AEG PROTECT 1.100 manual

UPS OPERATING INSTRUCTIONS PROTECT 1.100 PROTECT 1.150 PROTECT 1.200 PROTECT 1.[...]

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3 Thank you for deciding to purchas e the PROTECT 1. UPS from AEG Po wer Supply Sy stems. The following safety instruction s are an important part o f the operating instructio ns are will protect you against problems from operating errors and possible dangers. Please read these i nstructions care fully prior to commissioning![...]

4 1 Notes on these Operating Instructions Duty to provide information These operating instructions will hel p you to install and operate the U ninterruptible P ower S upply (UPS), PROTECT 1.100, PROTECT 1.150 or PROTE CT 1.200 as well as the corresponding external battery unit s PROTECT 1.100 BP o r PROTECT 1.BP20, all referred to as PROTECT 1 in t[...]

5 consequential damage. AEG will rescind all obligations such as warranty agreements, service cont racts, etc. ente red into by AEG or its representatives without prio r notice in the event of maintenance and repair work being carri ed out with anything other than original AEG pa rt s or spare parts purchased from AEG. Handling PROTECT 1. is design[...]

6 Table of Contents 1 Notes on these Operating Instructions ............................. 4 2 General Info rmation .......................................................... 8 2.1 Technology ................................................................ 8 2.2 System Description .................................................. 10 2.3 Technical d[...]

7 5.4.2 Connection of the battery cubicle PROT ECT 1. BP20 .................................................................. 36 5.5 Mechanical blocking of the PROTECT 1. ................ 37 6 Start-Up ........................................................................... 38 6.1 Operating modes .................................................[...]

8 2 General Information 2.1 Technology i PROTECT 1. is an U ninterruptible P owe r S upply (UPS) for essential loads such as small data centres, serve rs, network components, telecommunications equipment and similar units. It consists of: ♦ Mains filter with overvoltage protection (applia nce protection / class D) and mains e nergy backfeed prote[...]

9 Manueller Service - By pass Manual service bypass Elektron. Verriegelung Electronic locking EUE SBS PFC PFC Netzfilter Mains filter Last Load Netz Mains Filter Filter Gleichrichter Recti fier Wechselrichter Inve rter DC/ DC Booster DC/DC booster Ladegleichrichter Battery charger DSP Regelungslogik DSP control logic Komponentendarstellung Componen[...]

10 2.2 System Description The UPS is connected between the public utility mains and the loads to be protected. The power section of the rectifie r converts the mains voltage to DC voltage for supplying the inverter. The circuit technology used (PFC) enables sinusoidal current consumption and therefore operation with little system disturbance. A sep[...]

11 The greatest possible supply reli ability of connected loads is attained by the parallel connection of up to max. three PROTECT 1. UPS systems. The n+x technology thus guarantees maximum reliability through up to dou ble active redundancy on the one hand as well as on the other hand the possibility of increased power with simple redundancy or ev[...]

12 2.3 Technical Data Type rating PROTECT 1.100 10000 VA (cos ϕ = 0.7 ind.) 7000 W PROTECT 1.150 15000 VA (co s ϕ = 0.7 ind.) 10500 W PROTECT 1.200 20000 VA (co s ϕ = 0.7 ind.) 14000 W UPS input 3ph~ / N / PE Rated connection voltage 400 V/ 230 VAC Voltage range without 304 VAC – 478 VAC ± 3 % battery operation (rectifier) 176 VAC – 261 VAC[...]

13 Overload behaviour Up to 105% continuous; with mains supply > 105% – < 130% for 10 m in. 130% for 1 s Following this, automatic, uninterrupted switchover to integrated bypass (SBS). Switch-off after 1 min if overload continues to be present. (Switch back if overload decreases = load < 90%) Overload behaviour with Up to 105% continuous[...]

14 Communication Interfaces RS232 Sub-D (9-pin) Additionally: Communication slot for expansions (e.g. AS/400 / USB / remote signal indicator / SNMP, …) Shutdown software on CD “CompuWatch” for all com mon operating systems, e.g. Windows, Linux, Mac, Unix, FreeBSD, Novell, Sun General data Classification VFI SS 111 acc. to IEC 62040–3 Sustai[...]

