AEG Protect 1.1 manual

UPS OPER ATING INSTRUCTIO NS PROTECT 1.100 PROTECT 1.150 PROTECT 1.200 PROTECT 1 .[...]

2 Thank you fo r deciding to pu rchase t he PROTECT 1. UPS from AE G Pow er Solutions. The following safety instr uctions are an important part of the operating instruction s are will protect you against problems from operating errors and possible dangers. Please read these instructions carefully prior to commissioning![...]

3 1 Notes on these Operating Instructions Duty to provide information These operating instructions will help you to ins tall and operate the U ninterruptible P ower S uppl y (UPS), PROT ECT 1.100, PROTECT 1.150 or PRO TECT 1.200 as well as th e corresponding externa l battery units PROTECT 1.100 BP or PROTECT 1.BP20, all ref erred to as PROTECT 1 i[...]

4 liability for c onsequential damage. AEG will rescind all obligations such as warranty a greements, service c ontracts, etc. en tered into b y AEG or its repr esentatives wit hout prior notice in the event of maintenance and repair work being carried out with anything other than original AEG parts or spare parts purchas ed from AEG. Handling PROT[...]

5 Table of Contents 1 Notes on these Opera ting Instruc tions ............................. 3 2 General Inform ation .................................................... ...... 7 2.1 Technolog y ....................................... ......................... 7 2.2 System Descr iption .......................................... .......... 8 2.3 Tec[...]

6 6 Start-Up ......................... ............................... ................... 37 6.1 Operating Modes ................. ............................... ..... 38 6.1.1 Normal Operation ...................................... ......... 38 6.1.2 Battery Operation / Autonom ous Operation ....... 39 6.1.3 Bypass Operation ....................[...]

7 2 General Informa tion 2.1 Technology i PROTECT 1. is an U nint erruptible P ower S upply (U PS) for essential loads suc h as sm all data centr es, servers , net work c omponents, telecomm unications equipm ent and sim ilar units. It consists of : ♦ Mains filter with ov ervoltage protect ion (appliance protection / class D) and mains energ y ba[...]

8 2.2 System Description The UPS is connected between t he public utilit y m ains and the loads to be pro tected. Th e pow er se cti on of the re ct ifi er conv ert s the ma in s v ol tag e to DC vol tag e fo r sup ply ing th e in v er ter . Th e ci rcui t t e ch no lo gy u se d (P F C) en a bl e s sinu soi da l c ur re nt con su mpti o n and th er[...]

9 IG B T po we r se mi con du cto rs of th e in ve rt e r, a vo l ta g e syst em of th e h ig he st q uali ty a nd av a il abi li ty o n the se cur ed bu sb ar. In th e eve nt o f mai n s fau lt s (su ch as e.g . cur re nt fail ure s), the vo l ta ge co nt inue s t o b e supp l ie d f r om t he inv e r te r to th e l oa d wi tho u t any in te rru p[...]

10 Parallel system with PROTECT 1.150 Number of UPS units Available power 1 2 3 0 15 kVA 30 kVA 45 kVA 1 --- 15 k VA 30 kVA Active redundanc y degree 2 --- --- 15 kVA Parallel system with PROTECT 1.200 Number of UPS units Available power 1 2 3 0 20 kVA 40 kVA 60 k VA 1 --- 20 kVA 40 kVA Active redundanc y degree 2 --- --- 2 0 kVA[...]

11 2.3 Technical Data Type rating PROTECT 1.100 10000 VA (cos ϕ = 0.7 ind.) 7000 W PROTECT 1.150 15 000 VA (cos ϕ = 0.7 ind.) 10500 W PROTECT 1.200 20000 VA (cos ϕ = 0.7 ind.) 14000 W UPS input 3ph~ / N / PE Rated connection v oltage 400 V/ 230 VAC Voltage range with out 304 VAC – 478 VAC ± 3 % battery operation (rectifier) 176 VAC – 261 VA[...]

12 Overload behavio ur Up to 105% cont inuous; with mains suppl y > 105% – < 130% f or 10 min. 130% for 1 s Following this, autom atic, uninterrupted s witchover to integrated b ypass (SBS). S w i tc h -o ff a fte r 1 mi n i f o ve rl oa d c o n ti n u e s t o be p re se n t . ( S wi tch b a ck i f o ve rl oa d d ec re a se s = lo ad < 9[...]

