MITSUBISHI ELECTRIC AUTOMATION, INC.

UNINTERRUPTIBLE POWER SUPPLY SYSTEM 2033A(DDC) SERIES OWNERS / TECHNICAL MANUAL

2033AE Revision 2.3: June 10 2002

TABLE OF CONTENTS LIST OF TABLES .............................................................................................. ii LIST OF FIGURES ............................................................................................ iii INTRODUCTION ............................................................................................... iv 1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 3.4 3.5 4.0 5.0 6.0 7.0 GENERAL ................................................................................................ 1-1 DEFINITIONS ........................................................................................... 1-2 OVERVIEW .............................................................................................. 1-3 SPECIFICATIONS .................................................................................... 1-9 OPERATION CONTROLS AND INDICATORS ...................... 2-1 LED DISPLAY ........................................................................................... 2-2 KEYPAD ................................................................................................... 2-2 LIQUID CRYSTAL DISPLAY .................................................................... 2-3 EXTERNAL SIGNAL TERMINAL BLOCK ................................................. 2-9 INSTALLATION AND OPERATION ............................... 3-1 TRANSPORTATION AND INSTALLATION .............................................. 3-1 INSTALLATION PROCEDURE ................................................................ 3-1 PROCEDURE FOR CABLE CONNECTIONS .......................................... 3-2 OPERATING PROCEDURES .................................................................. 3-11 MAINTENANCE BYPASS SET-UP PROCEDURE .................................. 3-13 RESPONSE TO UPS FAILURE ................................... 4-1 PARTS REPLACEMENT ......................................... 5-1 FAULT CODES ................................................. 6-1 WARRANTY & OUT OF WARRANTY SERVICE .................... 7-1

List of Tables Table 1.1 Table 1.2 Table 1.3 Table 1.4 Table 1.5 Table 3.1 Table 3.2 Table 3.3 Table 3.4 Table 3.5 Power Specifications................................................................... 1-9 UPS Module Information ............................................................. 1-9 Input Cabinet Information............................................................ 1-9 Detail of Specifications................................................................ 1-10 Rating of Circuit Breakers (MCCB) ............................................. 1-11 and Fuses How to Transport and Install the System .................................... 3-1 List of Weights (lb.) ..................................................................... 3-1 Maximum Permitted Fault Current .............................................. 3-2 Recommended Cable Size and .................................................. 3-4 Torque Requirements Crimp Type Compression Lug .................................................... 3-5

ii

List of Figures Figure 1.1 Figure 1.2 Figure 1.3 Figure 1.4 Figure 1.5 Figure 2.1 Figure 2.2 Figure 2.3 Figure 2.4 Figure 2.5 Figure 2.6 Figure 2.7 Figure 2.8 Figure 2.9 Figure 2.10 Figure 2.11 Figure 2.12 Figure 2.13 Figure 2.14 Figure 2.15 Figure 2.16 Figure 2.17 Figure 2.18 Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Single Line Diagram-Normal Operation ...................................... 1-3 Single Line Diagram-Bypass Operation ...................................... 1-4 Single Line Diagram-Battery Operation....................................... 1-5 Single Line Diagram - UPS on Maintenance Bypass Operation. 1-5 UPS Parts Location..................................................................... 1-7 Operation/Display Panel ............................................................. 2-1 Main Screen................................................................................ 2-3 Bypass Screen............................................................................ 2-3 Input Screen................................................................................ 2-4 Output Voltage Screen................................................................ 2-4 Output Current Screen ................................................................ 2-4 Trend Graph Screen ................................................................... 2-5 Battery Screen ............................................................................ 2-5 Remote / Local Selection Screen................................................ 2-5 Operation Menu Screen .............................................................. 2-6 Battery Operation Screen............................................................ 2-7 Battery Low Voltage Screen........................................................ 2-7 Discharge Termination Screen.................................................... 2-7 Fault Indication Screen ............................................................... 2-8 External Signal Terminal Block ................................................... 2-9 Control Wiring for External Contacts........................................... 2-10 Remote "Start" Contact Connections .......................................... 2-11 External communication connector ............................................. 2-12 UPS Terminal Name ................................................................... 3-6 Diagram of input/output Terminals .............................................. 3-7 Start-up Menu ............................................................................. 3-11 Inverter Start / Stop..................................................................... 3-11

iii

INTRODUCTION Your Mitsubishi Uninterruptible Power System (UPS) is designed to provide many years of reliable protection from power failure, brown-outs, line noise, and voltage transients. manual contains descriptions required to operate the UPS. and retain it for future reference. To ensure optimum performance of the equipment, follow the manufacturer's instructions. This Please read this manual carefully

IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the 2033A(DDC) Series Uninterruptible Power Supply Systems that should be followed during installation and maintenance of the UPS and batteries. WARNING 1 Observe

Lethal voltages exist within the equipment during operation. all warning and cautions in this manual. serious injury or death. instructed.

Failure to comply may result in

Obtain qualified service for this equipment as

iv

WARNING

2 The

This UPS does not include a Bypass Input circuit breaker (MCCB). short circuits. and installed.

Bypass Input contactor (CB3) does not protect against load induced The bypass input circuit breaker (MCCB) is field supplied Breaker(MCCB)'s Specifications are as follows: Maximum Bypass Rating (AAC)

Capacity (kVA)

Bypass Voltage (VAC)

Recommended Breaker (A)

7.5 7.5 7.5 10 10 10 15 15 15 20 20 20 30 30 30 40 40 40 50 50 50 75 75 75

208 480 600 208 480 600 208 480 600 208 480 600 208 480 600 208 480 600 208 480 600 208 480 600

20.8 9.0 7.2 27.8 12.1 9.6 41.6 18.0 14.4 55.5 24.1 19.2 83.3 36.1 28.9 111.0 48.1 38.5 138.8 60.1 48.1 208.2 90.2 72.2

30 15 10 35 20 15 60 30 20 75 35 25 125 50 35 150 70 50 175 80 60 300 125 90

1.0

GENERAL The Mitsubishi 2033A(DDC) Series UPS is designed to provide continuous, clean electrical power to your critical load and to monitor power conditions affecting that load. specified battery time. If the input power is not restored promptly, back up power from the UPS battery permits the orderly shutdown of equipment supported by the UPS. operate and maintain. The 2033A(DDC) Series UPS is available in eight kVA sizes: 7.5, 10, 15, 20, 30, 40, 50 and 75kVA. Specifications for each kVA model appear in Section 1.3. The principles of operation described herein are applicable to all models. This manual provides an overview of the 2033A(DDC) Series components and their functions. It describes the appearance and purpose of operator controls and indicators. It contains procedures for operation, start-up, shutdown, and basic maintenance. The UPS is simple to start-up, In the event of an input power failure, the UPS will supply power to the critical load for the

1-1

1.1

Definitions UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS Module Cabinet includes the 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, the Inverter, the Static Transfer Switch, the Internal Bypass line, the operator controls, and the internal control system 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 UPS module 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. INPUT POWER - Power provided by the electrical utility company, or auxiliary generator, which is connected to the UPS for supplying the critical load. MAINTENANCE BYPASS SWITCH Internal wrap-around make-before-break rotary switch used to provide load and personnel safety when UPS is being maintained.

1-2

1.2

Overview The UPS provides two power paths between the utility source and the critical load as shown in Figures 1.1 and 1.2.

