Emerson 7400 manual

Single Phase UPS system S i n g l e m o d u l e a n d ‘1 + N’ ( e x p a n d a b l e ) U s e r M a n u a l UNINTERRUPTIBLE POWER SYSTEM EMERSON Network Power (India) Pvt. Ltd.[...]

Dear Customer, Please accept our thanks for giving us the privilege to serve you by choosing a Liebert make ‘UPS’. If this is your first Liebert UPS, we hope it is the beginning of a long relationship which delivers value to your organisation. If you al ready own and use a Liebert, we are doubly honoured by your decision of continuing this rela[...]

This manual contains information concerning the installation, operation and maintenance of the Series 7400 1Phase Uninterruptible Power System (UPS) for the single module and one plus one Systems. All relevant parts of the manual should be read prior to commencing installation. The UPS must be commissioned by an en gineer approved by the manufactur[...]

REGISTERED AND HEAD OFFICE REGISTERED AND HEAD OFFICE EMERSON NETWORK POWER (INDIA) PVT. LTD. PLOT NO. C - 20, ROAD NO. 19 WAGLE INDUSTRIAL ESTATE THANE – 400 604 MAHARASHTRA ,INDIA TELEPHONE: (00 91 22) 5807000 / 5802388 FAX: (00 91 22) 5800829 / 5828358 Z O N A L O F F I C E S MUMBAI B 414 - 424, Bhaveshwar Arcade, (opp. Shreyas cinema), LBS Ro[...]

Branch Offices: BARODA 39 / 2, Arunodaya Society, Alkapuri, BARODA - 390 005 Tel : 0265 - 314296, 330383 Fax: 0265 - 314296, 330383 JAMSHEDPUR Kashi kunj, Road no. 2, Gr. Floor Contract or’s area, Bistupur; JAMSHEDPUR – 831 001 Tel : 0657 - 437549 Fax: 0657 - 437549 CHANDIGARH SCO - 198 / 199 / 200, Sector – 34A, Near Labour Chowk, CHANDIGARH[...]

Safety Procedure WARNING This is a class A UPS product. In a domestic environment, this product may cause radio int erface in which case the user may be required to take additional measures. WARNING HIGH EARTH LEAKAGE CURRENT: EARTH CONNECTIONS IS ESSENTIAL BEFORE CONNECTING THE INPUT SUPPLY. This equipment must be earthed in accordance with local [...]

GENERAL As wit h other types of high power equipment, dangerous voltages are present within the UPS and battery enclosure. The risk of contact with these is minimised as the live component parts are housed behind a hinged, lockable door. Further internal safety screens make the equipment protected to IP20 standards. No risk exists to any personnel [...]

1 General Description 1 1.1 Introduction 1 1.2 Design Concept 1 1.2.1 Redundant vs Non redundant configurati on 1 1.2.2 7400 Module Design 2 1.2.3 Bypass Supplies 3 1.2.4 UPS Power Switch Configuration 4 1.2.5 Battery circuit breaker 4 1.2.6 One plus one parallel control 7 1.2.7 Common Battery 9 1.2.8 Operator Control Panel 10 1.2.9 Battery Circuit[...]

4 Optional Equipment 35 4.1 AS400 Interface Board (#10021512003) 36 4.1.1 AS400 Interface board outputs 36 4.1.2 Remote control inputs 36 4.1.3 Calibration 36 4.2 4 - Way AS400 Interface Board (#100201120004) 38 4.2.1 Remote control inputs 38 4.2.2 Calibration 38 4.3 Output Interface (Remote alarms) Board (#1002151 20007 & #100215120002) 40 4.3[...]

1 Series 7400 Single Phase 1+N U PS 1.1 Introduction The Uninterruptible Power Supply system is connected between a critical load, such as digital drives & automation, distributed digital Process Control System, telecom equipment, programmable logic controller, mission critical applications , computer, and its three phase mains power supply. Be[...]

2 Series 7400 Single Phase 1+N U PS As prev iously mentioned, each of the two modules forming the one - plus - one system is basically a standard single module 7400 series UPS. This section describes an individual module’s operating principles - the effects of the additional parallel control facilities on the standard module are described later. [...]

3 Series 7400 Single Phase 1+N U PS The circuit block annotated ‘Static Switch’ in figure 2 contains an electronically controlled switching circuit, which enables the critical load to be connected either to the Inverter output or to a Bypass power source via the ‘static bypass line’. Normally, the load is connected to the inverter; but in t[...]