15 Housing colour: Blackline Weight: PROTECT 1. 100 39 kg PROTECT 1. 150 55 kg PROTECT 1. 200 55 kg PROTECT 1. 100 BP 135 kg 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 PROTECT 1. meets the product s[...]

16 3 Safety Regulations 3.1 Important Instructio ns and Explanations The instructions for ope ration and maint enance, as well as the following safety regulations must be complied with to ensur e the safety of personnel as well as the continued av ailability of the unit. All personnel installing/dismantling, starting up, operating or servicing the [...]

17 ♦ Verify that the unit is disconnected from the power supply ♦ Earth and short-circuit the unit ♦ Provide protection by covers or barriers for any neighbouring live parts 3.3 Qualified Personnel The PROTECT 1. may only be tran sported, installed, connected and serviced by qualif ied personnel who are familiar with the pertinent safety and [...]

18 The PROTECT 1. may only be operate d with or connected to a three-phase power syste m with protective grounding u sing a mains connection cable wi th PE conductor that has been tested according to German stan dards (VDE). Risk of burning! The batter y has powerful short-circuit currents . Incorrect connection or i solation faults can lead to mel[...]

19 ♦ Do not connect household appliances such a s hairdryers to the UPS! Also take care when working with motor loads. It is essential to avoid back-feeding the inverter, e.g. if the load is intermittently operated in regenerative mode. Danger! Electric shocks! Even after the mains voltage has been disconnected, the compo nents within the UPS rem[...]

20 i Avoid using multiple outlet adapte rs with a central on/off switch as protection against uncontrolled load switch-off as well as for avoiding peak inrush cu rrents. Switch OFF the UPS using its main switch if you do not intend to use it for som e time. PROTE CT 1. must be switched off every evening if the electricity supply in your company is [...]

21 3.5 CE Certificate[...]

22 4 Set-up 4.1 Unpacking and Inspection The unit has been co mpletely checked and inspecte d. Although the unit has been packed and shi pped with the usu al care, transport damage cannot be completel y excluded. i Any claims due to transport damage must always be asserted against the transp ort company! Check the shipping container for damage on a[...]

23 Please keep plastic packa ging bags away from babies and children in order to safeguard again st suffocation accidents. Handle the components with care. Please take into a ccount the weight. It may be necessary to engage the help of a seco nd person. 4.2 Transport to Installation Site The PROTECT 1. is eq uipped with transport roll s for easy tr[...]

24 ♦ The contact surface must be smooth and level. It must also be sufficiently strong a nd sturdy to avoid vibration and shocks. ♦ Make sure that the mounting is able to sup port the weight, especially in conjunction with external b attery units (special accessories). ♦ Set up the units so that adequate air ci rculation is assured. There mus[...]

25 4.4 Overview: Connections , Operating / Display Elements 4.4.1 Front view PROT ECT 1 .100 PROTECT 1 .150 PROT ECT 1 .200 PROTECT 1.100BP PROTECT 1.BP20[...]

26 4.4.2 Display 1. OFF pushbutton 2. ON pushbutton / alarm off 3. Orange-coloured Bypass LED 4. Green Inverter LED 5. Orange-coloured Battery LED 6. Green Line LED 7 – 11. Bar graph LED (7-10 green, 11 orange -coloured) for UPS capacity utilisation or remaining bat tery capacity 7 . LED load (0-35%) battery capacity (96-100%) 8. L E D load (36-5[...]

27 4.4.3 Rear view (connections): PROT ECT 1 .100 PROTECT 1.150 / 1.200 1 2 3 4 5 6 7 8 N L 1 L 2 L 3 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 L 1 L 2 L 3 + - L N JP1 JP2 1.1 1.3 1.2 11 13 9 10 11 12[...]

28 Explanations : 1. Connection terminal cover for mains/UPS input (1.1) and output (1.3), additional pair of terminals for setting individual or parallel operation (1. 2); Battery connection terminals (PROTECT 1.150 / 1.200) 2. Mains input miniature circuit breaker 3. Manual bypass switch 4. Socket for external battery module (PROTECT 1.100) or co[...]