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

AC Bypass Input

CB Use supplied MCCB CB3 CONVERTER INVERTER

Static Transfer Switch

52S

Internal Make-Before-B reak Maintenance Bypass Switch

AC input CB1 FC 52C FB CB2 Power Flow Not in Use

Output

Battery cabinet

UPS Module

When the load is on the Inverter, the internal control system determines paths supplies power to the load. module is used. Input AC power flows through the UPS During normal

which of the two

operation, the path through the UPS

where it is converted to DC by the Rectifier/Charger. to provide power to the Inverter.

This DC power is utilized to charge the UPS battery and

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 Bypass Input circuit breaker(MCCB) for protection of the UPS and cables is field supplied and field installed. (See WARNING 2 on page iii).

1-3

FIGURE 1.2

Single Line Diagram - Internal Bypass. Load fed through static bypass line.

AC Bypass Input

CB Use supplied MCCB CB3 CONVERTER INVERTER

Static Transfer Switch

52S

Internal Make-Before-B reak Maintenance Bypass Switch

AC input CB1 FC 52C FB CB2 Power Flow Not in Use

Output

Battery cabinet

UPS Module

The Internal Static Bypass line is a Hard wired line through CB3, contactor 52S which supplies the critical load with unconditioned input power. operational. 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 a reduced load. The purpose of this line is to route power to the critical load while the UPS module is de-energized during Start-up before the system is fully

When power is restored after a low battery shutdown, the Rectifier/Charger automatically restarts operation, recharges the batteries, and the Inverter is automatically restarted without operator intervention. intervention. In the event of a power failure, the rectifier will de-energize and the batteries will discharge into the inverter and maintain power to the critical until a) the battery capacity expires and the inverter turns off, or b) input power is restored after which the converter will power the critical load and simultaneously recharge the batteries. battery operation. Figure 1.3 illustrates the flow diagram during The load is assumed by the inverter automatically without operator

1-4

FIGURE 1.3

Single Line Diagram - Battery Operation

AC Bypass Input

CB Use supplied MCCB CB3 CONVERTER INVERTER

Static Transfer Switch

52S

Internal Make-Before-B reak Maintenance Bypass Switch

AC input CB1 FC 52C FB CB2 Power Flow Not in Use

Output

Battery cabinet

UPS Module

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 during when the MBS is in the BYPASS mode.

FIGURE 1.4

Single Line Diagram - UPS on Maintenance Bypass Operation.

AC Bypass Input

CB Use supplied MCCB CB3 CONVERTER INVERTER

Static Transfer Switch

52S

Internal Make-Before-B reak Maintenance Bypass Switch

AC input CB1 FC 52C FB CB2 Power Flow Not in Use

Output

Battery cabinet

UPS Module

The rotary maintenance bypass switch is identified as 52CS in Figure 1.4. 52CS is a two position make-before-break transfer switch. The two positions are identified as NORMAL and
1-5

BYPASS. In the NORMAL position the load is fed by the UPS - either through the inverter or through the static bypass line. is in the static bypass mode. The transfer procedure to place the UPS in the maintenance bypass mode, and vice versa, is outlined below: TRANSFER FROM NORMAL MODE TO MAINTENANCE BYPASS MODE In the BYPASS position the load is powered by an external This transfer operation must be made while the UPS source such as the utility or a generator.

1. With inverter running, confirm Inverter Sync. displayed on UPS LCD (Liquid Crystal Display) is ON. 2. Press the inverter STOP key on UPS LCD. 3. Confirm UPS is on static bypass. 4. Rotate rotary switch from NORMAL position to BYPASS position. 5. Transfer is complete. UPS can now be powered down for maintenance. Load is fed by CB3 can be opened with SW2(CB3 close/open SWITCH). utility or generator source.

TRANSFER FROM MAINTENANCE BYPASS MODE TO NORMAL MODE

1. Confirm CB3 inside the UPS cabinet is closed (ON) with inverter running. 2. With inverter running, confirm Inverter Sync. displayed on UPS LCD is ON. 3. Press the inverter STOP key on UPS LCD. 4. Confirm UPS is on static bypass. 5. Rotate rotary switch from BYPASS position to NORMAL position. 6. Press the inverter START key on UPS LCD. 7. UPS will transfer to inverter automatically within a few seconds. 8. Load is now powered by the inverter.

1-6

FIGURE 1.5 UPS Parts Location

UPS module FRONT VIEW

Converter & Inverter Unit

11. 52CS 13. SW2 14. CB101 CB3 3. CB2 2. CB1 5. Grounding Bar

4. External contact signal terminal block

UPS module BACKSIDE OF FRONT DOOR

Inverter Start/Stop switch 6. Error RESET 12. Switch PCB DPAU-55 LCD panel Main PCB UPER 1. Emergency bypass switch Relay PCB RYDR
INV START STOP

Buzzer Stop

CNV SW OFF

BUZ ON

SYN

BYP

INV

MAINT OFF

TEST ON

DPAU-55

8.SW8 TEST switch 9.SW7 Maintenance 10. CN45 RS232C Connector 7. SW4 Load on Bypass switch

1-7

Description of Figure 1.5: 1. Emergency bypass switch. (SW1) This switch activates the bypass power supply for emergency reasons if the UPS is turned off. PERFORMED. 2. AC Input circuit contactor (CB1) Contactor for converter input power. Contactor for battery input. Refer to FIGURE 2.8 for details. 3. Battery Disconnect circuit contactor (CB2) Normal position is TRANSFER is

4. External contact signal terminal block Terminal block to connect contact signal input/output lines to and from external dry contacts. 5. Grounding bar (E). 6. "Error reset" switch This switch resets errors resulting from alarm conditions. (Do not operate this switch while inverter and converter are in operation). 7. Bypass manual change-over switch (FOR SERVICE PERSONNEL ONLY) This switch is used to transfer the UPS from inverter to static bypass for maintenance purposes. not operate it under normal operation. more than 10% of nominal. synchronous operation. 8. "Test mode" switch only. 9. Maintenance (Set) switch 10. RS232C connector (CN45) 11. Maintenance Bypass Switch (52CS). 12. Switches on DPAU board : FOR SERVICE PERSONNEL ONLY (Figure 1.6): - (6) Error RESET. - (7) SW4 (Load on Bypass Switch) - (8) SW8 (TEST Switch): Normal=Off side. - (9) SW7 (Maintenance Set Switch). - (10) CN45 (RS232C communication connector) 13. SW2 operates contactor CB3. For maintenance of UPS only. Normal position is ON. 14. Control Power circuit breaker (CB101) This switch sets the UPS menu parameters. 2) Return to "Normal" after use. This switch should be operated Authorized Service Personnel Do Transfers will be locked-out if the bypass voltage is

1) Uninterrupted switching is made at the time of

Switching is impossible at the time of asynchronous operation.