4 Series 7400 Single Phase 1+N U PS Figure 2 illustrates what is known as the “ Split Bypass” config uration. This is the standard configuration for all 1PH Models In the “ Split Bypass ” configuration the static bypass line is switched by a separate isolator to a dedicated ‘Bypass’ power source which also feeds the maintenance bypass l[...]

5 Series 7400 Single Phase 1+N U PS Figure 3A: Power Isolator ide ntification for 230V output system 10/ 40 kVA 50 kVA 60/ 80 kVA 105 kVA I2 Output Isolator I3 Maintenance Bypass Isolator I4 Static Bypass Isolator I1 Input Isolator 830 830 I4 Output Isolator I3 Maintenance Bypass Isolator I2 Static Bypass Isolator I1 Input Isolator I4 Output Isolat[...]

6 Series 7400 Single Phase 1+N U PS I2 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 830 830 I4 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 900 900 I4 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 1250 1250 I4 Output Isolator I3 Maintenance Bypass Isolator I1 Input Isolator 1400 1400 Figure[...]

7 Series 7400 Single Phase 1+N U PS When two of the standard 7400 modules just described are connected together to f orm a one - plus - one system, each module is fitted with an additional circuit board which allows the two modules to communicate with each other. Communication takes place via a single ribbon cable connected between the modules as i[...]

8 Series 7400 Single Phase 1+N U PS Battery charge current sharing: The illustration in figure 4 shows a dedicated battery installat ion for each module; however, it is possible to fit an option kit which allows the two modules in a one - plus - one system to share a common battery. Such an installation is shown in figure 5 overleaf. Figure 4: Para[...]

9 Series 7400 Single Phase 1+N U PS A “Common batt ery” option kit contains a DCCT (DC Current Transformers) which are fitted to the battery power lines and monitored by the parallel control logic. Each module monitors its battery charge current and compares it with the charge current provided by the other module. This enables a module to match[...]

10 Series 7400 Single Phase 1+N U PS The operator control panel is divided into three functional areas; ‘Mimic indications’, Control switches’ , and ‘LCD display panel’. Mimic Indications Six LEDs are mounted on a single line diagram to represent the variou s UPS power paths. These LEDs, which are annotated in figure7, show the current UP[...]

11 Series 7400 Single Phase 1+N U PS LS5 - Load on bypass: This led illuminates when the output isolator is closed and the load is connected to the bypass via the static switch. LS6 - Load on Inverter: This led illuminates when the output isolator is closed and the load is connected to the inverter via the static switch. Control switches Seven tact[...]

12 Series 7400 Single Phase 1+N U PS Switch S7 - Inverter ON: Pressing this switch activates the inverter and causes the load to be transferred to the inverter side of the static switch after the inverter voltage has had time to stabilise. Switch S8 - E mergency Stop: When the emergency stop switch is pressed it disables the static switch block ent[...]

13 Series 7400 Single Phase 1+N U PS LCD Display An LCD display, capable of showing two rows of 40 c haracters, is used to indicate the UPS operating parameters, warnings and alarms. A DIP switch fitted to the display microprocessor board enables the displayed language to be easily selected to English, French, Italian, Spanish or German. The lower [...]

14 Series 7400 Single Phase 1+N U PS 1.3 Safety Precautions In common with other types of high power equipment, dangerous voltages are present within the UPS and battery enclosure. The risk of contact with these voltages is minimised as the live component parts are housed behind a hinged, lockable door. Further internal safety screens make the equi[...]

15 Series 7400 Single Phase 1+N U PS 2.1 Introduction Starting and stopping the one - plus - one system is straightforward, however the modules’ response depends on whether it is configured as a Redundant or Non - Redundant system. The operating procedures are the same irrespective of the selected redundancy mode; in simple terms you start (stop)[...]

16 Series 7400 Single Phase 1+N U PS How to turn ON the System from a Shut down condition (Complete this actions on one module at a ti me) This procedure should be followed when turning on the one - plus - one system from a fully powered down condition - i.e. where the load is not being initially supplied through the internal Maintenance Bypass sup[...]

17 Series 7400 Single Phase 1+N U PS How to turn ON the Sys tem from a Maint. power - down condition (Complete this action on module at a time) This procedure should be followed to start the one - plus - one from a MAINTENANCE power - down condition - i.e. where the load is being initially powered through the internal maintenance bypass supply. Ste[...]

