Emerson 7400 Series User Manual
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Emerson 7400 Series User Manual

Emerson 7400 Series User Manual

Single phase ups system
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Single Phase UPS system
S i n g l e
m o d u l e
a n d
'1 + N' ( e x p a n d a b l e )
UNI N TERRUPTI B LE POWER SYSTEM
U s e r M a n u a l
EMERSON Network Power (India) Pvt. Ltd.
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  • Page 1 ‘1 + N’ ( e x p a n d a b l e ) UNI N TERRUPTI B LE POWER SYSTEM U s e r M a n u a l EMERSON Network Power (India) Pvt. Ltd.
  • Page 2 It is our constant endeavour to partner you for the growth and success of your business. This philosophy is reflected in our Mission statement “To deliver value through Air & Power Quality solutions to achieve customer delight”. Please do give us feedback to help us realize our Mission. Emerson Network Power (India) Private Limited...
  • Page 3 The Series 7400 1Phase UPS has been designed for Commercial / Industrial use only. The Series 7400 1Phase UPS is not designed for direct use in any life support application. If you encounter any problem with the procedures contained in this manual you should seek immediate assistance from Emerson Network Power (India) Pvt.
  • Page 4 R E G I S T E R E D A N D H E A D O F F I C E R E G I S T E R E D A N D H E A D O F F I C E EMERSON NETWORK POWER (INDIA) PVT. LTD. PLOT NO. C-20, ROAD NO. 19 WAGLE INDUSTRIAL ESTATE THANE –...
  • Page 5 Branch Offices: BARODA 39 / 2, Arunodaya Society, Alkapuri, BARODA-390 005 Tel : 0265-314296, 330383 Fax: 0265-314296, 330383 CHANDIGARH SCO-198 / 199 / 200, Sector – 34A, Near Labour Chowk, CHANDIGARH Phone: 0172-662 873 Mobile: 9814100901 CHENNAI No. 22, First Floor, Gopal Krishna Road, T.
  • Page 6 Safety Procedure WARNING This is a class A UPS product. In a domestic environment, this product may cause radio interface in which case the user may be required to take additional measures. WARNING HIGH EARTH LEAKAGE CURRENT: EARTH CONNECTIONS ESSENTIAL BEFORE CONNECTING THE INPUT SUPPLY. This equipment must...
  • Page 7 GENERAL As with other types of high power equipment, dangerous voltages are present within the UPS and battery enclosure. The risk of contact with these is minimised as the live component parts are housed behind a hinged, lockable door. Further internal safety screens make the equipment protected to IP20 standards.

  • Page 8: Table Of Contents

    General Description Introduction Design Concept 1.2.1 Redundant vs Non redundant configuration 1.2.2 7400 Module Design 1.2.3 Bypass Supplies 1.2.4 UPS Power Switch Configuration 1.2.5 Battery circuit breaker 1.2.6 One plus one parallel control 1.2.7 Common Battery 1.2.8 Operator Control Panel 1.2.9...
  • Page 9 Optional Equipment AS400 Interface Board (#10021512003) 4.1.1 AS400 Interface board outputs 4.1.2 Remote control inputs 4.1.3 Calibration 4-Way AS400 Interface Board (#100201120004) 4.2.1 Remote control inputs 4.2.2 Calibration Output Interface (Remote alarms) Board (#100215120007 & #100215120002) 4.3.1 Alarm Outputs 4.3.2 Remote control inputs Remote Alarm Monitor (RAM) for Single Module and 1+1 UPS System Maintenance...

  • Page 10: General Description

    If the mains power fails, the UPS continues to power the critical load from its battery source, leaving the load immune from power disturbances. The one-plus-one system comprises two standard 7400 series UPS modules which are modified to allow their outputs to be connected in parallel.

  • Page 11: Module Design

    RECTIFIER INVERTER (d.c) BATTERY Figure 1: Series 7400 UPS Single Module Block Diagram As previously mentioned, each of the two modules forming the one-plus-one system is basically a standard single module 7400 series UPS. This section describes an individual module’s operating principles - the effects of the additional parallel control facilities on the standard module are described later.

  • Page 12: Bypass Supplies

    B r e a k e r BATTERY B. BLOCK SCHEMATIC FOR 110V OUTPUT 1PH. UPS SYSTEM Figure 2: Series 7400 UPS Isolator configurations The circuit block annotated ‘Static Switch’ in figure 2 contains an electronically controlled switching circuit, which enables the critical load to be connected either to the Inverter output or to a Bypass power source via the ‘static bypass line’.

  • Page 13: Ups Power Switch Configuration

    ‘Bypass’ power source which also feeds the maintenance bypass line. The power switch locations in the various 7400 models are shown in Figure 3. With the exception of the maintenance bypass isolator, all the isolators shown must be closed during normal UPS operation.
  • Page 14 Series 7400 Single Phase 1+N UPS Output Maintenance Isolator Bypass Isolator 10/ 40 kVA Output Maintenance Isolator Bypass Isolator 1250 1250 60/ 80 kVA Figure 3A: Power Isolator identification for 230V output system Static Input Bypass Isolator Isolator Output Static...
  • Page 15 Series 7400 Single Phase 1+N UPS Output Maintenance Isolator Bypass Isolator 10/ 40 kVA Output Maintenance Isolator Bypass Isolator 60/ 70 kVA Input Isolator Input Isolator 1250 1250 Figure 3B: Power Isolator identification for 110V output system Output Maintenance Input...