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1.3 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 7.5kVA/6kW 10kVA/8kW 15kVA/12kW 20kVA/16kW 30kVA/24kW 40kVA/32kW 50kVA/40kW 75kVA/60kW
TABLE 1.2 UPS Module Information UPS (kVA) 7.5/10 15/20 30 40/50 75 CABLE ENTRY BOTTOM BOTTOM BOTTOM BOTTOM BOTTOM WIDTH (in/mm) 23.6 / 600 31.5 / 800 35.4 / 900 43.3 / 1100 43.3 / 1100

Input voltage 3 / 3 wire 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600

Output voltage 3 /3 or 4 wire 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600 208, 480, or 600

DEPTH (in/mm) 29.5 / 750 29.5 / 750 29.5 / 750 29.5 / 750 29.5 / 750

HEIGHT (in/mm) 63.0 / 1600 70.9 / 1800 70.9 / 1800 70.9 / 1800 70.9 / 1800

WEIGHT (lb.) 840 / 860 1150 /1200 1250 1600 /1650 1940

HEAT LOSS @ 208V (kBTU/h) 3.5 / 4.4 6.2 / 7.9 11.0 13.9 / 16.6 23.5

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TABLE 1.3 Detail of Specifications Rated Output kVA 7.5 15 20 30 40 50 75 Rated Output kW 6 12 16 24 32 40 60 AC INPUT CHARACTERISTICS Configuration 3 phase, 3 wire Voltage 208 V, 480 V, 600 V +10% ~ -15% Input Power Factor 0.98 typical Frequency 60 Hz 5% Reflected Current THD 3% max. at 100% load; 5% max. at 50% load STATIC BYPASS INPUT Configuration 3 phase, 3 or 4 wire Voltage 120/208 V, 277/480 V, 346/ 600 V 10% Frequency 60 Hz (3% Tracking window) BATTERY Type VRLA, Flooded Lead Acid, Nickel Cadmium Ride Through Application Specific Nominal Voltage 360 VDC Minimum Voltage 300 VDC Number of Cells 176 ~ 185 AC OUTPUT Configuration 3 phase, 3 or 4 wire Voltage 120/208 V, 277/480 V, 346/ 600 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% maximum THD at 100% Linear Load 4% maximum THD at 100% non-linear load Transient Response 3% maximum at 100% load step 1% maximum at loss or return of AC power 3% maximum at load transfer to/from static bypass Transient Recovery Less than 1 line cycle Voltage Unbalance 2% maximum at 100% unbalanced load Phase Displacement 1% maximum at 100% unbalanced load Inverter Overload 125% for 10 minutes; 150% for 10 seconds System Overload 1000% for 1 cycle (with bypass available) Bypass Overload 125% for 10 minutes Withstand Rating 65kA* *:with optional fuses (only 208V model)

Cooling Operating Temperature Relative Humidity Altitude Location Paint Color

ENVIRONMENTAL Forced Air 2 F ~ 104 F (0 C ~ 40 C). Recommended 68 F ~ 86 F (20 C ~ 30 C) 5% ~ 95% Non Condensing 3300 Feet (1000 meters); 5000 feet @ 0.99 derating Indoor (free from corrosive gases and dust) Munsell 5Y7/1 (Beige)

1-10

TABLE 1.4

Rating of Circuit Breakers (MCCB) and Fuses Description UPS Rating (kVA)
AC Input Contactor DC Input Contactor Static Bypass Input Contactor Control Power Circuit Breaker Converter Input Fuse Battery Input Fuse Bypass Input Fuse (only 208V model) Control Power Supply Input Fuse Output Voltage Sensor Fuse Bypass Voltage Sensor Fuse Bypass Input Zener Fuse CB3 Coil Input Fuse 40A / 660Vac 40A / 660V 80A / 660Vac 80A / 660V -

Component(s)
CB1 CB2 CB3 CB101 FCU, FCV, FCW FBP (OPTION) FSU, FSV, FSW FD1, FD2 FUL1, FUL2, FUL3 FUS1, FUS2, FUS3 FZS1, FZS2, FZS3 FBS1, FBS2

7.5
24A 24A 24A

Component Rating 10 15
24A 24A 24A 24A 24A 24A

@ 208V, 480V, 600V 20 30

65A 65A 65A 15 A 140A/660Vac 140A/660V 125A/660V 10A / 500Vdc 10A / 600Vac 10A / 600Vac 30A / 600 Vac 10A / 600 Vac 65A 65A 65A

3 phase, 60 Hz 40 50
150A 150A 150A 150A 150A 150A

75
220A 220A 220A

180A / 660Vac 180A / 660V 250A/660V

280A/660Vac 280A/660V 350A/660V

1-11

2.0

OPERATOR CONTROLS AND INDICATORS The 2033A(DDC) Series operator controls and indicators are located as follows: Circuit breakers and contactors UPS status indicators : Inside the module : Outside of door

FIGURE 2.1 Operation/Display Panel (Front panel)

3 4 5 6
LOAD ON INVERTER BATTERY OP. LOAD ON BYPASS LOAD ON BYPASS LCD FAILURE UPS FAILURE

2 1

EMRG.STOP

2-1

2.1 LED Display 1) Load on inverter (green) Turned on when power is supplied from inverter to the critical load. (Indicates the state of transfer switch "52C" of inverter.) 2) 3) Battery operation (yellow) Turned on when the battery is operating following an AC power failure.. Load on bypass (yellow) Turned on when power is supplied through bypass to load devices. (Indicates the state of transfer switch "52S" of bypass.) 4) 5) 6) Overload(yellow) Turned on when an overload has occurred to the system. LCD failure [ LCD FAIL ](red) Turned on when an error occurs on the LCD. UPS failure [ UPS FAIL ](red) [Annunciator: intermittent or constant tones] Turned on when an error occurs on the system. In this case, the details of error are indicated on the display panel.

2-2

2.3

Liquid Crystal Display (8) The Liquid Crystal Display (LCD) panel indicates the power flow, measured values, operational guidance, data record and error messages. The LCD panel is back-lit to facilitate viewing in different ambient lighting conditions. The LCD will automatically clear if the keyboard is not activated for 3 minutes. The ERROR indicator is cleared after 24 hours and can be reproduced by pressing any key on the panel.

2.3.1 Menus A) MAIN MENU (FIGURE 2.2) The LCD panel indicates the power flow, measured values and remote operation mode. The LCD panel shows the power flow. UPS Module. FIGURE 2.2 Main screen This allows the user to verify the status of the

The following will be displayed when the measuring point button on LCD panel is pressed. 1) Bypass Voltage (FIGURE 2.3) The voltages displayed are the Bypass input voltages (line-to-line) between phases A-B, B-C, C-A and frequency of the Bypass line. C-N are measured on 4 wire systems only. FIGURE 2.3 Bypass screen Line to neutral voltages A-N, B-N,

2-3

2) Input Voltage and Current (FIGURE 2.4) The voltages displayed are the RMS AC input voltages (line-to-line) between phases A-B, B-C C-A and frequency of the AC input line. and C currents are also displayed. FIGURE 2.4 Input screen The RMS values of phases A, B

3) Output Voltage, Output Current and Trend Graph The voltages displayed on the LCD include the inverter output voltages A-B, B-C, C-A. Line to neutral voltages A-N, B-N, C-N are displayed on 4 wire systems only. Inverter output frequency is also displayed. (FIGURE 2.5) The currents displayed and the RMS values and Peak Values of Phases A, B, C. N-current (Neutral) is display on a 4 wire system only. (FIGURE 2.6) The Trend Graph displays the Effective power values and the Reactive power values. (FIGURE 2.7) FIGURE 2.5 Output voltage screen FIGURE 2.6 Output current screen

2-4

FIGURE 2.7 Trend graph screen

4) Battery (FIGURE 2.8) This displays the charging, discharging or float mode of the battery, battery current and battery voltage. FIGURE 2.8 Battery screen

5) Remote / Local Selection (FIGURE 2.9) The system asks user to select whether the start & stop operation will be performed by a local or remote operation. FIGURE 2.9 Remote / Local selection

2-5

B)

OPERATION MENU (FIGURE 2.10) The following will be displayed when the OPERATION MENU button is pressed on the LCD FIGURE 2.10 Operation menu screen

1) START-UP GUIDANCE The display indicates the operation from closing circuit breakers to starting the inverter. When the inverter is started, the display shows the MAIN MENU. When the display changes, the annunciator sounds 3 times requesting user to perform next procedure. 2) STOP GUIDANCE The display indicates the operation of how to stop the inverter and UPS system. 3) EXTERNAL CONTACT INPUT The input of external contacts is indicated by closed or open contacts. 4) DATA RECORD Operation data and events is indicated. 5) REPORT Record data is indicated. 6) SET UP Time, Remote/Local selection and Equalizing charge are set. 7) SELECT UPS OUTPUT SOURCE This display is used to transfer the UPS from inverter to static bypass for maintenance purposes. to shutdown the

2-6

2.3.2 INPUT POWER FAILURE During an Input Power Failure the UPS will run on the Batteries. be displayed. FIGURE 2.11 Battery Operation Screen The following will The indication of battery operation, load factor, and time remaining.