29 5 Electrical Connection Caution Prior to commencing work, en sure that the connection cables are de- energised and that it is not possible to activate the power suppl y. i In order to avoid deformation of the supporting rail and to protect the base of the connectio n terminal against torsional forces, it is advisable to hold the cable in positio[...]

30 5.1 Safety of Personnel Note the following points when setting up the UPS system and its external battery units (special accessories): ♦ Disconnect the unit from the power supply ♦ Secure the unit against being switched back on ♦ Verify that the unit is disconnected from the power supply ♦ Earth and short-circuit the unit ♦ Provide pro[...]

31 ♦ Mount the connection cover of the cable clamping u nit. 5.2.2 Connection Cross-Secti ons and Fuse Protection The required dimensions can be found in the followin g table: PROTECT 1.100 PROTECT 1.150 * PROTE CT 1.200 * Max. current consumption (bypass) 46A 68A 91A Incoming mains cable (UPS input) min. max. 10 mm² 16 mm² 16 mm² 35 mm² 25 m[...]

32 5.3 Mains Connection 5.3.1 Preparation for the three -pha se main s connection Before connection work is performed on the UPS, make sure that: ♦ The values of the nominal voltage (supply) and frequency match those on the nameplate of the UPS. ♦ The earth connection ma t ches the prescribed IEC standards or the local regulations, ♦ The UPS [...]

33 ♦ Put the mains input miniature circuit breaker (no. 2, p. 27/28) in the “OFF” position. Connect the UPS terminal “ / PE “ (earth) with the corresponding earth terminal in the distribution cabinet. Connect the supply cable from the MI distribution to the terminals 1.1 of the UPS that are marked with “INP UT”: / PE = Ground N = Neut[...]

34 5.3.4 Connection of the Loads In order to ensure the safety of personnel during ins tallation work, make sure that the con nections are made un der the following conditions: ♦ No mains voltage present. ♦ The loads are switched off. ♦ UPS is switched off (dis play completely blank). To disconnect the PROTECT 1., carry out the following step[...]

35 5.4.1 Connection of the Batte ry Cubicle PROTECT 1.100 BP This battery cubicl e is completely preconfigured. The connection to the UPS unit is ready to be plugged in as a result of the supplied battery connection ca ble. PROTECT 1.100 with 1 batter y unit PROTECT 1.100 BP i PR OT E CT 1. 10 0 BP is o nly intended for connection to the UPS type P[...]

36 5.4.2 Connection of the Batte ry Cubicle PROTECT 1. BP20 Fig.: Rear view of the PROTECT 1.BP20 with cover removed. The battery cubicle is supplied with a separate battery string and separately enclose d battery fuses for safety and transport protection reasons. Pleas e also note the separate documentation enclosed with the battery cubicle. After[...]

37 If the battery cubicle is used in connection with the PROTECT 1.1.50 or PROTECT 1.200, the strai n relief is implemented with clamps. The battery system can now be activated. To do this, insert the two fuses  . As the last step, fasten each co ver that was initially removed. Fig.: PROTECT 1.BP20 in connection with the PROTECT 1.100 i PROTECT [...]

38 6 S t art-Up Compare the setting of the nomi nal output voltage of the UPS with the rated voltage valid in your country. The factory presetting is 230 V. Cha nges to 220 VAC o r 240 VAC can be made with the software “CompuWatch”. Switching on the PROTECT 1. on the mains 14. Make sure that all connections have bee n made according to the inst[...]

39 i Please shut down the entire sy stem again if you cannot solve a problem that occurs. To do this, press the OFF pushb utton for approx. 2 secon ds. Disconnect the UPS from the mains by actuating the mains input miniature circuit bre aker (no. 2, p. 27/28). Please contact our hotline (se e p. 5). 21. Whe n the displays are correctly lit as descr[...]