13 Communication Interfaces RS232 Sub-D (9-pin) Additionally: Com munication slot for expansions (e.g. AS/400 / USB / rem ote signal indicator / SNMP, …) Shutdown softwar e on CD “CompuW atch” for all comm on operating s ystems, e.g. W indows, Linux, Mac, Unix, FreeBSD, Novel l, Sun General data Classification VFI SS 111 acc . to IEC 62040 ?[...]

14 Housing colour: Blackline W eight: PROTECT 1. 100 39 kg PROTECT 1. 150 55 kg PROTECT 1. 200 55 kg PROTECT 1. 100 BP 135 k g PROTECT 1. BP20 170 kg Dimensions W x H x D: PROTECT 1.100/1.150/1.200 260 mm x 717 mm x 670 mm PROTECT 1.100 BP 260 mm x 717 mm x 670 mm PROTECT 1. BP 20 260 mm x 717 mm x 810 mm Directives The PROT ECT 1. meets the produc[...]

15 3 Safety Reg ulations 3.1 Important Instructions and Explanations The instruc tions f or operat ion and maintenance, as w ell as the following safety regulations m ust be complied with to ensure the safet y of pers onnel as well as the c ontinued availability of the unit. All personnel installin g/dismantling, starting up, operating or s ervicin[...]

16 ♦ Verify that the un it is disconnected fr om the power supply ♦ Earth and short-c ircuit the unit ♦ Provide protection by covers or barriers for an y neighbouring live parts 3.3 Qualified Personnel The PROTECT 1. may only be transported, installed, connected an d serviced by q ualified pers onnel who are familiar with the pertinent safety[...]

17 For hea lth and safety r easons, the unit must be earthed correctl y ! The PROTECT 1. m ay onl y be operated with or conn ected t o a three-p hase power system with protect ive grou nding using a m ains c onnection cable with PE conductor that h as been tested according to G erm an standards (VDE). Risk of burning! The battery has powerful short[...]

18 ♦ Ensure that no flu ids or foreign bodies can penetrate the housing! ♦ Do not block the air vents of the unit! Make sure, f or example, that chi ldren do not ins ert any objects in the ventilation openings ! ♦ Do not connect ho usehold app liances such as hairdryers to the UPS! Also take care when working with motor loads. It is essential[...]

19 Therefor e, take the follo wing safet y precautions when work ing with batteries: ♦ Take off watches, r ings and other m etallic objects! ♦ Only use tools with insulated handl es! i Avoid using multiple outlet adapters with a central on/off switch as protection agains t uncontrolled loa d switch-of f as well as for avoiding peak inrush curre[...]

20 3.5 CE Certificate[...]

21 4 Set-up 4.1 Unpacking and Inspection The unit has been completel y check ed and inspected. Although the unit has been pack ed and ship ped with the usual care, transpor t damage cannot be completely ex cluded. i Any claim s due to transport dam age must always be asserted against the transport company! Check the shipping cont ainer for damage o[...]

22 Please keep plastic packaging bags away from babies and children in order to saf eguard against s uffocation acc idents. Handle the com ponents with care. Please take into ac count the weight. It m ay be necess ary to engage the he lp of a second person. 4.2 Transport to Installation Site The PROT ECT 1. is equipped with transp ort rolls for eas[...]

23 4.3 Set-Up Note the following points when s etting u p the UPS system and its external batt ery units (special access ories): ♦ The contact surf ace must be sm ooth and level. It m ust also be suff iciently strong and sturd y to avoid vibration and shock s. ♦ Make sure that the m ounting is able to support the weight, especiall y in conjunc [...]

24 4.4 Overview: Connections, Operating / Display Elements 4.4.1 Front view PROTECT 1.100 PROTECT 1.150 PROTECT 1.200 PROTECT 1.100 BP PROTECT 1.BP20[...]

25 4.4.2 Display 1. OFF pushbutton 2. ON pushbutton / a larm off 3. Orange-coloured Bypass LED 4. Green Inverter LE D 5. Orange-coloured Batter y LED 6. Green Line LED 7 – 11. Bar gra ph LED (7-10 gre en, 11 orange-c oloured) for UPS cap acity utilisation or remaining batter y capacity 7. L ED l o a d ( 0 -3 5 %) b a tt e r y c a p ac i ty (9 6- [...]

