operators manual - always on ups systems canada inc. manual . m0403_tn_series_ext ... 8.2. qa /...

GES-TN11-Series – UPS External Wrap Around Bypass System

Operators Manual

M0403_TN_Series_Ext_Bypass_Manual V1.7 2012-06-12

M0403_TN_Series_Ext_Bypass_Manual V1.7 2012-06-12

Note The instructions contained in this manual are not intended to cover all of the details or variations in equipment, or to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, please refer the matter directly to Always“On UPS Systems Inc. Any electrical or mechanical modifications to this equipment, without prior written consent of Always“On UPS Systems Inc, will void all warranties and may void UL/cUL/CSA listing. Unauthorized modifications can also result in personal injury, death, or destruction of the equipment.

UPS Bypass System Please complete the below information and return it to Always“On UPS Systems Inc. This will activate the warranty. If additional information or technical assistance is required call: Always On UPS Systems Inc Sales and Technical Support Line

Toll free at 1-877-259-2976 Ext. 451 or (250) 491-9777 Ext. 451 or Fax (250) 491-9775

Or E-mail at [email protected] or visit our web site at www.alwayson.com

Or write to

Always On UPS Systems Inc. #100 – 150 Campion Road,

Kelowna, BC, V1X 7S8, Canada

Please complete the following information for your records. Model Number: ______________________________________________________________ Serial Number: ______________________________________________________________ Date of Installation: ____________________________________________________________ Inspected By: ______________________________________________________________

M0403_TN_Series_Ext_Bypass_Manual V1.7 2012-06-12 i

mailto:[email protected]

http://www.alwayson.com/

Table of Contents 1. INTRODUCTION ......................................................................................................................................... 1 2. SYSTEM DIAGRAMS ................................................................................................................................. 2

2.1. FOR 208VAC INPUT, 240/120VAC OUTPUT ............................................................................................... 2 2.2. FOR 240VAC INPUT, 240/120VAC OUTPUT ............................................................................................... 4 2.3. FOR 120VAC INPUT, 120VAC OUTPUT ...................................................................................................... 5 2.4. FOR 208VAC INPUT, 120VAC OUTPUT ...................................................................................................... 7

3. LAYOUT ........................................................................................................................................................ 9 4. SITE PREPARATION ............................................................................................................................... 12

4.1. DELIVERY ................................................................................................................................................. 12 4.2. INSPECTION ............................................................................................................................................... 12 4.3. STORAGE ................................................................................................................................................... 12 4.4. LOCATION ................................................................................................................................................. 13

5. INSTALLATION ........................................................................................................................................ 14 5.1. BYPASS UNIT ............................................................................................................................................ 14 5.2. TN SERIES UPS ......................................................................................................................................... 14

6. OPERATION .............................................................................................................................................. 17 6.1. SYSTEM START UP .................................................................................................................................... 17 6.2. SYSTEM SHUTDOWN – LOAD WILL LOSE POWER ....................................................................................... 18 6.3. BYPASS PROCEDURES ............................................................................................................................... 18 ENTERING BYPASS MODE .............................................................................................................................. 18 RESTORING NORMAL OPERATION .................................................................................................................. 18

7. TROUBLESHOOTING ............................................................................................................................. 19 8. CONTACT INFORMATION .................................................................................................................... 20

8.1. ADDITIONAL PURCHASES OR UPGRADES ................................................................................................... 20 8.2. QA / WARRANTY QUESTIONS ................................................................................................................... 20 8.3. SOFTWARE QUESTIONS ............................................................................................................................. 20

M0403_TN_Series_Ext_Bypass_Manual V1.7 2012-06-12 ii

1. Introduction Thank-you for choosing the Always On UPS External Bypass System. It is designed to provide a high degree of protection for the critical loads connected. This manual is a guide to installing and using the Bypass System. It includes important safety instructions for operation and correct installation. Please read this manual in its entirety before setting up, installing and powering up the equipment. Use of the external Bypass allows for maintenance or repair of the UPS system without interruption of power to the critical loads, while maintaining isolation.

M0403_TN_Series_Ext_Bypass_Manual V1.7 2012-06-12 1

2. System Diagrams Section 2.1 is for bypass systems and UPS systems configured with a 208VAC input and a 120/240VAC output. Section 2.2 is for bypass systems and UPS systems configured with a 240VAC input and a 120/240VAC output. Section 2.3 is for bypass systems and UPS systems configured with a 120VAC input and a 120VAC output. All configurations are completed at factory. If alternate configurations or required contact the factory before proceeding as reconfiguring the system will void the warranty and possible damage the system.