40 Once you have connected the UPS to a suitable main s connection, you can start operation usi ng the UPS main switch. Normally, the UPS operates co ntinuously. The UPS now supplies the output with v oltage, wh ich is sig nalled by the mains symbol (Line LED) and the invert er sym bol (Inverter LED) being lit. This operating mode, generally referr[...]

41 Energiefluss bei gestörtem Netz Power circuit with faulty mains supply Handumgehungspfad Manual bypass path Netz Mains GR REC EUE SBS WR INV Netzeingangssiche rungsautomat Mains input miniature circuit brea ker Lade GR Load REC Handumgehung Manual bypass Gesicherte Schiene Secured busbar Schematische Darstellung Schematic diagram Batterie Batte[...]

42 automatically. The supply of the inverter through the mains is resumed and the battery charger charge s the battery. The bar graph LED (LE D chain above the pictograph) indicates the remaining battery capacity durin g this operating mode (see chapter 8, p. 48 ff). 6.1.3 Bypass Operation Batterie Lade GR GR WR Hand- umgehung Handumgehungspfad EUE[...]

43 Bypass Line Inverter Battery This so-called passive redund ancy protects against the total failure of the voltage supply on the secu red busbar; however, in this operating mode, mains faults would directly affect the load. As a result, the el ectronics contin uously attempt to swit ch back to "online" / normal operating mode (e.g. when[...]

44 6.1.4 Manual Bypass Energiefluss bei aktivierter Handumgehung Powe r circuit with activated manual bypass Handumgehungspfad Manual bypass path Netz Mains GR REC EUE SBS WR INV Netzeingangssiche rungsautomat Mains input miniature circuit brea ker Lade GR Load REC Handumgehung Manual bypass Gesicherte Schiene Secured busbar Schematische Darstellun[...]

45 6.1.5 Unit overload The load on the UPS should never exceed the sp ecified rated load of the unit. If a unit overload occurs ne vertheless (from 105% of the specified unit rated lo ad) then t he Fault LE D light s up and an acoustic sig nal sounds (twice per s econd). The connected loads continue to be sup plied for a certai n length of time dep[...]

46 7 Interfaces and Communication 7.1 Computer Interface RS232 For the control of the UPS and convenient reading of status messages and measured values, various interfaces are available. The interface protoc ol is designed for operation with the "CompuWatch" shutdown and UPS management software from AEG. Use the supplied RS232 communicati[...]

47 The "Com puWatch" shutdown software suppo rts different operating systems, e.g. Windows 98SE/ME, Windows NT/2000/XP, Windows Vista, Linux SUSE, Linux RedHat, Novell Netware, IBM AIX, HP-U X, SUN Solaris, Mac OS, and others. Example of a “CompuWatch” screen Refer to the manual on the CD for d etails about installing the software on [...]

48 8 Displays and T roubleshooting 8.1.1 Signalling 22. OFF pushbutton Press the button for approx. 2 seconds to switch off the UP S. 23. ON button: Press the button for approx. 2 seconds to switch the UPS on. Deactivate acoustic alarm : Press the button during the alarm for approx. 2 seconds to switch off the alarm. UPS test : Press this button du[...]

49 27. Line LED (mains status): The green LED lights up when the mains voltage present is withi n the specified tolerance range. If this LED flashes, either the UPS connection has an inco rrect pin assignment (observe phase sequence / neutral conductor connection position) or the mains is o utside of the specified tolerance range. 28. to 11. Bar gr[...]

50 8.1.2 Overview Table of L ED Displays / Acoustic Warning Signals LED display (see chapter 8 on page 47) No. Operating mode Warni ng 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 a[...]

51 Overview table of LED display s / warning signals, cont. LED display (see chapter 8 on page 47) No. Operating mode Warning signal 19 Short-circuit o utput side Continuous warni n g si g nal 20 BUS voltag e abnormal Continuous warni n g si g nal 21 DC circuit faulty; poss. battery fault 1 acoustic signal per sec. 22 Battery char ger faulty Contin[...]

52 8.2 Faults PROTECT 1. outputs d etailed error messages b y means of which you or the service personnel ca n quickly and accurately localise and interpret any malfunctions that occur. You can find suggestions for action / solutions in the following to correct problems using error d escriptions according to chapt er 8.1.2: 8.2.1 Error Messages Mes[...]