26 4.4.3 Rear view (conn ections): PROTECT 1.100 PROTECT 1.150 / 1.200 1 2 3 4 5 6 7 8 N L 1 L 2 L3 J P 1 J P 2 L N 1.1 1.2 1.3 11 13 9 10 11 4 1 2 3 5 6 6 8 7 N L1 L 2 L 3 + - L N JP 1 J P 2 1.1 1.3 1.2 11 13 9 10 11 12[...]

27 Explanations : 1. Connection term inal cover for m ains/UPS input (1.1) and output (1.3), additional pair of term inals for setting indi vidual or parallel oper ation (1.2); Battery connect ion terminals (PROTECT 1.150 / 1.200) 2. Mains input miniature circu it breaker 3. Manual bypass switch 4. Socket for external batter y m odule (PROTECT 1.10[...]

28 5 Electrical Conn ection Caution Prior to comm encing wo rk , ensure that the connection cables are de-energ ised an d that it is not possible to act ivate the power sup ply. i In order to avoid def ormation of the su pporting rail and to protect t he base of the conn ection terminal against tors ional forc es, it is advisable to hold the cable [...]

29 5.1 Safety of Personnel Note the following points when s etting u p the UPS system and its external batt ery units (special access ories): ♦ Disconnect the un it from the power supply ♦ Secure the unit ag ainst being s witched back on ♦ Verify that the un it is disconnected f rom the power supply ♦ Earth and short-c ircuit the unit ♦ P[...]

30 ♦ Mechanicall y secure the cables with the strain relief clamps of the cable clamping unit. ♦ Mount the connecti on cover of the cable clamping unit. 5.3.1 Connection Cross -Section s and Fuse Protection The required dim ensions can be f ound in the followin g table: PR OT ECT 1 .1 00 PR OT ECT 1 .1 50 * P R OT EC T 1 .2 00 * M ax . cu rr e [...]

31 Alternativel y, the 10 k VA U PS system can also b e c onnected via a multi-wire rub ber-sheathe d cable. 5.4 Mains Connection 5.4.1 Preparation for t he three-phase ma ins connection Before connect ion work is performed on the UPS, m ake sure that: ♦ The values of the nom inal voltage (s upply) and frequency m atch those on the nam eplate of [...]

32 ♦ Pl ace th e “ main t en a n ce sw it ch” ma nu al by pas s on th e b ac k o f the UP S i n the “by pas s” pos i ti on . To d o t hi s, fir st re mov e t h e 4 s cr ew s o f t h e cov er (n o. 3, p . 26/ 27 ). ♦ Put the mains input miniature circ uit breaker ( no. 2, p. 26/27) in the “O FF” positi on. Connect the UPS term inal ?[...]

33 5.4.4 Connection of th e Loads In or der to ens ure the sa fety o f pe r so nn el du rin g ins ta lla tio n wo rk, make su re th a t the con n e cti on s are mad e un der the fo llo wi ng con di tio ns: ♦ No mains voltage pres ent. ♦ The loads are s witched off . ♦ UPS is switched off (display com pletely blank ). To disconnect the PROTECT[...]

34 5.5.1 Connection of th e Battery Cu bicle PROTECT 1.100 BP This batter y c ubicle is com pletely preconfigured. T he connection to the U PS unit is re ady to be plugged in as a result of the suppli ed battery connecti on cable. PROTECT 1.100 with 1 battery unit PROTECT 1.100 BP i P RO TE CT 1 .10 0 BP is onl y intended for connection to t he UPS[...]

35 5.5.2 Connection of th e Battery Cu bicle PROTECT 1. BP20 Fig.: Rear view of the PROTECT 1 .BP20 with cover re moved. The batter y cubicle is supplied with a sep arate batter y s tring and separat ely enclosed batter y fuses f or saf ety and tr ansport protection re asons. Please also n ote the separate documentation e nclosed with th e battery [...]

36 If the b attery cubicle is used in connecti on with th e PROTECT 1.1.50 or PROT ECT 1.200, the strain relief is implem ented with clamps. The battery s ystem can now be activat ed. T o do this, insert the two fuses  . As the last step, f asten each c over that was initia lly rem oved. Fig.: PROTECT 1. BP20 in connec tion with the PROT ECT 1.1[...]

37 6 St art- Up Compare the setting of the nom inal output voltage of the UPS with the rated voltage valid in your countr y. The factory presetting is 230 V. Cha nges to 220 VAC or 240 V AC can be made with the sof tware “Com puWatch”. Switching on the PROTECT 1. on the mains 1. Make sure that all connec tions have be en made according to the i[...]

