AEG 1.04 manual

UPS OPERATING INSTRUCTIONS PROTECT 1.040 PROTECT 1. M[...]

2 Thank you for deciding to pur chase the PROT ECT 1.M UPS from AEG Power Solutions. The following safety instructions are an im portant part of the opera ting instructions are will protec t you against problems from operating errors and possible dangers. Please read the se instructions carefully prior to commissioning![...]

3 1 Notes on these Operating Instructions Duty to provide information These operating instru ctions help you to install and operate the U ninterruptible P ower S upply (UPS) PROTECT 1.M as well a s its USV modules PROTECT 1.040 and associated extern al battery units PROTECT 1.M BP (referred to below jointly as PROTECT 1.M) in accordance with its de[...]

4 warranty agreements, service cont ra cts, etc. entered into by AEG or its representatives without prior notice in the event of maintenance and repair work being carried out wit h anything other than original AEG part s or spare parts purcha sed from AEG. Handling PROTECT 1.M is designed and constructed so that all necessary steps for start-up and[...]

5 Table of Contents 1 Notes on these Operat ing Instructions ............................. 3 2 Introduction ....................................................................... 7 2.1 Product description ..................................................... 7 2.2 Technical Data.......................................................... 10 3 Safety[...]

6 7 Adding/Removi ng Modules ...................................... 33 7.1 Active Redundancy .................................................. 33 7.2 Installing and Remo ving UPS Modules .................... 33 7.2.1 Basic procedur e for installing a PROTECT 1.040 UPS module ... 34 7.2.2 Basic procedur e for removing a PROTECT 1.040 UPS module .. [...]

7 2 Introduction 2.1 Product description i PROTECT 1.M ("M" for modular structure) is a n U ninterruptible P ower S upply (UPS) for important loads such as small data centres, servers, network com ponents, telecommunication facilitie s and the like. The PROTECT 1.M connection to the mains ca n be either three or one-phase. The l oad co nn[...]

8 The PROTECT 1.M has been designe d for operating up to six UPS modules. Depending on the output power req uired, the unit is operated in norma l mode with between o ne and six modules installed. These modules can easily be installed, removed or replaced und er a very wide range of operating conditions. PROTECT 1.M uses a high-perfor mance communi[...]

9 disturbance. Separate battery char gers config ured with switch mode power supply techn ology are responsible for chargi ng or trickle-charging the battery connect ed in the intermediate circuit. The configuration of thes e charging rectifiers means the harmonic co ntent of the charging curre nt for the battery is almost zero, which increases the[...]

10 An integrated, manually operated bypass unit ensures an uninterrupted supply to the connected loads in the case of maintenance and/or service work. The internal electronic part (with the exception of the metal-clad manual bypass) can be disconnected via the mains input miniature circuit breakers. Fig.: Table showing the level of redundancy depen[...]

11 176 VAC – 264 VAC ±3% (Bypass) Frequency 50 Hz / 60 Hz (Automatic detection) Frequency tolerance ran ge ±4 Hz Current consumption at full load (max.) PROTECT 1.M (system) 44 A (3ph~) or 132 A (1ph~) / 155 A (Bypass) PROTECT 1.040 (module) 7.3 A (3ph~) or 22 A (1ph~) System distur bance factor λ ≥ 0.98 UPS output Nominal voltage output 220[...]

12 Battery Nominal DC voltage (intermediate circu it) 120 Vdc DC window 102 Vdc – 160 Vdc ±1% Trickle charge voltage 137 Vdc ±1 % Battery charging current (max.) 3.5 Adc per UPS module Communication Interfaces RS232 (Sub-D9) RS485 (Sub-D9 / RJ45) Additionally: Communication slot for optional expansion cards (e.g. AS/400 / SNMP, etc.) Shutdown s[...]