The LCD will display a battery low voltage announcement when battery capacity is near depletion. FIGURE 2.12 Battery Low Voltage Screen

The End of Battery Discharge announcement is displayed when the battery end voltage is reached. At that time, the inverter will perform an electronic shutdown to prevent battery loss of life typical of extreme deep discharge conditions. The inverter will automatically restart to power the load and the batteries will be simultaneously recharged after input power is restored. Details of the End of Battery announcement is shown in Figure 2.13. FIGURE 2.13 Discharge Termination Screen

2-7

2.3.3 FAULT INDICATION (FIGURE 2.14) The display shows a fault code, description of fault and a guidance of what action is to take place by the user. A maximum of 10 faults are displayed at the same time. When an input power failure occurs during the fault Indication, the fault indication and input power failure are alternatively displayed at 5 second intervals. FIGURE 2.14 Failure indication screen

2-8

2.4

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. A functional description of the input/output port is presented below. Layout of terminals is shown in Figure 2.15

FIGURE 2.15 External Signal Terminal Block

1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

EMERGENCY STOP IN0: REMOTE INVERTER STOP IN1: REMOTE INVERTER START IN2: POWER DEMAND IN3: ASYNCHRONOUS IN4: BATTERY TEMP. HIGH IN5: ROOM TEMP. HIGH OUT0: LOAD ON BYPASS OUT1: LOAD ON INVERTER OUT2: BATTERY OPERATION OUT3: CONVERTER OPERATION UPS FAILURE UPS FAILURE OUT4: BATTERY LOW VOLTAGE OUT5: OVERLOAD

2-9

A)

Output Contacts(for external alarm annunciation) Output contacts consist of form A dry type contacts. values or lower. Rated value of all output The external relay can contacts is 120Vac/0.5Aac or 30Vdc/1Adc. Operate all dry contacts at their rated Figure 2.16 illustrates typical installation. also be a lamp, LED, computer, etc. FIGURE 2.16 Control Wiring for External Contacts

UPS Cabinet Terminal Relay Contact

External to UPS Cabinet Relay Coil Terminal Power Source

Details of output alarm contacts : Terminals 22 to 21 "Load on Bypass" contact (OUT0) Activated when the power is supplied from the static bypass input. Terminals 24 to 26 "Load on Inverter" contact (OUT1) Activated when the power is supplied by the inverter. Terminals 25 to 26 "Battery Operation" contact (OUT2) Activated when the battery is operating following an AC power failure. Terminals 27 to 28 Converter Operation contact (OUT3) Activated when the converter is operating. Terminals 29 to 30 "UPS failure" contact Activated when a major fault has occurred to the system. Terminals 31 to 32 "UPS failure" contact Activated when a major fault has occurred to the system. Terminals 34 to 33 "Battery Low Voltage" contact (OUT4) Activated when DC voltage dropped below discharge end during inverter operation. Terminals 35 to 34 "Overload" contact (OUT5) Activated when an overload has occurred to the system.

2-10

NOTE:

The UPS is equipped with a selectable output contact feature. The above alarms are the default settings. Contact MITSUBISHI ELECTRIC AUTOMATION, INC. for set-up information.

B)

Input Contacts(for remote access of UPS) External contacts are provided by the user of the UPS system. the UPS is 24Vdc. Provide external dry contact accordingly. NOTE: Terminal voltage at

Do not apply voltage to remote access input terminals. UPS may result.

Damage to

Refer to Figure 2.17 for typical wiring configuration. Although this figure applies to the remote start/stop terminals, the same wiring arrangement is used for emergency stop; asynchronous command; power demand; battery temperature high. FIGURE 2.17 Remote "Start" Contact Connections

UPS Cabinet Relay Coil Common 24 VDC Relay Coil current : 8.3mA Start

External to UPS Cabinet

Start Switch

Use Momentary Switches

Details of input contacts for remote access : Terminals 7 to 8 "Emergency Stop" contact input Used to perform a remote UPS emergency power off (EPO). The load will be dropped. Terminals 9 to 10 Remote "Inverter Stop input terminal (IN0) UPS must be programmed Refer to Operations Menu for procedure. UPS must be programmed Used to stop inverter from a remote location. for remote operation.

Terminals 11 to 12 Remote "Inverter Start input terminal (IN1) Used to start inverter from a remote location. for remote operation. Refer to Operations Menu for procedure.

Terminals 13 to 14 "Power Demand Command" contact input (IN2) Used to control the input current limit to the UPS converter (usually during generator operation). Power demand is turned ON when the contact is
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closed.

Power demand is turned OFF when the contact is open.

Terminals 15 to 16 "Asynchronous Command" contact input (IN3) Used to create an asynchronous condition between the static bypass source and the inverter. closed. Asynchronous condition is enabled when the switch is Asynchronous condition is disabled when the switch is opened. The

Terminals 17 to 18 BATTERY TEMP. HIGH contact input (IN4) Input fed by a thermocouple that monitors battery temperature. conditions. External thermocouple is user supplied Terminals 19 to 20 ROOM TEMP. HIGH contact input (IN5) Input fed by a thermocouple that monitors room temperature. External thermocouple is user supplied. NOTE : In all cases, a switch having a plate is recommended in order to reduce converter float voltage level is reduced for battery over-temperature

possibility of accidental operation.

2.5 External communication connector This is a RS232C port for DiamondLink. Layout of connector is shown in Figure 2.18. FIGURE 2.18 External communication connector
CN45 D-SUB 25Pin
1 2 3 4 5 6 7 8 9 10 11 12 13

Pin 2. TXD : Transmit data Pin 3. RXD : Receive data Pin 7. GND : Signal ground Pin 9. 5VS : DC5V supply Pin 10. GND : Ground Pin 11. 5VS : DC5V supply

14 15 16 17 18 19 20 21 22 23 24 25

PCB DPAU-

2-12

3.0 3.1

INSTALLATION AND OPERATION Transportation and Installation TABLE 3.1 How to transport and install the system Transportation Transport unit with forklift. Use eye bolts (supplied) to carry with overhead crane. Installation Using the holes (4 - 24) pre drilled into the UPS channel base, anchor the unit using appropriate hardware.

Note : Do not transport in a horizontal position.

Cabinets should be maintained

upright within +/- 15 during handling.

3.2 Installation Procedure A) Note the load tolerance of the floor Refer to Table 3.2 for list of weights of UPSs. TABLE 3.2 List of UPS weights 7.5 840 10 860 15 1150 20 1200 30 1250 40 1600 50 1650 75 1940

UPS Capacity (kVA) Weight (lb.)

