inverter Unit

6.Maintenance bypass transfer switch

SWM

4.AC input, AC output terminal

Cooling fan

1.Display PCB

DPAU-58

5.Grounding bar 2.Relay PCB

RYDR-X

RYDR-O/

RYDR-X

9.CN62 RS232C

D-sub Connector

8.External contact signal terminal block

(for RYDR-X only)

10.CN64 RS232C

D-sub Connector (for RYDR-X only)

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FIGURE 1.8a Main control PCB UPER-Y

FIGURE 1.8b Main control PCB UPFR-K

MCBR-T

UPER-Y

11.SW3

BOOT switch

12.SW1

RESET switch

7.SW2

TEST switch

UPFR-K

11.SW13

BOOT switch

12.SW14

RESET switch

7.SW11

TEST switch

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Description of UPS parts, referred to in Figure 1.5:

1. Display PCB DPAU-57/DPAU-58

Switches on DPAU-57/DPAU-58 board : FOR SERVICE PERSONNEL ONLY (Figure 1.6):

- (7) SW5 (TEST switch)

2. Relay PCB RYDR-O/RYDR-X board

Signal I/F on RYDR-O/RYDR-X board : (Figure 1.7):

- (8) External contact signal terminal block

- (9) CN62 (RS232C communication connector)

- (10) CN64 (RS232C communication connector)

3. Main PCB UPFR-Y/UPFR-K

Switches on UPFR-Y/UPFR-K board : FOR SERVICE PERSONNEL ONLY (Figure 1.8):

- (7) SW2(UPFR-Y)/SW11(UPER-K) (TEST switch)

- (11) SW3(UPFR-Y)/SW13(UPER-K) (BOOT switch).

- (12) SW1(UPFR-Y)/SW14(UPER-K) (RESET switch)

4. AC input, AC output terminal Refer to Figure 3.3 for details

5. Grounding bar (E)

6. Maintenance Bypass Switch (52CS/SWM) (FOR SERVICE PERSONNEL ONLY) This switch is used to transfer the load from inverter power to external power for maintenance purposes. Do not operate it under normal operation.

7. "Test mode" switch (FOR SERVICE PERSONNEL ONLY) This switch changes system operation to the test-mode. This switch is mounted on Display PCB and Main PCB. (This switch should not be operated by personnel other than an Authorized Service Engineer).

8. External contact signal terminal block Terminal block to connect contact signal input/output lines to and from external dry contacts. Refer to FIGURE 2.3 for details.

9. RS232C connector (CN62)

Refer to Figure 2.6 for detail.

10. RS232C connector (CN64)

11. "BOOT" switch (FOR SERVICE PERSONNEL ONLY) This switch boots the processor on the main control circuit board following alarm conditions. (Do not operate this switch while inverter and converter are in operation).

12. "Reset" switch (FOR SERVICE PERSONNEL ONLY) This switch resets errors resulting from alarm conditions. (Do not operate this switch while inverter and converter are in operation).

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1.4 Specifications

The UPS name plate displays the rated kVA as well as nominal voltages and currents.

The name plate is located on the interior side of the UPS front door.

TABLE 1.1 Power Specifications

Rated output

Power

Input voltage

3 ∅ / 4 wire

Output voltage

3 ∅ /3 or 4 wire

7.5kVA/6kW

10kVA/8kW

15kVA/12kW

20kVA/16kW

30kVA/24kW

40kVA/32kW

50kVA/40kW

TABLE 1.2 UPS Module Information

UPS

(kVA)

CABLE

ENTRY

WIDTH

(in/mm)

DEPTH

(in/mm)

HEIGHT

(in/mm)

WEIGHT

(lb./kg)

HEAT LOSS

@ 208V

(kBTU/h)

7.5 BOTTOM 17.7 / 450 31.5 / 800 43.3 / 1100 562 / 255* 3.2

10 BOTTOM 17.7 / 450 31.5 / 800 43.3 / 1100 562 / 255* 3.9

15 BOTTOM 17.7 / 450 31.5 / 800 43.3 / 1100 816 / 370* 5.1

20 BOTTOM 17.7 / 450 31.5 / 800 43.3 / 1100 816 / 370* 6.5

30 BOTTOM 23.6 / 600 31.5 / 800 59.0 / 1500 1235 / 560* 8.8

40 BOTTOM 27.6 / 700 31.5 / 800 59.0 / 1500 1082 / 490 11.9

50 BOTTOM 27.6 / 700 31.5 / 800 59.0 / 1500 1082 / 490 14.6

*：7.5-30kVA Including batteries

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TABLE 1.3 Detail of Specifications