2.1. For 208VAC Input, 240/120VAC Output

NFB-2P2W+G

INPUT

UPS INPUT

BATTERIES

TN SERIES UPS

BYPASS

120/240VacTO LOAD3W+GN-G

BONDED

UPSELECTRONICS

OUTPUTBYPASS

UPS

BATTERY

ISO. TRANS.UTILITY

208Vac

208Vac2W+G

120/240Vac3W+G

Figure 2.1.1

Block Diagram of Bypass System


L1 L2 G

2P

240208

120

0120

00

L1

BYPASS SWITCH

L2 N

N

L1

L2

G

L1 L2 G

*N-G BONDED

*

208Vac 2W+G

120/240Vac3W+G

T1

TN SERIESUPS

ACINPUT

ACOUTPUT

RED BLK GRN

BLUE

RED

RED BLK GRN

GRN WHT BLK RED

RED

WHT

BLK

BLUE

WHT

WHTBLKRED

7

53

1

6

2

BLK

UPS INPUT

Figure 2.1.2

Wiring Diagram of Bypass Unit

208VacINPUT

L1

L2

G

B+

B-EXTERNAL

BATTERY

BATTERY

INPUT

EMI /SURGE

INTERNALBATTERIES

CHARGER

UPSELECTRONICS

SNMP OR AS400

RS-232/DRY CONTACT

EMI

MAINTBYPASSSWITCH

240208

0

12088

0120

0

L1

N

L2

120Vac

120Vac240Vac

OUTPUTTERM. BLOCK

OUTPUT

G

Figure 2.1.3 Wiring Diagram of UPS


2.2. For 240VAC Input, 240/120VAC Output

N_Series_Ext_Bypass_Manual V1.7 2012-06-12 4

NFB-2P 2W+G

INPUT

UPS INPUT

BATTERIES

TN SERIES UPS

BYPASS 120/240VacTO LOAD3W+GN-G

BONDED

UPSELECTRONICS

OUTPUTBYPASS

UPS

BATTERY

ISO. TRANS.UTILITY

240Vac

240Vac 2W+G 120/240Vac

3W+G

Figure 2.2.1 Block Diagram of Bypass System

L1 L2 G

2P

240208

120

0120

00

L1

BYPASS SWITCH

L2 N

N

L1

L2

G

L1 L2 G

*N-G BONDED

*

240Vac 2W+G

120/240Vac3W+G

T1

TN SERIESUPS

ACINPUT

ACOUTPUT

RED BLK GRN

BLUE

RED

RED BLK GRN

GRN WHT BLK RED

RED

WHT

BLK

BLUE

WHT

WHTBLKRED

7

53

1

6 2

BLK

UPS INPUT

Figure 2.2.2 Wiring Diagram of Bypass Unit

M0403_T

240Vac INPUT

L1 L2 G

B+ B- EXTERNAL

BATTERY BATTERY

INPUT EMI /

SURGE

INTERNAL BATTERIES

CHARGER

UPSELECTRONICS

SNMP OR AS400RS-232/DRY CONTACT

EMI

MAINTBYPASSSWITCH

240208

0

120 88

0 120

0

L1 N

L2

120Vac

120Vac240Vac

OUTPUTTERM. BLOCKOUTPUT

G

Figure 2.2.3

Wiring Diagram of UPS

2.3. For 120VAC Input, 120VAC Output

NFB-1P 2W+G

INPUT

UPS INPUT

BATTERIES

TN SERIES UPS

BYPASS

120Vac TO LOAD 2W+G

* N-G BONDED

UPS ELECTRONICS

OUTPUT BYPASS

UPS

BATTERY

120/120Vac

UTILITY 120Vac

240Vac 2W+G

120Vac 2W+G

TN SERIES EXT BYPASS

120/240Vac

*




Figure 2.3.2 Wiring Diagram of Bypass System

SNMP OR AS400

Figure 2.3.3

Wiring Diagram of UPS

240Vac INPUT

L1

L2

G

B+

B- EXTERNAL

BATTERY

BATTERY

INPUT

EMI / SURGE

INTERNAL BATTERIES

CHARGER

UPS ELECTRONICS

RS-232/DRY CONTACT

EMI

MAINT BYPASS SWITCH

240 208

0

120 88

0 120

0

L

N 120Vac

OUTPUT TERM. BLOCK

OUTPUT

G

L N G

2P

240208

120

0 120

0 0

BYPASS SWITCH

N L

N

L

G

L1 L2

*N-G BONDED

*

120 Vac 2W + G

I/P

T2

TNUP

ACINPUT

BLK WHT

RED

RED BLK

BLK

UPS INPUT

BLK120 Vac2W + GOUTPUT

SERIESS

ACOUTPUT

7 5 3 1

6

2 0 0 WHT

0DRE

110BLK

0 BLK

BLUE110

110DRET1

110 RED

BLK

BLUE

WHT RED

N. B. B.

WHT

BLK

BLK

BLK

RED

BLK

BLK

RED

RED

BLUE

M0403_T

2.4. For 208VAC Input, 120VAC Output



Figure 2.4.2 Wiring Diagram of Bypass System

M0403_T


Figure 2.4.3 Wiring Diagram of UPS

3. Layout

L1AC INPUT

L2 L1 NTO UPSINPUT

L2FROM UPS

OUTPUT

L1 L2 N L1 L2GND GNDAC OUTPUT

Power Input and Output Terminal Strip + Ground Lugs

UPS Input Breaker

Maintenance Bypass Switch

5-6kVA

Figure 3.1 Back of the 6kVA Bypass Unit


L1AC INPUT

L2 L1 NTO UPSINPUT

L2FROM UPS

OUTPUT

L1 L2 N L1 L2GND GNDAC OUTPUT


Power Input and Output Terminal Strip + Ground Lugs

8-10kVA

UPS Input Breaker

Figure 3.2

Back of the 8-10kVA Bypass Unit



12-15kVA