B)

Minimum clearance required for ventilation Right side Left side Back side Top side 1.0" (25 mm) (not required when sidecars are used) 1.0" (25 mm) (not required when sidecars are used) 0.0" (0.0 mm) (15, 20, 30, 40, 50 and 75kVA) 4.0 (100 mm) ( 7.5 and 10kVA) 23.6" (600 mm) (for air flow)

C)

Space requirement for routine maintenance Allow the following space at the time of installation. Front Sides Rear 39.4" (1000 mm) 0.0" (0.0 mm) 0.0" (0.0 mm)

3-1

D)

External Battery Supply Please refer to the following when installing batteries: 1. 2. The customer shall make reference to the battery manufacturer's installation manual for battery installation and maintenance instructions. The maximum permitted fault current from the remote battery supply and the DC voltage rating of the battery supply over-current protective device are shown in Table 3.3. TABLE 3.3 Maximum Permitted Fault Current DC VOLTAGE RATING (V) 360 360 360 360 360 360 360 360 MAXIMUM FAULT CURRENT (A) 25,000 25,000 25,000 25,000 25,000 30,000 30,000 30,000

UPS CAPACITY (kVA) 7.5 10 15 20 30 40 50 75

3.3

Procedure for Cable Connections I. Confirm the capacity of the UPS being installed. Identify the input/output power terminal blocks as shown in the appropriate Figure 3.1 through Figures 3.2-a~d. II. Connect the grounding conductor from the input service entrance to the UPS ground bar. III. A. Two (2) sources feeding the UPS: Connect the converter input power cables from the input service entrance to the converter input power terminals identified as A10, B10, C10 in Figures 3.2-a~d. Input cables must be sized for an ampacity larger than the maximum input drawn by the converter. B. to WARNING 2). Refer to Table 3.4 for recommended cable sizes. Connect the bypass input power cables from the input service Bypass input cables must be sized for an ampacity larger Refer to Table 3.4 for Confirm that an external bypass input circuit breaker (MCCB) is installed (refer entrance to the bypass input power terminals identified as A30, B30, C30 and N60 in Figures 3.2-a~d. than the maximum output current capacity of the UPS. recommended cable sizes. 3-2

IV. A.

One (1) source feeding the UPS: 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 bypass input power cables from the input service Input cables must be sized for an ampacity larger than the Refer to Table 3.4 for recommended entrance to the bypass input power terminals identified as A30, B30, C30 and N60 in Figures 3.2-a~d. cable sizes. B. Using adequately sized conductors per Table 3.4 and referring to the appropriate figure identified in Figures 3.2-a~h, jumper bypass terminals A30, B30, C30 to converter input power A10, B10, C10 identified Figures 3.2-a~d. maximum current capacity of the UPS.

V.

Referring to Figures 3.2-a~h, connect UPS load terminals A60, B60, C60 and N60 to load distribution panel. Refer to Table 3.4 for cable sizes.

VI.

Connect external signal terminal block as needed. Refer to section 2.4 and Figure 2.15 for functional description. recommended. 12 AWG, or less, shielded conductor is

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.

3-3

Table 3.4
UPS Capacity (kVA) 7.5kVA (208V) 7.5kVA (480V) 7.5kVA (600V) 10kVA (208V) 10kVA (480V) 10kVA (600V) 15kVA (208V) 15kVA (480V) 15kVA (600V) 20kVA (208V) 20kVA (480V) 20kVA (600V) 30kVA (208V) 30kVA (480V) 30kVA (600V) 40kVA (208V) 40kVA (480V) 40kVA (600V) 50kVA (208V) 50kVA (480V) 50kVA (600V) 75kVA (208V) 75kVA (480V) 75kVA (600V)

Recommended cable size and torque requirements

Input Side * 1, 2 Cable Torque Size (in. lbs) 10 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 6 AWG 100-135 or larger in. lbs 6 AWG 100-135 or larger in. lbs 6 AWG 100-135 or larger in. lbs 3 AWG 200-269 or larger in. lbs 3 AWG 200-269 or larger in. lbs 3 AWG 200-269 or larger in. lbs 1 AWG 200-269 or larger in. lbs 1 AWG 200-269 or larger in. lbs 1 AWG 200-269 or larger in. lbs 2/0 AWG 200-269 or larger in. lbs 2/0 AWG 200-269 or larger in. lbs 2/0 AWG 200-269 or larger in. lbs 250MCM 347-469 or larger in. lbs 250MCM 347-469 or larger in. lbs 250MCM 347-469 or larger in. lbs Output Side * 1, 2 Cable Torque Size in. lbs 12 AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 10AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 12 AWG 42-56 or larger in. lbs 12 AWG 42-56 or larger in. lbs 6 AWG 100-135 or larger in. lbs 10 AWG 42-56 or larger in. lbs 12 AWG 42-56 or larger in. lbs 3 AWG 200-269 or larger in. lbs 8 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 1 AWG 200-269 or larger in. lbs 6 AWG 100-135 or larger in. lbs 8 AWG 42-56 or larger in. lbs 2/0 AWG 200-269 or larger in. lbs 4 AWG 100-135 or larger in. lbs 6 AWG 100-135 or larger in. lbs 250 MCM 347-469 or larger in. lbs 2 AWG 200-269 or larger in. lbs 4 AWG 100-135 or larger in. lbs Bypass Side * 1, 2 Cable Torque Size in. lbs 12 AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 10AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 14 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 12 AWG 42-56 or larger in. lbs 12 AWG 42-56 or larger in. lbs 6 AWG 100-135 or larger in. lbs 10 AWG 42-56 or larger in. lbs 12 AWG 42-56 or larger in. lbs 3 AWG 200-269 or larger in. lbs 8 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 1 AWG 200-269 or larger in. lbs 6 AWG 100-135 or larger in. lbs 8 AWG 42-56 or larger in. lbs 2/0 AWG 200-269 or larger in. lbs 4 AWG 100-135 or larger in. lbs 6 AWG 100-135 or larger in. lbs 250 MCM 347-469 or larger in. lbs 2 AWG 200-269 or larger in. lbs 4 AWG 100-135 or larger in. lbs DC Input Side * 1, 2 Cable Torque Size in. lbs 12AWG 42-56 or larger in. lbs 12AWG 42-56 or larger in. lbs 12AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 10 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 8 AWG 42-56 or larger in. lbs 6 AWG 100-135 or larger in. lbs 6 AWG 100-135 or larger in. lbs 6 AWG 100-135 or larger in. lbs 4 AWG 100-135 or larger in. lbs 4 AWG 100-135 or larger in. lbs 4 AWG 100-135 or larger in. lbs 2 AWG 200-269 or larger in. lbs 2 AWG 200-269 or larger in. lbs 2 AWG 200-269 or larger in. lbs 1/0 AWG 200-269 or larger in. lbs 1/0 AWG 200-269 or larger in. lbs 1/0 AWG 200-269 or larger in. lbs 4/0 AWG 347-469 or larger in. lbs 4/0 AWG 347-469 or larger in. lbs 4/0 AWG 347-469 or larger in. lbs

*1 - Voltage drop across power cables not to exceed 2% of nominal source voltage. *2 - Allowable ampacities based on 75 C insulation at an ambient temperature of 30 C. more than 3 conductors in a raceway without derating.