Rated Output kVA 7.5 10 15 20 30 40 50 Rated Output kW 6 8 12 16 24 32 40

AC INPUT CHARACTERISTICS

Configuration 3 phase, 4 wire Voltage 120/208 V +15% ~ -25% Frequency 60 Hz ± 5% Reflected Current THD 4% typ. at 100% load; 7% typ. at 50% load

BATTERY

Type VRLA Ride Through 8min.

at 100% load

5min.

at 100% load

11min.

at 100% load

7min. at 100% load

5min. at 100% load

Nominal Voltage 360 Vdc Minimum Voltage 300 Vdc Number of Cells 180

AC OUTPUT

Configuration 3 phase, 3 or 4 wire Voltage 120/208 V Voltage Stability ±1% Frequency 60 Hz Frequency Stability ±0.01% in free running mode Power Factor 0.8 nominal Power Factor range 0.8 ~ 1.0 lagging (within output kW rating) Voltage THD 2% typical THD at 100% Linear Load

4% typical THD at 100% non-linear load Transient Response ±3% typical at 100% load step

±1% typical at loss/return of AC power ±3% typical at load transfer to/from static bypass

Transient Recovery 16.7 ms Voltage Unbalance 2% typical at 100% unbalanced load Phase Displacement 1deg. typical at 100% load Inverter Overload 150% for 1 minute System Overload 150% for 1 minute, 1000% for 1 cycle (with bypass available) Bypass Overload 150% for 1 minute, 1000% for 1 cycle Crest Factor Capabilities 3:1

ENVIRONMENTAL

Cooling Forced Air Operating Temperature 2° F ~ 104° F (0° C ~ 40° C). Recommended 59° F ~ 77° F (15° C ~

25° C) Relative Humidity 5% ~ 95% Non Condensing Altitude 0 ~ 5000 feet No Derating Location Temperature-controlled, indoor area free of conductive contaminants

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TABLE 1.4 Rating of Contactors and Fuses

Component(s) Description Component Rating @ 208V,3 phase, 60 Hz UPS Rating (kVA) 7.5 10 15 20 30 40 50

CB1 AC Input Contactor 60A 100A 150A 150A

CB2 DC Input Contactor 60A 100A 150A 150A

CB3

Static Bypass Input

Contactor 60A 100A 150A 150A

52C AC Output Contactor 60A 100A 150A 150A

FIU,FIV,FIW AC Input Fuse 140A/660V 180A/ 600V

280A/ 660V

280A/ 660V

FBP,FBN Battery Input Fuse 140A/660V 180A/ 600V

280A/ 660V

280A/ 660V

FOU,FOV,FOW AC Output Fuse 140A/660V 180A/ 600V

280A/ 660V

280A/ 660V

F1,F2,F3 UPER-Y/UPFR-K 6.3A/250V 6.3A/

250V

6.3A/ 250V

6.3A/ 250V

F1 CABR-JA 12A/600V

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2.0 OPERATOR CONTROLS AND INDICATORS

The 2033C Series operator controls and indicators are located as follows:

Maintenance bypass switch and contactors : Inside the module UPS status indicators : Door exterior

FIGURE 2.1 Operation/Display Panel (Front panel)

2033C SERIES UPS

INV OP. BYP OP.

FAILURE BAT OP.

START STOP SILENCE CLEAR

EPO 1

6 7 8 9 10

MBP

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2.1 LED Display and keypad

1) 7 SEGMENT LED DISPLAY (red) The 7 segment LED Indicates the status of the UPS and error codes.

(Refer to failure code list in section 6.)

During normal operation, LED indication is shown in figure 2.2.

FIGURE 2.2 7 segment LED display for normal operation

2) Load on inverter [INV OP.] (green)

Illuminated when power is supplied from inverter to the critical load.

3) Battery operation [BAT OP.] (yellow)

Illuminated when the battery is operating following an AC power failure.

4) Load on bypass [BYP OP.] (yellow)

Illuminated when power is supplied to load devices by static bypass.

5) UPS failure [FAILURE] (red)

Illuminated when UPS is in fault mode.