38 i Pl eas e shu t dow n the ent ire sy st e m ag ai n if y ou ca nno t solv e a pro ble m th at o ccu rs. To do th i s , p re ss th e OFF pu shb ut ton fo r ap pro x. 2 se con d s. Di sco n ne ct th e UPS fro m t he mai ns by a ct uat in g th e mai n s in pu t mi ni a tu re ci rc u it bre ake r (no. 2, p . 26/ 27) . Pl ea se con ta ct ou r h ot l[...]

39 continuously supplied with reliable and “clean” voltage with no interruptions in th is operating m ode. The bar graph LED (LED chain above the p ictograph) indicates the c urrent capa city utilisation of the UP S in this operating m ode (see chapter 8, p. 45 ). 6.1.2 Battery Operation / Autonomou s Operation Battery Load REC REC INV Manual b[...]

40 The inverter is s witched off if the battery voltage dro ps below a factory-set m inimum voltage value. Never store the unit in this condition! T he discharged batter y system s hould be recharged within a week at the la test. W hen the volt age and frequenc y are within the tolerance range again after the m ains is restored , th e rect ifiers s[...]

41 This so-called passive red undancy pro tects against the total failure of the vo ltage s upply on the sec ured busbar; however, in this operat ing m ode, m ains faults would directl y affect the load. As a res ult, t he e lectronics continuousl y attem pt to switch bac k to "online" / norm al operating mode (e.g. when the overload or o[...]

42 The m anual bypass en ables m aintenance and service personnel to perform work on the PROTECT 1. without having to switch off the load circuit. If the current suppl y fails while the manual bypass is active, a total failur e of the load supp ly results. For this reaso n, it should be s witched back to norm al operating mode as s oon as possible.[...]

43 7 Interfaces and Communicatio n 7.1 Computer Interface RS232 For the contr ol of the UPS and conveni ent readin g of st atus messa ge s and m ea sur ed value s, vario us inte rface s are avai lable. The inte rface prot ocol is de sign ed for operat ion with th e "C ompu W atch " shu tdow n and UPS m an age ment softwa re fro m A EG. Us[...]

44 The "CompuW atch" shutdown sof tware supports diff erent operating systems , e.g. W indows 98S E/ME, W indow s NT/2000/XP, W indows Vist a, Linux , No vell Netware, IBM AIX, HP-UX, SUN Sol aris, Mac OS X, an d others. Example of a “Co mpuWatch” scre en Refer to the m anual on the CD for details about inst alling the software on the[...]

45 8 Displays and T r oubleshooting 8.1.1 Signalling 1. OFF pushbutton Press t he b utton f or approx. 2 seconds t o switch off the UPS. 2. ON button: Press the button f or approx. 2 seconds to switch th e UPS on. Deactivate acoust ic alarm : Pres s the button during the alarm for approx. 2 secon ds to switch off the alarm . UPS test : Press this b[...]

46 6. Line LED (mains st atus): T he green LED lights up when the m ains voltage pres ent is within the specified tolerance ra nge. If this LED flashes, either the UPS co nnection has an incorr ect pin assignment (obser ve phase sequence / neutral conductor connect ion position) or th e mains is outside of the specif ied tolerance rang e. 7. to 11.[...]

47 8.1.2 Overview Table of LED Displa ys / Acoustic Warn ing Signals LED displa y (see chapter 8 on page 47) No. Operating mode Warning signal 1 0% – 35% utilisation none 2 36% – 55% utilisation none 3 56% – 75% utilisation none 4 76% – 95% utilisation none 5 Normal mode (mains present) 96% – 105% utilisation none 6 0% – 20% capacity 1 [...]

48 Overview table of LED displays / w arning signals, c ont. LED displa y (see chapter 8 on page 4 7) No. Operating mode Warning signal 19 Short-circuit output side Conti nuous warning signal 20 BUS voltage abn or mal Continuous warning signal 21 DC circuit faulty; poss. battery fault 1 acoustic signal per sec. 22 Battery charger faulty Conti nuous[...]

49 8.2 Faults PROTECT 1. outputs detai led error messages b y means of which you or th e service personnel ca n quick ly and accuratel y localise and interpret an y m alfunctions that occur. You can find s uggestions for actio n / solutions in the f ollowing t o correct problems using error desc riptions according to chapter 8.1.2: 8.2.1 Error Mess[...]