Not

3-4

TABLE 3.5 WIRE SIZE (CODE) 2 1 1/0 2/0 3/0 4/0 250 MCM 300 MCM 350 MCM 400 MCM 500 MCM 600 MCM 750 MCM 1000 MCM

Crimp Type Compression Lug WIRE STRAND CLASS B I B I B I B I B I B I B I B I B I B I B I B I B I B I RECOMMENDATION VENDOR BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY BURNDY ILSCO BURNDY CAT. NO. YA2C CRB-2L YA1C-LB YA1C CRA-1L YA25-LB YA25 CRA-1/OL YA25-LB YA26 CRA-2/OL YA27-LB YA27 CRB-3/OL YA28-LB YA28 CRB-4/OL YA29-LB YA29 CRA-250L YA30-LB YA30 CRA-30OL YA32-LB YA31 CRA-350L YA34-LB YA32 CRA-40OL YA34-LB YA34 CRA-500L YA38-LB YA36 -----YA39-LB YA39 CRA-750L YA44-LB YA44 CRA-1000L ------CRIMP TOOL REQUIRED BURNDY TYPE Y35 OR Y46 COLOR KEY DIE INDEX BROWN 10 BROWN 10 GREEN 11 / 375 GREEN 11 / 375 GREEN 11 / 375 PINK 12 / 348 PINK 12 / 348 PINK 12 / 348 BLACK 13 BLACK 13 BLACK 13 ORANGE 14 / 101 ORANGE 14 / 101 ORANGE 14 / 101 PURPLE 15 PURPLE 15 PURPLE 15 YELLOW 16 YELLOW 16 YELLOW 16 WHITE 17 / 298 WHITE 17 / 298 WHITE 17 / 298 RED 18 / 324 RED 18 / 324 RED 18 / 324 BLUE 19 / 470 BLUE 19 / 470 BLUE 19 / 470 BROWN 20 / 299 BROWN 20 / 299 BROWN 20 / 299 GREEN 22 / 472 GREEN 22 / 472 -----------PINK 300 BLACK 24 / 473 BLACK 24 / 473 WHITE 27 WHITE 27 WHITE 27 ------------

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.

3-5

Fig.3.1 UPS Terminal Designation

AC Bypass Input Terminals: A30,B30,C30, N60 AC input Terminals: A10,B10, C10 Static Transfer Switch CB3 CONVERTER INVERTER 52S Output Terminals: A60,B60,C6 0, N60

CB1

FC Terminals: BP,BN

52C FB CB2

Battery cabinet

UPS Module

3-6

FIGURE 3.2 a Input/Output Power Terminals (40 kVA, 50 kVA, 75 kVA UPS)

Power Stage

52CS

DP AU

CB 3
LC D
Static Bypass Input

A30 B30 C30 N30 UPS Output

CB 2

CB 1

UP ER

A60 B60 C60 N60

BN BP (Battery Input)

A10 B10 C10 (Converter AC input)

ALL POWER TERMINALS USE 5/8 (15 MM) DIAMETER BOLTS

3-7

FIGURE 3.2 b Input/Output Power Terminals (30 kVA UPS)

Power Stage

52CS

DP AU

CB 3
LC D

Static Bypass Input

A30 B30 C30 N30

UPS Output
A60 B60 C60 N60

CB2

CB 1
UP ER

BN BP A10 B10 C10 (Battery (Converter AC input) Input)

ALL POWER TERMINALS USE 3/8 (8 MM) DIAMETER BOLTS

3-8

FIGURE 3.2 c Input/Output Power Terminals (15 kVA, 20 kVA UPS)

Power Stage

52CS

DP AU

CB 3
LC D

Static Bypass Input

A30 B30 C30 N30

UPS Output
A60 B60 C60 N60

CB 2

CB 1
UP ER

BN BP A10 B10 C10 (Battery (Converter Input) AC input)

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

3-9

FIGURE 3.2 d Input/Output Power Terminals (7.5 kVA, 10 kVA UPS)

Power Stage

52CS

DP AU

CB 3
LC D

Static Bypass Input

A30 B30 C30 N30

UPS Output
A60 B60 C60 N60

CB 2

CB 1
UP ER

BN BP A10 B10 C10 (Battery (Converter Input) AC input)

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

3-10

3.4 Operating Procedures A) 1. 2. 3. 4. 5. 6. UPS Start-up Procedure Verify that SW2 (contactor CB3 operator) is in the OFF position. Close Control Circuit Breaker (CB101). Verify that the External Bypass input Circuit Breaker(user supplied. Refer to warning 2) is closed. Place SW2 in the ON position. Within about ten (10) seconds the AC Input Circuit Contactor (CB1), followed by the Battery Disconnect Circuit Contactor (CB2), will automatically close. The audible annunciator will sound and the instruction "PRESS START / STOP KEY" will be displayed on the LCD panel. ( Figure 3.3) Press the "Inverter Start" key in the START/STOP menu on the LCD panel. (Figure 3.4) FIGURE 3.3 START-UP MENU FIGURE 3.4 INVERTER START/STOP

7.

When the message "LOCAL" is displayed on the LCD panel, the inverter start operation can only be performed locally at the UPS front panel. by remote operation only. be. When the message "REMOTE" is displayed on the LCD pane, the inverter start operation can be started Lock-out of one inverter start mode is inherent and cannot

8. 9.

If a local inverter start operation is required (at the UPS), select "Local" in "Remote/Local" function via the Operation menu. Select LOCAL mode. Within five (5) seconds, the Inverter will start-up and begin supplying power to the critical load.

10. If power is not supplied to the load, follow the instructions on the LCD panel.

B) 1. 2.

UPS Shutdown Procedure If a total UPS shutdown is required, verify that the critical load is OFF. Select "STOP MENU" from the Operations menu. 3-11

3. 4.

Press the "INVERTER STOP" key in the START/STOP menu on the LCD panel. The UPS will transfer the load to the static bypass line. When the "LOCAL" is displayed on the LCD panel, the operation can be performed at the UPS front panel. When the "REMOTE is displayed on the LCD pane, the If the inverter stop operation is "Remote/Local" selection Inverter can be stopped by remote operation only. in the Operations menu. Select Local mode.

required locally (at the UPS), select to "LOCAL" from the 5.

Generally, the Inverter alone will be stopped and the Converter will remain energized to float-charge the batteries.

If stopping the converter is required, open control circuit breaker CB101. automatically. WARNING : Verify the load is OFF if the next step is to be performed.

The battery

disconnect contactor (CB2) and the converter input contactor (CB1) will both open

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

Power

to the critical will be lost after execution of the next step. The load will drop.
6. 7. If turning off all power to critical load is desired, open the Bypass input Circuit Breaker(MCCB inside the users cabinet) manually. Contactor CB3 will open automatically.

CAUTION : All UPS power terminals are still live. Lethal voltages present.

De-energize all external sources of AC and DC voltages before handling UPS.

3.5 A)

Maintenance bypass set-up procedure Transfer of load from inverter to maintenance bypass Stop the inverter by pressing the START/STOP key on the LCDs Main Menu. Simultaneously press the tow (2) STOP keys per the instructions. (Note : inverter STOP function inhibited if bypass and inverter are out of sync.) 2. 3. 4. 5. Confirm via the flow diagram on the LCD that the load is fed from the UPS static bypass line. After confirming Step2, rotate cam switch from NORMAL (UPS) to BYPASS (maintenance bypass). UPS can now be powered down per instructions on the LCDs OP. MENU. Transfer is now complete. Load is fed from external source (Utility or generator). 3-12

1.

B) 1. 2. 3. 4. 5. 6.

Transfer of load from maintenance bypass to inverter Confirm SW2 is closed and Static Bypass line is on and energized. Close CB101. Confirm via the flow diagram on the LCD that the UPSs output is fed from the static bypass line. After confirming Step2, rotate cam switch from BYPASS (maintenance bypass) to NORMAL (UPS). Press inverter START key on LCD to transfer load to inverter. Transfer is now complete. Load is protected by UPS.

3-13

4.0

RESPONSE TO UPS FAILURE

UPS FAULT

Depress Silence Alarm Key on MAIN menu. Annunciator Silence

Recording of Fault

Refer to the list of fault codes for the description of the error. Take necessary action per the guidance on the display.