6) Inverter start [START] (green)

Inverter start button.

When pressed, the load will transfer from the static bypass line to the inverter.

7) Inverter stop [STOP] (gray) Inverter stop button. When pressed, the inverter can be stopped.

The load will transfer from the inverter to the static bypass line.

8) Alarm Silence [SILENCE] (gray) Audible alarm is silenced when this button is pressed.

9) Clear [CLEAR] (gray) Clears errors in UPS system.

10) Emergency Power Off [EPO] (red) Shuts down UPS when pressed. Load is dropped.

11)Load on maintenance bypass [MBP] (red) Illuminated when power is supplied to load devices by maintenance bypass.

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2.2 External Signal Terminal Block

The UPS is equipped with a series of input/output terminals for the external annunciation of alarms and the remote access of certain UPS functions. Layout of terminals is shown in Figure 2.3, with a functional description of the input/output port presented:

FIGURE 2.3 External Signal Terminal Block (NEC Class2)

TB

BATTERY TEMP. HIGH (Optional)

- For external battery cabinet.

EMERGENCY STOP (Optional)

SUMMARY ALARM

LOAD ON INVERTER

LOAD ON BYPASS

BATTERY OPERATION

CONVERTER OPERATION

BATTERY LOW VOLTAGE

OVERLOAD

(User supplied dry contact)

(User supplied sensor and dry contact)

UPS

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A) Output Contacts (for external alarm annunciation)

Output contacts consist of form “A” dry type contacts. The rated capacity of all output contacts is 120Vac/0.5Aac or 30Vdc/1Adc. All dry contacts must be operated at their rated values or lower. Figure 2.4 illustrates a typical installation. The external relay can also be a lamp, LED, or computer, etc.

FIGURE 2.4 Control Wiring for External Contacts

Terminal

UPS Cabinet External to UPS Cabinet

Relay

Coil

Power Source

Relay Contact Terminal

Details of output alarm contacts :

Terminals 5 to 6 “Summary Alarm” contact Activated when a fault alarm occurs.

Terminals 7 to 8 “Load on Inverter” contact Activated when the power is supplied by the inverter.

Terminals 9 to 10 “Load on Bypass” contact Activated when the power is supplied by the static bypass input.

Terminals 11 to 12 “Battery Operation” contact Activated when the battery is operating following an AC power failure.

Terminals 13 to 14 “Converter Operation” contact Activated when the converter is operating.

Terminals 15 to 16 “Battery Low Voltage” contact Activated when battery voltage drops below discharge end voltage level during inverter operation (i.e. During AC failure conditions).

Terminals 17 to 18 “Overload” contact Activated when a system overload occurs.

User supplied

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B) Input Contacts (for remote access of UPS)

External contacts are provided by the user of the UPS system. The terminal voltage at the UPS is 24Vdc. External dry contacts are to be provided accordingly.

WARNING: Do not apply voltages to remote access input terminals.

Damage to UPS may result.

Refer to Figure 2.5 for a typical wiring configuration. Although this figure shows the emergency stop configuration, the same wiring arrangement is used for battery temperature high. See below for terminal connection details.

FIGURE 2.5 Remote "Stop" Contact Connections

１

Relay Coil current : 8.3mA Use Momentary Switches

UPS Cabinet External to UPS Cabinet

Relay

Coil

24 VDC

Emergency Stop

Details of input contacts for remote access :

Terminals 1 to 2 “Emergency Stop” contact input

Used to perform a remote UPS emergency power off (EPO).

The load will be dropped.

Terminals 3 to 4 “Battery Temp. High” contact input Input fed by a thermocouple that monitors battery temperature.

The converter float voltage level is reduced for battery over-temperature conditions. The external thermocouple will be user supplied

NOTE: In all cases, a switch having a protective cover is recommended in order to reduce possibility of accidental operation.

User supplied

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2.3 External communication connector

This is an RS232C port for “DiamondLink”* monitoring software. The layout of the connector is shown in Figure 2.6.

FIGURE 2.6 External communication connector (NEC Class2)

Pin 1. : Not used Pin 2. RXD : Receive data Pin 3. TXD : Transmit data Pin 4. DTR : Always high level Pin 5. GND : Signal ground Pin 6. : Not used Pin 7. RTS : Always high level Pin 8. : Not used Pin 9. : Not used

* Consult MITSUBISHI ELECTRIC AUTOMATION, INC. for detail on “Diamond Link” monitoring software and its capabilities.