Figure 3.3 Back of the 12-15kVA Bypass Unit


UPS Input Breaker

Power Input And Output Terminal Strip + Ground Lugs

4. Site Preparation

4.1. Delivery Upon receiving the Bypass Unit, inspect the packaging integrity and the physical condition of the cabinet carefully. In the event that physical damage is visible, the carrier must be informed immediately and a claim filed with them. Inform Always On as soon as the claim has been filed. A copy of the claim should be faxed to Always On at (250) 491-9775. A detailed report of the damage is necessary for carrier insurance claim.

4.2. Inspection Unpack the system carefully. Be sure to notice the packing method, and retain the box and packing material. If you must return the system at any time, you must repack it the way it was originally shipped. Visually inspect the system for damage that may have occurred during shipment. If there is damage, or anything is missing, contact the dealer from whom you purchased the unit, and save the packaging for future shipment. When the system has passed the initial inspection, record the installation date on the back panel of the unit and in the space provided towards the front of this manual. Included with Bypass System: User manual

4.3. Storage If the system is to be stored prior to installation, it should be placed in a dry area where it will not be exposed to dirt, moisture or other contaminants. Extreme storage temperatures are: -30ºC to +60ºC


4.4. Location The Bypass System is intended for installation in a temperature-controlled indoor area, free of conductive contaminants. Qualified individuals should conduct installation. Below is an example of one installation.

BATTERYPACK

"On"Always

Figure 4.1 Typical System Layout - Front View


Figure 4.2 Typical System Layout - Rear View

M0403_T

5. Installation WARNING! The Bypass system should be installed by a qualified technician or personnel and wired in accordance with local and national electrical codes. Be sure the polarities and voltage match the rating of the unit. Check that the loads being protected are within the capacity of the system. Ensure no power has been applied to the systems and nothing has been turned on before proceeding.

5.1. Bypass Unit Note: All connections are available at the rear of the Bypass unit, See Figure 3.2 For a detailed wiring diagram, See Figure 5.1

1. Connect the critical loads to AC Output located on the Input/Output terminal block of the Bypass Unit.

2. Connect input cabling from the utility source to ‘AC Input’ located on the Input/Output terminal block of the Bypass Unit.

WARNING! Do NOT apply utility at this time. WARNING! Do NOT turn ON the UPS at this time.

5.2. TN Series UPS

1. If an optional Battery Bank has been purchased, connect the Battery Bank to the UPS. Refer to the Battery Bank Operators Manual for instructions.

2. Connect input cabling from ‘To UPS AC Input’ located on the Input/Output terminal block of the Bypass Unit to the UPS input terminal block.

3. Connect the output of the TN Series UPS to ‘From UPS AC Output’ located on the Input/Output terminal block of the Bypass Unit.

WARNING! Do NOT apply utility at this time. WARNING! Do NOT turn the UPS on at this time.



OUTPUT I/P L2

INPUT TN SERIES UPS

I/P L1 B- B+

EXT BATT

GND O/P L2 O/P

L1 O/P N

O/PL2

ACINPUT

I/PL1

I/PL2

O/P N O/P

L1 GND

TO UPS AC INPUT

N I/P L2 I/P

L1 O/PL2

O/PL1

FROM UPS AC OUTPUT AC

OUTPUT

GND

INPUTUTILITY

L1GND L2 N TO LOAD

L1 L2

BYPASS UNIT

GND

TO OPTIONAL BATTERY CABINET(S)