13 Site altitude Up to 1000 m at nominal output Use more than 1000 m above sea level results in the following reduction in output power: Housing colour Blackline Weight: PROTECT 1.M (chassis) 75 kg PROTECT 1.040 (module) 15 kg per module Dimensions W x H x D: PROTECT 1.M (chassis) 442 mm x 965 mm x 700 mm PROTECT 1.040 (module) 405 mm x 87 mm x 530[...]

14 3 Safety Regulations 3.1 Important Instructions and Explanations The instructions for ope ration and maint enance as well as the following safety regulations must be complied with to ensure the safety of personnel as well a s to ensure the continued availability of the unit. All per sonnel installing/dismantling, starting up, operating or servic[...]

15 ♦ 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 protection by covers or barriers for any neighbouring live parts 3.3 Qualified Personnel The PROTECT 1.M may only be transported, installe[...]

16 The output can be live, even when the UPS is not connected to the mains supply! For health and safety reasons, the uni t must be earthed correctly ! The PROTECT 1.M may only be operated with o r connected to three-phase or AC voltage power systems with protective grounding using a mai ns connection cable with PE conductor that has been tested ac[...]

17 UPS must be absolutely dry prio r to start-up. As a result, leave it to acclimatise for at least two hours. ♦ Never connect the mains input and the UPS output! ♦ Ensure that no fluids or foreign bodies can penetrate the housing! ♦ Do not block the air vents of the unit! Make sure, for example, that children do not insert any objects in the[...]

18 Batteries can cause elect ric shocks and high short-circuit c urrents. Therefore, take the following safety precautions when working with batteries: ♦ Take off watches, rings and other metallic objects ! ♦ Only use tools with insulated han dles! 3.5 CE certificate[...]

19 4 Set-up 4.1 Unpacking and Inspection The unit has been completely checked a nd inspected. Although the device has been packe d and shipped with the usual degree of care, damage du ring transport cannot be ruled out completely. i Claims for damage during tran sport must always be made with the transport company! Check the shipping container for [...]

20 2. Remove the foam from the unit (see Fig. 2); remove the plastic wrapping; 3. Remove the lower module and the foam from the frames (see Fig. 3); 4. Now, with the assistance of at least one other p erson, carefully lift the system cabinet off the pallet and move it to the installation location. Fig. 1 Fig. 2 Fig. 3 Attention Do not use a lowlift[...]

21 4.2 Transport to Installation Site The PROTECT 1.M is equipped with transport rolls for easy transport to the intended installation site. It is recommende d to install the UPS where: ♦ The connection wo rk can be convenien tly carried out; ♦ There is enough space for proper o peration and, if necessary, for periodic and extraordinary mainten[...]

22 4.3 Set-Up Note the following points when setting up the UPS system and its external battery units (special accessories): ♦ 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 e[...]

23 5 External V iew 5.1 Front and Rear View of PROTECT 1.M (chassis) Rear view of PROTECT 1.M Front view with slot covers removed Front view with slot covers mounted LED indicators LC display Keys for UPS menu navigation System On/Off Communication por t Communicatio n module Slot cover caps with intake air channelling UPS modules PROTECT 1.040 Com[...]

24 5.2 Front/Rear and 3D View PROTECT 1.040 (UPS module) 5.3 Fans Handles with latc hing for easy removal or ins ertion of a PROTECT 1. 040 UPS modul e Front view Rear view Fans RS232 Blade-connect male Orientation marki ngs for optimum displacement of th e centre of grav ity when holding a PROTECT 1.040 U PS module 3D view[...]

25 Front and Rear View (communication module) 5.4 Front View of LCD Panel Co nne c to r REA R V I EW Ha n d le L C D c o m m unic a tion p o r t FR O N T VI E W SI D E V I E W 3D view Front view Handle Communication port for connecting the LC display Rear view Blade-connect LCD C o m m u n ic at io n L in e Slot cover cap Slot cover cap with integr[...]

26 5.5 Display Panel 1. "Normal": The green LE D lights when the UPS is supplying the loads with voltage via the inverters (normal operation). 2. "On Battery": The yellow LED lights when the UPS is supplying power from the battery. 3. "Bypass": The yellow LED light s when the UPS is supplying the loads with mains volta[...]