CN62

D-SUB 9Pin (male)

RYDR-O/ RYDR-X

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3.0 INSTALLATION AND OPERATION

3.1 Transportation and Installation

TABLE 3.1 How to transport and install the system Transportation Installation

Transport unit with forklift. Pull out the UPS cabinet as shown in Figure 3.1 Fix the UPS unit in place using the four (4) leveling feet.

NOTE: Do not transport in a horizontal position. Cabinets should be maintained upright within +/- 15° of the vertical during handling.

3.2 Handling

The UPS is shipped in export packaging. Remove the UPS from the package only when it is ready for installation. Refer to Figure 3.1 for handling.

FIGURE 3.1 Handling

RAMP

Roof of the package during shipping

Leveling feet

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3.3 Installation Procedure

A) Note the load tolerance of the floor Refer to Table 3.2 for list of UPS weights:

TABLE 3.2 List of UPS weights

UPS Capacity (kVA) 7.5 10 15 20 30 40 50

Weight (lb.) 562 562 816 816 1235 1082 1082

NOTE: 40kVA and 50kVA UPS have batteries external to module cabinet.

Please refer to the remote battery supply installation manual.

B) Minimum clearance required for ventilation Right side 1.0" (25 mm) (not required when sidecars are used) Left side 1.0" (25 mm) (not required when sidecars are used) Back side 7.8" (200 mm) Top side 39.4" (1000 mm)

C) Space requirement for routine maintenance Allow for the following space at the time of installation.

Front 39.4" (1000 mm) Sides 1.0" (25 mm) Rear 7.8" (200 mm)

D) Battery Please refer to the following when installing and maintaining batteries:

1. Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

2. When installing or replacing batteries, install or replace with the same number and type per Table 3.3

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TABLE 3.3 Type and number of battery

Type Manufacturer Number

7.5kVA, 10kVA PM12-7.2

NP7-12

Power Battery Inc.

Yuasa Corp.

15kVA, 20kVA PM12-18

NP18-12B

Power Battery Inc.

Yuasa Corp.

30kVA PM12-18

NP18-12B

NP18-12BFR

Power Battery Inc.

Yuasa Corp.

Yuasa Corp.

40kVA, 50kVA

NOTE: 40kVA and 50kVA UPS batteries are external to module cabinet.

Please refer to the remote battery supply installation manual.

CAUTION - Do not dispose of battery or batteries in a fire. The battery may explode.

CAUTION - Do not open or mutilate the battery or batteries. Released electrolyte is harmful to the skin and eyes and may be toxic.

CAUTION - A battery can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working on batteries:

! Remove watches, rings, or other metal objects.

! Use tools with insulated handles.

! Wear rubber gloves and boots.

! Do not lay tools or metal parts on top of batteries.

! Disconnect charging source prior to connecting or disconnecting battery terminals.

3.4 Procedure for Cable Connections (Refer to Table 3.4 for cable sizes.)

I. Confirm the capacity of the UPS being installed. Identify the input/output power terminal blocks as shown in the appropriate Figure 3.2 or Figure 3.3-Figure 3.5.

II. Connect the grounding conductor from the input service entrance to the UPS ground bar.

III. Confirm that an external input circuit breaker sized to protect both the converter input and the bypass lines is installed. Consult equipment nameplate for current ratings. Connect the AC power source cables from the input service entrance to the UPS’ INPUT power

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MITSUBISHI ELECTRIC 2033C SERIES UPS

terminals identified as A, B, C and N in Figure 3.3-Figure 3.5. Input cables must be sized for an ampere rating larger than the maximum current capacity of the UPS.

IV. Refer to Table 3.4 for recommended cable sizes. Referring to Figure 3.3-Figure 3.5, connect UPS’ OUTPUT load terminals A, B, C and N to load distribution panel.

V. Connect external signal terminal block as needed. Refer to section 2.2 and Figure 2.3 for functional description. 12 AWG, or less, shielded conductor is recommended.

NOTES: 1. Confirm that all UPS internal contactors (breakers) "CB1", "CB2", and "CB3" are open before energizing UPS.