18 Series 7400 Single Phase 1+N U PS Mimic panel LEDs LS4 and LS6 should extinguish on both modules and LS5 should illuminate to show that the load has been transferred to the static bypass line. Note: On a redundant system both Inverter OFF switches (S6) must be operated before LS5 illuminates but in a non - redundant system the Inverter OFF switc[...]

19 Series 7400 Single Phase 1+N U PS IMPORTANT The Maintenance Bypass Isolator may be operated at any time when the UPS is powered down to connect / disconnect eac h load to the raw maintenance bypass supply if required. Emergency Stop The emergency stop pushbutton is located behind a hinged safety shield to prevent inadvertent operation. When this[...]

20 Series 7400 Single Phase 1+N U PS[...]

21 Series 7400 Single Phase 1+N U PS 3.1 Introduction WARNING Do not apply electrical power to the UPS equipment before the arrival of the commissioning engineer WARNING The UPS equipment should be installed by a qualified engineer in accorda nce with the information contained in this chapter and the drawing package shipped inside the UPS cabinet. [...]

22 Series 7400 Single Phase 1+N U PS The UPS cabinets can be moved by fork lift or crane. Fork lift apertures are provided in the sides of the base plate and are accessible after removing blanking covers fitted to the side panel ventilation grills. Roof - mounted eye - bolts are fitted to enable the cabinet to be crane - handled. These can be remov[...]

23 Series 7400 Single Phase 1+N U PS In 25kVA to 125 kVA module installations the batteries associated with the UPS equipment are usually contained in a purpose - built battery cabinet/ r ack which sits alongside the main UPS equipment. Sealed, maintenance - free batteries are normally used in this type of installation. Due to their increased capac[...]

24 Series 7400 Single Phase 1+N U PS Note: If ‘side’ cable entry is to be used ensure that the blanking plates are removed before finally fixing the cabinet position. 5. All UPS models have a stabilising bar fitted to t he output transformer T1 and input choke L1 during shipment. This should be removed when the UPS has been placed in its final [...]

25 Series 7400 Single Phase 1+N U PS 3.3 Connecting UPS Power Cables WARNING Ø Before cabling - up the UPS, ensure that you are aware of the location an d operation of the external isolators that connect the UPS Input / Bypass supply to the mains distribution panel. Ø Check that these supplies are electrically isolated and post any necessary warn[...]

26 Series 7400 Single Phase 1+N U PS In the 25 - 40kVA UPS 1 PH models the input mains / bypass cables, UPS output cables and battery cables are connected to busbars located behind a safety cover just below the power isolator switches - as shown in figure 11. A terminal block is used for connecting the control cables to the battery circuit breaker [...]

27 Series 7400 Single Phase 1+N U PS 6. Co nnect the safety earth and any necessary bonding earth cables to the copper earth busbar located on the floor of the equipment below the power connections. Note: - The earthing and neutral bonding arrangement must be in accordance with local and national c odes of practice. 7. Connect the battery circuit b[...]

28 Series 7400 Single Phase 1+N U PS Figure 11: Cable connection 25 - 40kVA, 230V, 1 Ph. Figure 12: Cable connection 50 kVA, 230V, 1 Ph. NU RU I1 I2 I3 I4 NS RS RI SI TI NU RU NI RI SI TI NS RS I1 I4 I3 I2 - +[...]

29 Series 7400 Single Phase 1+N U PS Figure 14: Cable connections for 105 kVA, 230V, 1 Ph. Figure 13: Cable connection 60 / 80 kVA, 230V, 1 Ph. U2 N2 I4 I3 I2 I1 U3 N3 NI UI VI WI RU NU RS NS RI SI TI + - I1 I2 I3 I4[...]

30 Series 7400 Single Phase 1+N U PS I1 I1 I3 I2 NS NU RU RS RI SI TI + - Figure 15: Cable connection 25 - 40kVA, 110V, 1 Ph. Figure 16: Cable connection 50kVA, 110V, 1 Ph. RU NU - + I1 I1 I3 I2 NS1 RS1 NS2 RS2 RI SI TI[...]

31 Series 7400 Single Phase 1+N U PS Figure 18: Cable connections for 105 kVA, 230V, 1 Ph. Figure 17: Cable connection 60 / 70 kVA, 110V, 1 P h. RU + - I1 NU NS RS RI SI TI I2 I3 + - I1 RI SI TI N2 N3 N2 U3 U2 I2 I3[...]