27 6 Inst allation 6.1 Installation Notes 1. This unit must be installed by qualified personnel in accordance with the locally applicable electri cal regulations. 2. The PROTECT 1.M uses fans for cooling, which means sufficient ventilation must be provided at the installation location (see also chapter 6.2: Installation area). 3. A battery system w[...]

28 b. Connection with three-phase input Note: If using three-phase mai ns connection, make sure the phase sequence is co rrect. The UPS cannot start up if the phase sequence is wrong, and a n alarm will sound. At the same time, "Phase sequence e rror" appears on t he LC display. Make sure the neutral cond uctor is connected correctly as w[...]

29 5. Connection cross-secti ons and fuse protection[...]

30 i If you are using fuse load break switch for mains fusing, please select miniature circuit breakers with "D" characteristic. Route wires individually to guarantee reliable strain relief. Preferably use special rubber-insulated wire NSGAÖU or NSGAFÖU, NYY or Radox 4GKW-AX.[...]

31 6.2 Set-up and Installation of the Modules 1. To set up the unit, position it in its installation location and use a spanner to tu rn the height- adjustable feet until they reach the floor. The feet are located at the four co rners of the b aseplate. 2. Push the communication module into the top left- hand corner of the upp ermost slot (see illu[...]

32 Hold the UPS module firmly at the sides whe n pushing it in. Your thumbs should ma ke contact with the orienta tion marks on the UPS module (see illustration below). 4. Install the slot cover caps: Insert the slot cov er caps from bottom to top over each i ndividual slot. To ensu re optimum cooling of the individual UPS modules, continuous opera[...]

33 7 Adding/Removing Modules 7.1 Active Redundancy n+x technology is one of the most reliable configurations. "n" represents the minimum number of PROTECT 1.040 UPS modules that requires the total power; "x" repre sents the number of redundant PROTECT 1.040 UPS modules, i.e. the number of fault-tolerant modules that the system c[...]

34 7.2.1 Basic procedure for installing a PROTECT 1.04 0 UPS module 1. Remove the slot cover cap from the rack i n which the UPS module is going to be installed. 2. Grip the UP S module at the sides with both hands. The black dots on the top of the UPS module serve as orientation marks for whe re to position your thumbs i n order to have the centre[...]

35 8 Operating and Maintenance 8.1 Operation 1. Make sure that the phase sequence is co rrect if you are using a three-phase main s connection (L1, L2, L3). If you are using a single-pha se mains connection, ma ke sure that phase L1 has been selected and correctly conn ected to the UPS. 2. Furthermore, make sure that the neutral conducto r has been[...]

36 3) Press ESC 4) Press ▼ for the following information Note: When the mains is connected for the first time, the UPS doe s not output any voltage (Figs. corresp ond to this status) 5) Press ▼ again 6) Press ▼ again for the following information for the following inform. Note: The status of each UPS module is displayed cyclically in the bott[...]

37 8.1.1 Start-up 1) Switch on 2) Press the 3) Press the ↵ / Return key ▼ key 4) Once again, press the ↵ / Return key 8.1.2 Shutting down 1) Switch off 2) Press the 3) Make selec tion ↵ / Return key SELFTEST Æ UPS ON SETUP INQUIRE CONFIRM TURN UPS ON Æ NO, CANCEL YES, CONFIRM UPS IS TURNING ON PLEASE WAIT… LOAD: 0% BATT: 136 I / P VOLT:[...]

38 8.1.3 Inquiries 1) Menu inquiries 2) Press the ↵ / Return key 3) Switch-off option 1: Load supply via bypass "SWITCH TO BYPASS" 4) Switch-off option 2: Load supply directly off "TURN OFF OUTPUT" CONFIRM SWITCH TO BYPASS Æ NO, CANCEL YES, CONFIRM CONFIRM WARNING: OUTPUT OFF Æ NO, CANCEL YES, CONFIRM 5) Select "YES, CO[...]