2. UPS power terminals are supplied with stud type fittings. It is recommended that compression lugs be used to fasten all input/output power cables. Refer to Table 3.5 for recommended compression lugs and appropriate crimping tool

Table 3.4 Recommended Cable Size and Torque Requirements

UPS Capacity Input Side

* 1

Output Side

* 1

(kVA)

Cable *2 Size

Torque

(in. lbs)

Cable *2 Size

Torque

in. lbs

7.5kVA (208V)

8 AWG

or larger

in. lbs

8 AWG

or larger

in. lbs

10kVA (208V)

8 AWG

or larger

in. lbs

8 AWG

or larger

in. lbs

15kVA (208V)

8 AWG

or larger

in. lbs

8 AWG

or larger

in. lbs

20kVA (208V)

6 AWG

or larger

in. lbs

6 AWG

or larger

in. lbs

30kVA (208V)

2 AWG

or larger

in. lbs

2 AWG

or larger

in. lbs

40kVA (208V)

2/0 AWG

or larger

in. lbs

2/0 AWG

or larger

in. lbs

50kVA (208V)

2/0 AWG

or larger

in. lbs

2/0 AWG

or larger

in. lbs

*1 - Voltage drop across power cables not to exceed 3% of nominal source voltage.

*2 - Allowable ampere ratings based on 90 °C insulation at an ambient temperature of 30 °C. No more than 3 conductors in a raceway without de-rating. Copper conductors assumed.

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TABLE 3.5 Crimp Type Compression Lug

WIRE

SIZE

WIRE

STRAND

RECOMMENDATION CRIMP TOOL REQUIRED

BURNDY TYPE Y35 OR Y46

(CODE) CLASS VENDOR CAT. NO. COLOR KEY DIE INDEX

8 B

BURNDY YA8C-L2 RED 49

6 B

BURNDY YA6C-L3 BLUE 7 / 374

4 B

BURNDY YA4C-L3 GRAY 8 / 346

2 B

BURNDY YA2C-L BROWN 10

2/0 B

BURNDY YA26-L3 BLACK 13

NOTE: When using crimp type lugs, the lugs should be crimped to the specifications given in the manufacturer's instructions for both crimp tool and lug.

Fig.3.2 UPS Terminal Designation

Terminals:

INPUT

A,B,C,N

Terminals:

OUTPUT

A,B,C,N

Output AC input

BATTERY

CB3

Static Transfer Switch

52C CB1 FO FI

CONVERTER INVERTER

UPS Module

CB2

FB

52CS

40kVA, 50kVA:

External Battery

52CS(7.5-20kVA) 52MB&52L(30-50kVA)

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FIGURE 3.3 Input/Output Power Terminals (7.5kvA - 20kVA)

Control printed circuit boards

Fan

Inverter and Converter

52CS

Input/Output Power Terminal Designation

ALL POWER TERMINALS USE 1/4” (6 MM) DIAMETER

BOLTS

A B C N A B C N

(INPUT) (OUTPUT)

Battery Battery

Battery Battery

RYDR-O/RYDR-X

NORMAL

TRANSFER

BYPASS

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FIGURE 3.4 Input/Output Power Terminals (30kVA)

Converter & Inverter Unit

Cooling fan

A B C N A B C N

Battery

Battery

Battery

Battery

RYDR-X

N P

(INPUT) (OUTPUT)

TRANSFER

NORMAL BYPASS

MBS

(DC INPUT)

Control printed circuit boards

Grounding bar AC Input/Output Power Terminal Designation

HOLE DIAMETER: 0.36” (9 MM)

DC Input Power Terminal

HOLE DIAMETER: 0.28” (7 MM)

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FIGURE 3.5 Input/Output Power Terminals (40kvA - 50kVA)

Control printed circuit boards

Converter & Inverter Unit

Cooling fan

A B C N A B C N N P

(AC INPUT) (AC OUTPUT) (DC INPUT)

Grounding bar

MBS

BYPASS

TRANSFER

NORMAL

RYDR-X

Input/Output Power Terminal Designation

HOLE DIAMETER: 0.47” (12 MM)

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3.5 Operating Procedures

A) UPS Start-up Procedure

1. Close External Input Circuit Breaker (User supplied. Refer to warning 2).

2. The “BYP.OP.” illuminates and power is supplied to the critical load from the static bypass line automatically.

3. Within ten (10) seconds, the “INV.OP.” LED flashes and the Inverter starts. The UPS will automatically transfer the load from the static bypass line to the inverter and the “INV.OP.”

light illuminates.