50 Message / display Cause So lution Duration of the emergency pow er supply shorter than setpoint. Batteries not completely charged / batteries aged or faulty. Charge the batterie s for at least the rechar ging time acc. to chapter 2.3, and check their capa city. If the problem re mains, contact your de aler. “Line” LED and “Faul t” LED li[...]

51 9 Parallel Operation 9.1 Principle of Operation P R O TE C T 1. h a s be en d e si gn ed fo r p ar al le l op er at i on wi th n+ x te ch no lo gy (“ n ” he re st an d s fo r th e nu mbe r of un i t s re q u i re d fo r l o a d su p p ly , “ x” f o r t he d e g ree o f r ed un da ncy ). U p to 3 un it s o f t he s a me ty pe ca n be c on[...]

52 The activ ely red unda nt pa rall el operati on automat ically swi tch es to power- inc reas ing operati on if the outpu t powe r req uirement exceed s the UPS sin gle blo ck power , i.e . the deg ree of re dund ancy is decr ea sed or is co m pl etely elimi na ted . Con ver sely , the active UPS redun dan cy degre e automat ically in crea se s a[...]

53 communication of the units switched in parallel tak es place via the 25-p in parallel o peration c able(s) include d in the scope of deliver y. For t hi s purpo se, first remov e the parall el port cove rs (no . 5, p. 26 /27 ) and connect the UPS unit s wi th each othe r wi th one par allel operat ion cabl e each. Use one paral lel ope rat ion c[...]

54 each UPS are in the “Bypass” position and all mains input m iniature c ircuit break ers (no. 2, p. 26/27) on the back of each UPS ar e in t he “O FF” position. 4. Check the position of the central ex ternal m anual bypass. This m ust be in th e “ Bypass” position, i.e. supply of the load busbar by the sup plying mains. 5. Now close a[...]

55 7. N o w a c t ua t e t h e ma i n s i np u t mi ni a tu re c i r c u it b re a ke r s ( n o. 2 , p . 2 6 /2 7 ) on ea ch U PS on e af te r t h e o t he r . Move them to the "ON" position. 8. Move the “m aintenance sw itch” m anual bypass switches (no. 3, p . 26/27) on the b ack of each UPS to the “ UPS” position. Fina lly, f a[...]

56 11. W hen the displ ays are lit as desc ribed, s witch on your loads one after the other. W hen doing this, take care not to exceed the m aximum perm itted load capacit y of the UP S system s. Also tak e into account the reserve capacities if active redundanc y should be required. 9.3.2 Changes to the pa rallel system If you would like to add a [...]

57 10 Maintenance The PROTECT 1. c onsists of state-of -t he-art, non- wearing components. W e do, however, recom mend visual chec ks (above al l batter y and fan c hecks) at regular intervals (at least every 6 m onths) to m aintain contin uous availability and operational reliab ility. CAUTION! Ensure that the work area is c ordoned off and always[...]

58 CAUTION! PROTECT 1. must be disconnect ed from the power suppl y prior to carrying out the f ollowing work. If large quantities of dust have acc umulated, the unit should, as a precaution, b e cleane d with dry com pressed air, in order to ensure adequate heat dis sipation. The intervals at which visual c hecks should be perf ormed are largely d[...]

59 11 Sto rage, Disma ntling and Disp osal 11.1 Storage Long s torage t imes without ch arging or discharging the batter y at regular intervals m ay lead to perm anent damage of the batter y. If the batter y is stored at room temperature (20 C to 30 C), it will automatical ly discharge at a r ate of 3 -6% per month du e to in ternal reactions. Stor[...]

60 12 List of T erms 12.1 Technical terminology DC/DC booste r Circuit technolo gy for increasing a DC voltage to a higher voltage lev el SBS S tatic Bypass Switch Appliance protectio n Term from overvoltag e technology Cla ssic ma ins over voltage pr ote cti on c ons ists o f a lig htning s urge ar res ter (c las s B) , o verv olt age pro tect ion[...]

61 Guarantee Certificate T y pe: …….……………… …................ ............................ .......... Unit number: ……… ….……………......... ........................ ......... Date of purchase: .… ……………… ...........…………… ………. Dealer stam p / signature Errors and changes excepted. AEG Power[...]