Primary Action

Information to Service Center

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

Note The error code indicated on the LCD display panel at the time of UPS alarm condition is very important. In order to reduce repair time, please include this information, along with the operation status and load status, on all correspondence with Mitsubishis field service group.

4-1

5.0 PARTS REPLACEMENT Contact Mitsubishi or its Authorized Service Center on all issues regarding the replacement of parts. A) Battery operating temperature. Battery end of life is defined as the state of charge resulting Replace

Battery lifetime may vary according to the frequency of use and the average ambient in an ampere-hour capacity less than, or equal to, 80% of nominal capacity. battery if capacity is within this percentage. B) UPS Component Parts schedule. environment. Recommended replacement time interval varies with operating Contact Mitsubishi or its Authorized Service Center for application

Contact Mitsubishi or its Authorized Service Center for a complete parts replacement

specific recommendations.

5-1

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. the LCD display panel. Note details of alarm message on

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

B) If a circuit breaker (MCCB) is in the trip state, depress the toggle to reset the breaker before closing it again.

6-1

Fault Code List

Note 11. Note 1 Note 2 Note 3 Note 4

Code indication
UF003 UF007 UF052 UF053 UF056 UF057 UF058 UF059 UF060 UF102 UF103 UF105 UF106 UF107 UF151 UF152 UF153 UF154 UF156 UF157 UF158 (Note10) UF159 UF160 UF161 UF162 UF201

Status massage
CONVERTER ABNORMAL SENSOR ABNORMAL CB1 TRIPPED CB1 ABNORMAL CONVERTER OVERLOAD CONVERTER OVERTEMPERATURE COOLING FAN ABNORMAL CONVERTER ABNORMAL CONVERTER ABNORMAL DC OVERVOLTAGE DC UNDERVOLTAGE SENSOR ABNORMAL DC CAPACITANCE ABNORMAL CB2 ABNORMAL DC VOLTAGE ABNORMAL DC VOLTAGE ABNORMAL CB2 TRIPPED CB2 ABNORMAL CB2 TRIPPED (BATTERY OVERTEMPERATURE) BATTERY OVERTEMPERATURE BATTERY LIQUID LEVEL LOW DC GROUND FAULT SENSOR ABNORMAL CB2 TRIPPED (DC VOLTAGE ABNORMAL) BATTERY ABNORMAL INVERTER OVERVOLTAGE

Contents
Preliminary charge impossible Converter input current sensor circuit abnormality Input circuit breaker CB1 has tripped Input circuit breaker CB1 abnormal Converter input overcurrent Overheating of converter circuit parts Abnormality of cooling fan (converter circuit) Converter control circuit abnormality Converter IPM abnormal Overvoltage of DC voltage Low voltage of DC voltage DC voltage sensor circuit abnormality Electrolytic capacitor abnormality Battery disconnect circuit breaker CB2 abnormal Does not return to float voltage after power supply is resumed (24 hours) Does not return to equalizing voltage after power supply is resumed Battery disconnect circuit breaker CB2 has tripped. CB2 turned OFF Battery temperature abnormality (UF157) lasted a long time (Note 6) Battery temperature abnormality Battery solution level drop (Note 7) Grounding of DC circuit Sensor abnormality of battery circuit Does not return to float voltage after power supply is resumed (48 hours) (Note 6) Battery abnormal detected by battery self test. Output overvoltage during inverter power supply (+ 15%)

External Failure Guidanc Buzzer send-out e lamp contact

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 2 1 1 2 [2] [2] [1] [1] [1] [1] [1] [1] [2] [2] [2] [2] [2] [2] [1] [1] [1] [1] [1] [1] [1] [1] [1] [1] Major Major Minor Minor Minor Minor Minor Minor Major Major Major Major Major Major Minor Minor Minor Minor Minor Note 5 Minor Note 5 Minor Note 5 Minor Minor Minor Lit up Lit up Flicker Flicker Flicker Flicker Flicker Flicker Lit up Lit up Lit up Lit up Lit up Lit up Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker

Code No.
64 1 97 96 192 194 193 198 199 5 6 2 77 66 116 117 100 101 107 106 105 112 114 196

[2]

Major

Lit up

12

6-2

Note 11.

Note 1

Note 2

Note 3

Note 4

Code indication
UF215 UF216 UF254 UF255 UF256 UF257 UF258 UF301 UF302 UF303 UF304 UF305 UF306 UF309 UF351 UF352 UF355 (Note10) UF356 UF357 UF358 UF359 UF360 UF362 UF401 UF402 UF451 UA801 UA802 UA803 UA804 UA805 (Note10) UA806 UA807 UA808

Status massage
FREQUENT OVERLOAD! INVERTER ABNORMAL 88C ABNORMAL 52C ABNORMAL OUTPUT VOLTAGE ABNORMAL 52C ABNORMAL OVERLOAD UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR INVERTER VOLTAGE ABNORMAL

Contents
Load switching was made frequently during overload Inverter IPM abnormal Fan power source abnormality during operation 52C turned OFF during inverter power supply Inverter output voltage fell out of +/- 5% 52C not turned OFF when manual transfer Frequent overload Control microcomputer abnormality Control microcomputer abnormality Control microcomputer abnormality Control microcomputer abnormality Control circuit abnormality Control power source circuit abnormality Inverter output voltage abnormality before inverter power supply

External Failure Guidanc Buzzer send-out e lamp contact

4 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 11 4 4 4 [2] [2] [1] [1] [1] [1] [1] [2] [2] [2] [2] [2] [2] [2] [1] [1] [1] [1] [1] [1] [1] [1] [1] [2] [2] [1] [1] [1] [1] [1] [1] [1] [1] [1] Over Over Over Major Note5 Major Minor Minor Minor Minor Minor Major Major Major Major Major Major Major Minor Minor Minor Minor Minor Minor Minor Minor Minor Major Major Minor Note 5 Note 5 Note 5 Note 5 Lit up Lit up Flicker Flicker Flicker Flicker Flicker Lit up Lit up Lit up Lit up Lit up Lit up Lit up Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Lit up Lit up Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker

Code No.
86 34 197 128 109 98 201 19 28 29 31 21 16 83 115 111 130 123 124 125 126 127 195 84 85 99 239 161 236 251 237 216 217 218

CONTROL FUSE BLOWN Battery circuit's fuse burnt SUPPLY OF CONTROL CIRCUIT ABNORMAL UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR "INVERTER START " BUTTON ABNORMAL "INVERTER STOP " BUTTON ABNORMAL "INVERTER SUPPLY" BUTTON ABNORMAL "BYPASS SUPPLY" BUTTON ABNORMAL UPS CONTROL CIRCUIT ERROR 52S ABNORMAL 52S ABNORMAL 52S ABNORMAL AC INPUT VOLTAGE OUT OF RANGE AC INPUT FREQUENCY OUT OF RANGE AC INPUT PHASE ROTATION ERROR CONVERTER ABNORMAL AMBIENT TEMPERATURE ABNORMAL INVERTER OVERLOAD > 100% INVERTER OVERLOAD > 110% INVERTER OVERLOAD > 125% Control circuit abnormality Control circuit abnormality Control circuit abnormality "INVERTER START" button is abnormal (Local) "INVERTER STOP" button is abnormal (Local) "INVERTER SUPPLY" button is abnormal "BYPASS SUPPLY" button is abnormal 52S control circuit abnormality (Note 8) 52S not turned ON, or 52S turned ON without any command 52S not turned OFF, or 52S turned OFF without any command 52S not turned ON, or 52S turned ON without any command when manual transfer AC input voltage fell out of +/- 18% range Ac input frequency fell out of converter synchronization follow-up range Phase rotation is inverted when input voltage is normal CONV switch was turned off. Temp. abnormality in room where installed Overload exceeded 105% (Note 9) Overload exceeded 110% (Note 9) Overload exceeded 125% (Note 9)

6-3

Note 11.