NOTE: If LED Display indicates code “81”, please check position of EPO button. If EPO button is in the ON position, press the button to clear EPO as shown in figure 3.6. Press the “CLEAR” button. If LED Display indicate code “99”, press the “CLEAR” button again.

FIGURE 3.6 EPO button

EPO position Normal position

B) UPS Shutdown Procedure

1. If a total UPS module (inverter and converter) shutdown is required, press the "STOP" button on the front panel. Within 3 seconds the “BYP.OP.” LED will illuminate and the UPS will transfer the load to the static bypass line.

WARNING: Verify the load is OFF if the next step is to be performed .

NOTE: Power to the critical load is supplied through the static bypass line.

Power to the critical load will be lost after execution of the next step.

The load will drop.

2. If turning off all power to the critical load is desired, open the AC Input Circuit Breaker (User supplied.).

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CAUTION : In bypass mode, all UPS power terminals are still live. Lethal voltages are present. De-energize all external sources of AC and DC power before handling UPS.

C) EPO (Emergency Power Off) Procedure

If an all power supply shutdown is required in an emergency situation, press the "EPO" button on the front panel. The UPS will be shutdown and no power is supplied to the load.

WARNING : With EPO operation, although all output power from the UPS is shutdown, it is necessary to manually open the input circuit breaker (user supplied), to remove the input power to the UPS.

3.6 Maintenance bypass set-up procedures

The transfer procedure to place the UPS in maintenance bypass mode, or from bypass mode to normal operation mode is outlined below:

A) Transfer of load from inverter to maintenance bypass

1. On the front panel, press the "STOP" button. The “BYP.OP.” LED illuminates within 3 seconds.

2. After confirming that the “BYP.OP.” LED is illuminated, Rotate the MBS(52CS/SWM) clockwise to the “TRANSFER” position (Do not rotate 52CS/SWM if the “BYP.OP.” LED is NOT illuminated).

3. After 3 seconds, rotate 52CS/SWM clockwise to the “BYPASS” position.

4. Transfer complete. Load is now powered from the external source. UPS can be shutdown.

B) Transfer of load from maintenance bypass to inverter

1. Rotate 52CS/SWM counterclockwise from the “BYPASS” position to the “TRANSFER” position, wait 5 seconds.

2. On the UPS, confirm the “BYP.OP.” LED is illuminated. If not, press the “STOP” button.

3. Rotate 52CS/SWM counterclockwise to the “NORMAL” position.

4. On the UPS, press the “START” button. The “INV.OP.” LED should illuminate.

5. Transfer complete. Load now powered by the inverter.

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4.0 RESPONSE TO UPS FAILURE

Depress “SILENCE” button on the front panel.

Refer to the list of fault codes for a description of the error. See section 6. For fault codes

Take necessary action per the list of fault codes in section 6 of this manual.

When faults occur, contact the Authorized Mitsubishi Service Representative or call Mitsubishi at 1-800-887-7830.

Note The error code indicated on the 7 Segment LED Display at the time of UPS alarm condition is very important. In order to minimize repair time, please include this information along with the operation status and load status, on all correspondence with Mitsubishi’s field service group.

UPS FAULT

Annunciator Silence

Recording of Fault

Primary Action

Information to Service Center

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5.0 PARTS REPLACEMENT

Contact Mitsubishi or its Authorized Service Center on all issues regarding the replacement of parts.

A)A)A)A) Battery Battery lifetime may vary according to the frequency of use and the average ambient operating temperature. Battery end of life is defined as the state of charge resulting in an ampere-hour capacity less than, or equal to, 80% of nominal capacity. Replace battery if capacity is within this percentage.

B)B)B)B) UPS Component Parts Contact Mitsubishi or its Authorized Service Center for a complete parts replacement schedule.

Recommended replacement time interval varies with operating environment. Contact Mitsubishi or its Authorized Service Center for specific application recommendations.

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6.0 FAULT CODES

This section covers the fault codes, their description and required action.

At time of error :

A) Verify and record the occurrence of the alarm. Note fault code on the 7-segment LED Display .

Contact Mitsubishi Electric Automation, Inc. at 1-800-887-7830.

B) If the External AC Input Circuit Breaker (MCCB) is in the trip state, depress the toggle to reset the breaker before re-closing.