32 Series 7400 Single Phase 1+N U PS 3.5 Battery Circuit Breaker Boxes A battery circuit breaker box houses the battery circuit breaker and its controller board and is used to connect the battery to the UPS in installations where the batteries are not contained in the st andard battery cabinet. It is most likely used with 60 – 125 kVA UPS models.[...]

33 Series 7400 Single Phase 1+N U PS Usually the ‘box’ is fitted as close as possible to the batte ries. Figure 19 shows the details of the power and control cable connections between the circuit breaker box and UPS itself. These are similar to the connections made to the battery cabinet, previously described. As a safety precaution, remove the[...]

34 Series 7400 Single Phase 1+N U PS[...]

35 Series 7400 Single Phase 1+N U PS Several items of optional equipment are available for fitting to the 7400 series UPS for the use by the customer as required. These options are: o IBM AS400 Interface o IBM AS400 Interface with 4 - way output o Output Interface Board o Remote Alarms Board. o Input filter In additi on to these options, it is poss[...]

36 Series 7400 Single Phase 1+N U PS 4.1 AS400 Interface Board (#100215120003) The AS400 Interface board connects the five most oper ationally critical UPS alarms to an IBM AS400 computer, which is designed to monitor such alarms and respond to their appearance: * Mains failure * Load on inverter * Low battery and/or battery circuit breaker open * [...]

37 Series 7400 Single Phase 1+N U PS TB - M2 TB - M1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Synchro off Inverter off Mains or Rectifier Failure Load on Inverter Low Battery Load on Mains Load on Maintenance Bypass Control Inputs RL1 - 2 RL2 - 2 RL3 - 2 RL4 - 2 RL5 - 2 A S 4 0 0 I N T E R F A C E B O A R D P a r t N o . 1 0 0 2 1 5 1 2 0 0 0 3 [...]

38 Series 7400 Single Phase 1+N U PS 4.2 4 - WAY AS400 Interface Board (#100201120004) The 4 - way AS - 400 Interface board connects fiver critical UPS alarms to four output terminal blocks M1 - M4 as shown in figure 22 . These alarm signals can be connected to a IBM AS 400 computer designed to monitor such alarms, or to a Remote Alarm Monitor pane[...]

39 Series 7400 Single Phase 1+N U PS 1 7 1 7 1 7 1 7 1 7 1 7 1 7 1 7 M2 M3 M4 M5 1 2 3 SH1 CN1 A S 4 0 0 I N T E R F A C E B O A R D P a r t N o . 1 0 0 2 0 1 1 2 0 0 0 4 2 3 4 5 Synchro off Inverter off TB - M1 Control Inputs RL7 RL9 RL6 RL8 RL10 1 Common 2 3 4 5 6 7 Mains or Rectifier Failure UPS On Low Battery Load on Mains Load on Maintenance B[...]

40 Series 7400 Single Phase 1+N U PS 4.3 Output Interface (Remote Alarms) Board (100215120007 & 100215120002) Two remote alarm boards, shown in figure 23 & 24, similar in funct ion and differing only in their connections to the terminal blocks M1 - M3, enable the alarm signals generated within the UPS to be connected by means of volt - free[...]

41 Series 7400 Single Phase 1+N U PS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M3 RELAY RELAY MAINS VOLTAGE OK RECTIFIER ACTIVE BATTERY OK PRE - ALARM END OF DISCHARGE INVERTER OK SYNCHRO OK LOAD ON UPS LOAD ON BYASS OVER TEMPERATURE OVERLOAD MAINT, BYPASS ENABLED STATIC BYPASS[...]

42 Series 7400 Single Phase 1+N U PS 4.4 Remote Alarm Monitor (RAM) for Sing le Module & “1 + 1” UPS System. This will contain following items: 1. Remote Alarm Monitor for Single Module #270154000001. 2. Remote Alarm Monitor for 1+1 Module #270154000003. This unit is always used in conjunction with Alarm interface PCB #100215120002, only. R[...]

43 Series 7400 Single Phase 1+N U PS Figure 25: Remote alarm monitors for single module and 1+1 configuration[...]

44 Series 7400 Single Phase 1+N U PS MAINS OK (BYPASS) RECTIFIER ACTIVE BATTERY OK END OF DISCHARGE INVERTER OK SYNCHRO OK LOAD ON UPS LOAD ON BYPASS OVER TEMPERATURE OVERLOAD MAINT. BYP. ENABLED STATIC BYPASS ISOLATOR CLOSED OUTPUT SWITCH CLOSED SYNCHRO INHIBIT INVERTER ON/OFF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M1 1 2 3 4 5 6 7 8 9 10 11 12 13 14[...]