Note 1

Note 2

Note 3

Note 4

Code indication
UA809 UA810 UA811 UA812 UA813 UA814 UA816 UA817 UA818 UA819 UA820

Status massage

Contents

External Failure Guidanc Buzzer send-out e lamp contact

4 4 5 5 5 5 [1] [1] [1] [1] [1] [1] [1] 13 5 12 12 [2] [1] [1] [1] Minor Minor Note 5 Over Over Note 5 Note 5 Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker Flicker

Code No.
219 220 240 231 242 243 244 232 241 229 230

UA821

UA822 UA823 UA824 UA826 UA827 UA830 UA831

INVERTER OVERLOAD > Overload exceeded 150% (Note 9) 150% Momentary over-current during Inverter OVERLOAD power. BYPASS VOLTAGE OUT Bypass voltage fell out of +/- 10% range at OF RANGE manual transfer BYPASS VOLTAGE OUT Bypass voltage fell out of +/- 20% range OF RANGE BYPASS PHASE Phase rotation is inverted when bypass ROTATION ERROR voltage is normal BYPASS FREQUENCY Bypass frequency fell out of inverter OUT OF RANGE synchronization follow-up range EXTENDED BYPASS Bypass power supply continued for many OPERATION hours EMERGENCY STOP Emergency stop applied ACTIVATED Transfer cannot be permitted because TRANSFER ABNORMAL Bypass voltage abnormal REMOTE SWITCH There is an error with the remote start ON(START) switch. REMOTE SWITCH There is an error with the remote stop ON(STOP) switch. UPS STOPPED (TRANSFER INHIBITED - Transfer cannot be permitted because INVERTER AND BYPASS Bypass voltage abnormal ASYNCHRONOUS) GENERATOR Transfer cannot be permitted because OPERATION , INHIBITED Generator operation contact is ON BYPASS OPERATION CB1 OFF CB2 OFF CB101 OFF 52C NOT PERMITTED AC INPUT UNDERVOLTAGE EMERGENCY BYPASS SWITCH ON INTERRUPTED TRANSFER OCCURRED WHEN TRANSFERRING TO BYPASS SOURCE BATTERY DEPLETED AC input circuit breaker CB1 turned OFF Battery disconnect circuit breaker CB2 turned OFF Control power source breaker CB101 turned OFF during inverter operation "52C PERMISSION" switch turned to OFF AC input voltage fell out of - 10% range Emergency bypass switch turned to <Emergency> When transfer to the bypass supply, occurs interrupted transfer. DC voltage dropped below discharge end during inverter operation

[1]

Flicker

249

[1] 6 7 8 9 3 10 [1] [1] [1] [1] [1] [1]

Flicker Flicker Flicker Flicker Flicker Flicker Flicker

246 224 225 226 233 234 245

UA832

[1]

Flicker

248

UA834

10

[2]

Note 5

255

UA835

UPS STOPPED (TRANSFER INHIBITED - Transfer cannot be permitted because BYPASS INPUT Bypass voltage is abnormal ABNORMAL) OVERLOAD Converter overload 5

[1]

Flicker

250

UA836

[1]

Flicker

221

6-4

(Note 1) Numbered guidance: 1: 2: 3: 4: 5: 6: 7: 8: 9: Contact Mitsubishi. Verify battery is operating within recommended voltage and temperature ranges. Verify input power source is properly connected. Reduce load. Verify bypass power source is within amplitude and frequency. Close CB1. Close CB2. Close CB101. Reduce load and restart.

10: Press the reset button. 11: Reduce room temperature to within specified UPS operating limits 12: Verify remote switch is properly connected and/or functional. 13: Place switch in OFF position. (Note 2) Audible annunciator: [1] intermittent sound, [2] continuous sound. (Note 3) "Major" is defined as major failure. Inverter transferred 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. UPS will transfer 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 4) Indicates one of two possible LED illumination patterns - continuously on (lit) or intermittent (flicker). (Note 5) External send-out possible by option setting. (Note 6) Trips the battery breaker CB2. (Note 7) For other than sealed-type battery.

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(Note 8) Place UPS Emergency Bypass switch in the BYPASS position. Contact Mitsubishi. (Note 9) If the specified time passes, will transfer to the bypass power supply. (Note 10) Shows only when corresponding option settings are made. (Note 11) Code indication means: UA ------------- Alarm UF ------------- Failure U0 ------------- Converter circuit failure U1 ------------- DC circuit failure U2 ------------- Inverter circuit failure U3 ------------- Control circuit failure U4 ------------- Bypass system failure U8 ------------- Alarm U00 - U49 ------ Major failure U50 - U99 ------ Minor failure

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7.0 Warranty & Out of warranty Service

The Mitsubishi Electric UPS Systems Group Service Department has many Authorized Service Centers place strategically throughout the US, Canada and Latin America. For both in warranty and out of warranty service, please contact Mitsubishi Electric Automation, Inc. at (847) 478-2500. To register your UPS for warranty purposes, please complete the warranty registration form and fax it to the Mitsubishi Electric UPS Systems Group, Service Department fax line shown on the registration form. (Next page) For warranty purposes, it is essential that any and all service work that may be required on your Mitsubishi brand UPS equipment is performed by a Mitsubishi Electric Authorized Service Center. The use of non-authorized service providers may void your warranty.

Mitsubishi Electric Automation Inc, UPS Systems Group Service Department 500 Corporate Woods Parkway, Vernon Hills, Illinois 60061, USA Phone: (847) 478-2500 Fax: (847) 478-2290

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Mitsubishi Electric Automation, Inc.

UNINTERRUPTIBLE POWER SUPPLIES
500 Corporate Woods Parkway, Vernon Hills, IL 60061 Phone: (847) 478-2643, Fax: (847) 478-2290

UPS Warranty Registration

__ Register UPS for Warranty __ Address Change

To validate the Warranty on your UPS this form must be filled out completely by Customer and returned.
CUSTOMER INFORMATION
Your Name: Company Name: Division / Department: Address: City: Country: Business Phone: E-Mail: @ UPS Model #: Start-Up Date: / Signature: / Date: / Which ONE of These Best Describes Your Organizations Primary Business Classification? {Energy Producer} __ Utility __ Alternate Energy {Manufacturing Co.} __ OEM __ Process __ Consumer Goods __ Electronics __ Power Quality Equipment __ Commercial Business __ Electrical Contractor __ Healthcare __ Internet __ Education/Univ. Service {Service} __ Consulting __ Engineering __ Outsourcing __ Financial/Legal/Insurance {Expectations} {Government} __ Military __ Municipals __ Federal/State/Local __ Communications __ Distributors/Reps __ Other __________________ Would you like to receive future product updates and news? __Yes __ No Overall how was Start-Up performed: __Unsatisfactory __ Satisfactory __ Exceeded / Capacity (kVA): UPS Serial #: Ext: State: Province: Fax: Internet Address: Zip Code: Job Title:

Authorized Mitsubishi Service Company (if known):

Number of Employees at This Location is: __ 1 19 __ 20 49 __ 50 99 __ 100 - 249 __ 250 - 499 __ 500 - 999 __1000 or more

After Start-Up has been done Fax completed Form to:

(847) 478-2290
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