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Failure Code List Note 1 Note 2 Note 3

7seg. LED Code Status Guidance Buzzer External send-out contact Failure LED

00 Test mode (Pulse check) - [1] - -

01 Maintenance mode - [1] - -

10 Battery circuit abnormal Call service engineer [1] Minor Flicker

11 Battery test - - - -

12 Battery circuit abnormal Call service engineer [1] Minor Flicker

13 Battery depleted warning - [1] Alarm Flicker

14 Battery depleted - [2] Alarm Lit up

15 Battery temperature abnormal Check battery [1] Alarm Flicker

16 Battery temperature abnormal Check battery [1] Minor Flicker

17 Battery charge voltage abnormal Call service engineer [1] Alarm Flicker

18 DC voltage abnormal Call service engineer [1] Minor Flicker

19 Battery depleted (Converter overload) Check AC input voltage [2] Major Lit up

21 AC input voltage out of range Check AC input voltage [1] Alarm -

22 AC input phase rotation error Check AC input voltage [1] Minor Flicker

23 Converter overload Call service engineer [1] Alarm Flicker

24 Converter over current Call service engineer [1] Minor Flicker

25 Converter abnormal (DCOV) Call service engineer [2] Major Lit up

26 Converter abnormal (DCUV) Call service engineer [2] Major Lit up

27 Converter abnormal Call service engineer [2] Major Lit up

28 Converter abnormal at pre-charge Call service engineer [2] Major Lit up

31 Inverter voltage abnormal Call service engineer [1] Minor Flicker

32 Inverter abnormal (VLOV) Call service engineer [2] Major Lit up

33 Inverter abnormal (VLUV) Call service engineer [2] Major Lit up

34 Inverter abnormal (OC) Call service engineer [2] Major Lit up

35 Inverter abnormal Call service engineer [2] Major Lit up

36 52C abnormal Call service engineer [1] Minor Flicker

37 52C abnormal Call service engineer [1] Minor Flicker

41 Bypass voltage out of range Check bypass input - Alarm Flicker

42 Bypass frequency out of range Check bypass input - Alarm Flicker

43 Interrupted transfer - [1] Alarm Flicker

44 Transfer warning - - Alarm -

46 Overload interrupt transfer Press clear button [1] Alarm Flicker

47 Overload interrupt transfer Press clear button [1] Alarm Flicker

51 Synchronous control abnormal Call service engineer [1] Minor Flicker

52 Transfer circuit abnormal Call service engineer [1] Minor Flicker

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Note 1 Note 2 Note 3 7seg. LED Code Status Guidance Buzzer External send-out contact Failure LED

53 Transfer circuit abnormal Call service engineer [1] Minor Flicker

54 Control circuit error Call service engineer [2] Major Lit up

55 Control circuit error Call service engineer [2] Major Lit up

56 Control circuit error Call service engineer [2] Major Lit up

57 Control circuit error Call service engineer [2] Major Lit up

58 Control circuit error Call service engineer [1] Minor Flicker

59 Control circuit error Call service engineer [2] Major Lit up

71 Overload Reduce load [1] Alarm Flicker

72 kW overload Reduce load [1] Alarm Flicker

73 Instantaneous overload Reduce load [1] Alarm Flicker

74 Load abnormal Check load [1] Alarm Flicker

76 Overload Reduce load [1] Alarm Flicker

81 Emergency stop activated - [1] Alarm Flicker

82 Fin temperature abnormal Call service engineer [2] Major Lit up

96 Control circuit error Call service engineer [2] Major Lit up

97 Restart after battery depleted - - Alarm -

98 Control circuit error Call service engineer [2] Major Lit up

99 Start up Press Clear button - Alarm -

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(Note 1)

Audible annunciator: [1] intermittent sound, [2] continuous sound.

(Note 2)

• "Major" is defined as a major failure. Load transferred from inverter to the static bypass line;

• "Minor" is defined as a minor failure. UPS continues to operate normally, but cause of alarm must be identified;

• “Over" is defined as an overload condition. Load will transfer from inverter to the static bypass line and may or may not return to the inverter. Return to inverter will occur only if overload corrects itself and output load is within rating of UPS. (Note: Inverter may need to be restarted manually subsequent to an output bolted fault.)

(Note 3)

Indicates one of two possible LED illumination patterns - continuously on (lit) or intermittent (flicker).