53 Message / display Cause Solution Duration of the emergency power supply shorter than setpoint. Batteries not completely charged / batteries aged or faulty. Charge the batteries for at least the recharging time acc. to chapter 2.3, and check their capacity. If the problem remains, contact your dealer. “Line” LED and “Fault” LED light up, [...]

54 9 Parallel Operation 9.1 Principle of Operation PROTECT 1. has bee n designed for parallel o peration with n+x technology (“n” here stands for the number of units required for load supply, “x” for the degree of redu ndancy). Up to 3 units of the same type can be connecte d in parallel here to i ncrease the output power and/or achieve hig[...]

55 This results in the following co nstellations with n+x technology: 1 + 0 Use of 1 unit max. 10, 15 or 20 kVA No redundancy 1 + 1 Use of 2 units max. 10, 15 or 20 kVA Single redundancy 1 + 2 Use of 3 units max. 10, 15 or 20 kVA Double redundancy (max. expansion level) 2 + 0 Use of 2 units max. 20, 30 or 40 kVA No redundancy 2 + 1 Use of 3 units m[...]

56 The UPS outputs are each connected with the parallel operation busbar via an isolator. The instructions from chapter 5 apply here too. The following always holds true fo r the UPS input and output conductors: The differenc e in length in co nductors up to 20 m per UPS can be max. 20% and max. 10% for l engths > 20 m per UPS. The jumper instal[...]

57 9.3 Operation of the UPS in a parallel system The start-up process i s uncomplicated, does not require any prior knowledge and i s basically oriented to the pro cedure described in chapter 6. If you have obtained the parallel operation board from AEG Power Supply Systems, you can find fur ther spec ial i nstr ucti ons th ere. The displays in the[...]

58 1 9 . Now actuate the mains input miniature circuit breakers (no. 2, p. 27 /28) on each UPS one after the other. M o v e them to the "ON" position. 20. Move the “maintenance switch” manual bypa ss switches (no. 3, p. 27/28 ) on the back of each UPS to the “UPS” position. Finally, fasten the covers on each UPS again using the 4 [...]

59 23. When the display s are lit as describe d, switch on your loads one after the ot her. When doing this, take care not to exceed the maximum permitted load capacity of t he UPS sy stems. Al so take into accoun t the reserve capacities if active red undancy should be required. 9.3.2 Changes to the parallel system If you would like to add a UPS t[...]

60 10 Maintenance The PROTECT 1. consists of state-of-the-art, non-wearing components. We do, however, recommend visual checks (above all battery and fan chec ks) at regular intervals (at least every 6 months) to maintain continuous availability and operational reliability. CAUTION! Ensure that the work area is co rdoned off and always observe the [...]

61 CAUTION! PROTECT 1. must be disconnected from the power supply prior to carrying out the following work. If large quantities of dust h ave a ccumulated, the unit sh ould, as a precaution, be cleaned with dry co mpressed air, in orde r to ensure adequate heat dissipation. The intervals at which visual checks should be p erformed are largely deter[...]

62 11 S torage, Dismantling and Disposal 11.1 Storage Long storage times without charging or discharging the battery at regular intervals m ay lead to permanent damage of the battery. If the battery is stored at room te mperat ure (20 C to 30 C), it will automatically discharge at a ra te of 3-6% per mo nth due to internal reactions. Stori ng the b[...]

63 12 List of T erms 12.1 Technical terminology DC/DC booster Circuit technology for increa sing a DC voltage to a higher voltage lev el SBS S tatic B ypass S wi tch Appliance protection Term from overvoltage technology Classic mains overvoltage pr otection consists of a lightning surge arrester (class B), overvoltage protection (class C) and, fina[...]

64 Guarantee Certificate Type: …….……………….…............... .............. ........... .............. Unit number: ………….…..…………… ............... ........... .....::::::: Date of purchase: ……………………...........……………………. Dealer stamp / signature Errors and chang es excepted. AEG Power [...]