B+ B-

Figure 5.1

External Wiring Diagram for the 208VAC and 240VAC system

120 VAC OUTPUT

I/P L2

240 VAC INPUT

TN SERIES UPS

I/P L1 B- B+

EXT BATT

GND O/P L O/P

N

ACINPUT

I/PL

I/PN

O/P N O/P

L1GND

240 VACTO UPS

AC INPUT

I/P N

I/P L O/P

L2O/PL1

120 VAC FROM UPS AC OUTPUT AC

OUTPUT

GND

120 Vac INPUTUTILITY

LGND N N TO LOAD120 VAC

L1

BYPASS UNIT

TO OPTIONAL BATTERY CABINET(S)

B+ B- GND

Figure 5.2 External Wiring Diagram for the 120VAC systems

M0403_T


Figure 5.3 External Wiring Diagram for the 208//120VAC systems

6. Operation 6.1. System Start Up

1. Ensure that all connections are secure and correct as per Installation Instructions.

2. Confirm that the Bypass Switch on the UPS is in the INV position. 3. Confirm that the Bypass Switch on the Bypass Unit is in the INV

position. 4. Confirm that the Battery Breaker on the UPS is in the OFF position. 5. Confirm that the Input Breaker on the UPS is in the OFF position. 6. Confirm that the UPS Input Breaker on the Bypass Unit is in the OFF

position. 7. Remove the cover plate on any Battery Cabinets (if applicable). 8. Switch all Battery Breakers on the Battery Cabinets to the ON position

(if applicable). 9. Switch the Battery Breaker on the UPS to the ON position. 10. Apply utility power to the system. 11. Switch the UPS Input Breaker on the Bypass Unit to the ON position. 12. Switch the Input Breaker on the UPS to the ON position. The UPS will enter Stand-By Mode. The LCD will become illuminated, and fans will start. 13. Press the ON/OFF Button on the front panel of the UPS to turn it ON

(hold the ON/OFF Button for 3 seconds or until the UPS beeps and displays “Ready On”).

The UPS will automatically perform a self-test and then go to line mode. 14. Turn on loads sequentially as required.



6.2. System Shutdown – Load will lose power 1. Turn off loads sequentially as required. 2. Press the ON/OFF Button on the front panel of the UPS to turn it OFF

(hold the ON/OFF Button for 5 seconds or until the UPS beep stops and the LCD displays “Shutdown”). The UPS will shutdown. The LCD will display “UPS Off” for a few seconds and then switch to Stand-By Mode.

3. Switch the Input Breaker on the UPS to the OFF position, and wait 10 seconds before proceeding. The UPS will fully shutdown. The fans will stop, and the LCD will extinguish.

4. Switch the Battery Breaker on the UPS to the OFF position. 5. Switch the Battery Breakers on any attached Battery Cabinets to the

OFF position (if applicable). 6. Switch the UPS Input Breaker on the Bypass Unit to the OFF

position. 7. Remove utility power from the system.

The System is now completely shutdown.

6.3. Bypass Procedures This Bypass System provides the user with the ability to isolate the UPS from the utility power without disrupting power to the load. The UPS can be completely shutdown and even removed so that maintenance can be performed safely, without the load experiencing any downtime. Caution: Only operate the Bypass switch on the Bypass Unit when the UPS is in MAINTENANCE BYPASS mode.

Entering Bypass Mode

1. Put the UPS into Maintenance Bypass Mode by following the instructions found in the UPS Operators Manual.

2. Turn the Bypass Switch on the Bypass Unit to the BYPASS position. 3. Switch the UPS Input Breaker on the Bypass Unit to the OFF position. The UPS is now isolated from utility.

Restoring Normal Operation

1. Ensure the UPS is in MAINTENANCE BYPASS mode. 2. Switch the UPS Input Breaker on the Bypass Unit to the ON position. 3. Turn the Bypass Switch on the Bypass Unit to the NORMAL position. 4. Put the UPS into Normal Operation by following the instructions found in

the UPS Operators Manual. The system is now operating in Normal Mode.

7. Troubleshooting Problem Possible Cause Action to Take Cannot be switched to Bypass Mode

Utility not available at input of bypass system

• Confirm Utility supply and connection.

Cannot be switched to UPS Mode

UPS power not available • Confirm UPS supply and connection

Caution: Only operate the Bypass switch when the UPS is in MAINTENANCE BYPASS mode.


8. CONTACT INFORMATION

8.1. Additional Purchases or Upgrades Always On UPS Systems Inc. Bldg 1 – 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 451 Fax: (250) 491-9775 Email: [email protected] Website: www.alwayson.com

8.2. QA / Warranty Questions

Always On UPS Systems Inc. Bldg 1 – 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 209 Fax: (250) 491-9775 Email: [email protected] Website: www.alwayson.com

8.3. Software Questions

Always On UPS Systems Inc. Bldg 1 – 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 204 Fax: (250) 491-9775 Email: [email protected] Website: www.alwayson.com








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