45 Series 7400 Single Phase 1+N U PS MAINS OK (BYPASS) RECTIFIER ACTIVE BATTERY OK END OF DISCHARGE INVERTER OK SYNCHRO OK LOAD ON UPS LOAD ON BYPASS OVER TEMPERATURE OVERLOAD MAINT. BYP. ENABLED STATIC BYPASS ISOLATOR CLOSED OUTPUT SWITCH CLOSED SYNCHRO INHIBIT INVERTER ON/OFF OUTPUT INTERFACE PCB MOUNTED IN MODULE 1 1 2 3 4 5 6 7 8 9 10 11 12 13 [...]

46 Series 7400 Single Phase 1+N U PS[...]

47 Series 7400 Single Phase 1+N U PS 5.1 Introduction This chapter contains the procedures necessary to effect general maintenance of the UPS module and battery. Certain procedures entail ga ining internal access to the UPS, and should only be undertaken by a competent engineer who is familiar with the operation and layout of the equipment and unde[...]

48 Series 7400 Single Phase 1+N U PS Carry out the following checks from the mimic panel and log the results: 1. Measure and record the battery float charge voltage. 2. Measure and record the battery charge current. 3. Measure and record the UPS output voltage on all three phases. 4. Measure and record the UPS outpu t line currents. If these are si[...]

49 Series 7400 Single Phase 1+N U PS 6. Carry out a tho rough examination of the UPS power components and sub - assemblies, paying particular attention to the following - Electrolytic capacitors - Check for signs of leakage, buckling etc. Magnetic components - Check for signs of overheating, security of fi xture and signs of delamination. Cables an[...]

50 Series 7400 Single Phase 1+N U PS[...]

51 Series 7400 Single Phase 1+N U PS 6.1 Troubleshooting UPS systems The UPS contains complex electronic control circuits that require a firm understanding in order to carry out comprehensive fault diagnosis and repair of the equipment. The following information aims to provide a trained user with sufficient knowledge to understand the nature of a [...]

52 Series 7400 Single Phase 1+N U PS Corrective Action When all the indications have been noted, you should refer to the following fault interpretation charts and carry out the actions detailed against any led whose status is abnormal. If you are unsure as to how to undertake the actions detailed - or if several LED indications are abnormal and you[...]

53 Series 7400 Single Phase 1+N U PS LED NORMAL ACTIONS TO BE TAKEN IF ABNORMAL NUMBER STATE LS1 LS2 LS3 ON ON ON If this led is OFF it signifies a problem either with the incoming mains supply or the rectifier section. See accompanying alarm messages. Check the following: a) Input isolator is closed. b) Input supply voltage is within 20% of nomina[...]

54 Series 7400 Single Phase 1+N U PS ** Note that in one - plus - one system configured with a redundant module, it is possible for one of the two modules to shut down (due to fault for e xample) without turning on its static switch. In fact when in a redundant module configuration a module’s static switch is disabled whenever its partnering modu[...]

55 Series 7400 Single Phase 1+N U PS 6.2 Display Panel Message Interpretation The following table lists the various messages displayed on the operator panel together with a description of their interpretation. D ISPLAY MESSAGE INTERPRETATION EMERGENCY STOP INVERTER OFF OR FAILED OVERTEMPERATURE OVERLOAD BATTERY C/B OPEN OUTPUT C.B. OPEN RECTIFIER O[...]

56 Series 7400 Single Phase 1+N U PS DISPLAY MESSAGE INTERPRETATION UPS ON MAINTENANCE BYPASS INVERTER UNSYNCHRONISED BATTERY ON LOAD MAINS FAILURE LOAD ON BYPASS This is a status warning that the load is being powered through the m aintenance bypass line and is unprotected from mains supply abbreviations. Due to the fact that the UPS power supplie[...]

57 Series 7400 Single Phase 1+N U PS A N N E X U R E Inter Connection cable details Any system essentially needs UPS module. However many customers need auxiliary cubicles such as Input Isolation Transformers, Battery Current Sharing Kit, 1+1 Paralleling kit, Bypass SCVS / SVR or Bypass Line Transformers. In case any of the auxil iary cubicle or co[...]

58 Series 7400 Single Phase 1+N U PS[...]