39 3) Press the ↵ / Return key a t the "PHONE" item, for example 8.1.4 Setup (press ESC to exit the afo rementioned menus) The user can enter the User Setup menu by entering the password (the initial password is " 1234" and should be changed by the user) and set the follo wing parameters (UPS in BYPASS mode!): 1) Setup menu 2)[...]

40 5) Select SETUP, 6) E.g. if the number of e.g. REDUNDAN and redundant modules is 0, … press ↵ / Return The redundancy setup applies after the Setup menu is exited, i.e. the UPS displays "Overload" if the power is more tha n 8 kVA / 5.6 kW. 7) Switch on the PROTECT 1.M in battery mode: Having ensured that the batteries are conne cte[...]

41 8.2 Maintenance 1. Maintenance of the UPS and battery replacement should be performed by well trained expert pe rsonnel. 2. Batteries that have not been used for some time must be charged up every three months at no rmal ambient temperature and every two months if the ambient temperature is high. 3. The three switches on the back, from top to bo[...]

42 8.3 Shutdown and UPS Management Software The "Compu Watch" software specially develop ed for these purposes by AEG continuously ch ecks the mains supply and the UPS status. In conjunction with the "intelligent" UPS, this guar antees the availability of the EDP co mponents as well as the data security. The "Compu Watch&qu[...]

43 9 Communication Interfaces The PROTECT 1.M ha s RS232 and RS485 interfaces as well as an expansion slot: As external connection s, it is possible to use either an AS400 card (optional) or an SNMP/ SNMP PRO card (optional) for the expansion slot. 1. The standard RS232 interface i s for the "CompuWatch" control software. 2. The RS485 con[...]

44 10 T roubleshooting and Fault Rectification If error messages are di splayed, please refer to the following table in order to localise the fault that has occurred and to find information about what measures to take to rectify the fault. If you cannot resolve the problem(s), please contact t he Service Center (see page 5 "Hotline"). 1. [...]

45 11 Reference T a ble for the Display and UPS Operating Problems 11.1 Normal operation LED indications Warning signal LC displays Notes Operating stat us / Operating problems Normal (Normal) Battery (On Battery) Bypass (Fault) Fault (Fault) Mains in tol erance range None Mains not in tolerance, i.e. batt. operation 1 acoustic signal every 4s &quo[...]

46 11.4 Warning Signal if Battery System Not Connected, e.g. battery fuse failure LED indications Warning signal LC displays Notes Operating stat us / Operating problems Normal (Normal) Battery (On Battery) Bypass (Fault) Fault (Fault) Bypass mode 1 acoustic signal every 4 s "UPS is not connected to the battery" Check battery system; poss[...]

47 11.6 Overload Protection LED indications Warning signal LC displays Notes Operating stat us / Operating problems Normal (Normal) Battery (On Battery) Bypass (Fault) Fault (Fault) Overload in normal op eratio n UPS warning 1 acoustic signal every 2 s "Output overload" Reduce the load Overload in normal op eratio n > Switchover Contin[...]

48 12 Minimum Number of Battery Packs Batteries with differe nt capacity ha ve specific charging and discharging characteristics. St andard configuratio ns have been defined in order to make optimum use of the service life. Th e hatched part shows the pe rmitted configurations. Configuration table for b attery cabinet systems equipped with 24 or 28[...]

49 The following tables show t he achi evable standby times according to the UPS expansion level and c apacity utilisation as well as depending on the optional battery cabin et units that are connected ex-works:[...]

50[...]

51 13 List of terms 13.1 Technical terminology DC/DC booster Ci rcu it tec hno lo gy for in cre asi ng a D C voltage to a higher voltage level SBS S tatic B ypass S witc h Appliance protection Term from overvoltage technology Classic mains overvoltage prot ection consists of lighting surge arrester (class B), ov ervoltage protection (class C) and, [...]

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