  • Page 16: One Plus One Parallel Control

    7400 module to form part of a one-plus-one system it is not a straightforward proposition. The inter-module parallel control responsibilities are complex but...
  • Page 17 Series 7400 Single Phase 1+N UPS Bypass Supply Mains Supply BATTERY BATTERY Mains Supply Bypass Supply RECTIFIER INVERTER RECTIFIER INVERTER Figure 4: Parallel control in a one-plus-one system Battery charge current sharing: The illustration in figure 4 shows a dedicated battery installation for each module;...

  • Page 18: Common Battery

    Series 7400 Single Phase 1+N UPS Bypass Supply Mains Supply BATTERY Mains Supply Bypass Supply 1.2.7 Common Battery RECTIFIER INVERTER 1+1 PARALLEL CONTROL Common Batt. Panel 1+1 PARALLEL CONTROL RECTIFIER INVERTER Figure 5: ‘Common Battery’ configuration A “Common battery” option kit contains a DCCT (DC Current Transformers) which are fitted to the battery power lines and monitored by the parallel control logic.

  • Page 19: Operator Control Panel

    Series 7400 Single Phase 1+N UPS Uninterruptible Power System 1.2.8 Operator Control Panel Uninterruptible Power System Figure 7: Mimic Panel MEASUREMENTS Figure 6: Operator Control Panel The operator control panel is divided into three functional areas; ‘Mimic indications’, Control switches’, and ‘LCD display panel’.
  • Page 20 Series 7400 Single Phase 1+N UPS M E A S U R E M E N T S ALARM I N V E R T E R ((•)) Figure 8: Control Panel Switches LS5 - Load on bypass: This led illuminates when the output isolator is closed and the load is connected to the bypass via the static switch.
  • Page 21 Series 7400 Single Phase 1+N UPS Switch S7 - Inverter ON: Pressing this switch activates the inverter and causes the load to be transferred to the inverter side of the static switch after the inverter voltage has had time to stabilise.

  • Page 22: Battery Circuit Breaker

    Series 7400 Single Phase 1+N UPS *** ALARM *** EMERGENCY STOP *** ALARM *** INVERTER OFF OR FAILED *** ALARM *** OVER TEMPERATURE *** ALARM *** OVERLOAD *** ALARM *** BATTERY CB OPEN *** ALARM *** OUTPUT CB OPEN *** ALARM ***...

  • Page 23: Safety Precautions

    Series 7400 Single Phase 1+N UPS 1.3 Safety Precautions 1.3.1 General 1.3.2 Batteries 1.3.3 Test Equipment 1.3.4 Personnel In common with other types of high power equipment, dangerous voltages are present within the UPS and battery enclosure. The risk of contact with these voltages is minimised as the live component parts are housed behind a hinged, lockable door.

  • Page 24: Operating Instructions

    It can be cancelled at any time by pressing the ‘Alarm Reset’ pushbutton. Note 3: The 7400 series UPS incorporates an optional automatic boost charge facility which can be used in systems containing non-sealed lead-acid batteries. If this type of battery is used in your installation you may notice that the battery charger voltage will be greater than its nominal 432Vdc when the mains supply returns from a prolonged outage.
  • Page 25 Series 7400 Single Phase 1+N UPS How to turn ON the System from a Shut down condition (Complete this actions on one module at a time) This procedure should be followed when turning on the one-plus-one system from a fully powered down condition - i.e. where the load is not being initially supplied through the internal Maintenance Bypass supply.
  • Page 26 Series 7400 Single Phase 1+N UPS How to turn ON the System from a Maint. power-down condition (Complete this action on module at a time) This procedure should be followed to start the one-plus-one from a MAINTENANCE power-down condition - i.e. where the load is being initially powered through the internal maintenance bypass supply.
  • Page 27 Series 7400 Single Phase 1+N UPS How to turn OFF the System but continue to provide Load power through the Maintenance Bypass This procedure should be followed if one-plus-one is to be powered-down while continuing to supply load through the maintenance bypass line. Note that during this procedure the load will be unprotected against mains supply disturbances once the inverter(s) has been switched off.
  • Page 28 Series 7400 Single Phase 1+N UPS How to totally Power down the System This procedure should be followed only if the one-plus-one AND LOAD are to be completely powered down. Step Action Press the Inverter OFF switch (S6) on both modules.
  • Page 29 Series 7400 Single Phase 1+N UPS...

  • Page 30: Introduction

    Series 7400 Single Phase 1+N UPS C h a p t e r 3 C h a p t e r 3 Installation Procedure 3.1 Introduction Do not apply electrical power to the UPS equipment before the arrival of the...

  • Page 31: Equipment Positioning And Environmental Considerations

    UPS is to operate in a dirty environment. Cooling air flow All the models in the 7400 range are forced-cooled with the aid of internal fans. Cooling air enters the module through ventilation grills located at the bottom of the front, back and side panels (and the door in the case of the 50, 60, 80, 105 &...

  • Page 32: Battery Location

    UPS using the most direct route possible. Emerson Network Power (India) Pvt. Ltd. offer a purpose-designed remote battery circuit breaker box, containing the circuit breaker and its necessary control board, as a standard option kit.
  • Page 33 Series 7400 Single Phase 1+N UPS Note: If ‘side’ cable entry is to be used ensure that the blanking plates are removed before finally fixing the cabinet position. 5. All UPS models have a stabilising bar fitted to the output transformer T1 and input choke L1 during shipment.

  • Page 34: Connecting Ups Power Cables

    Series 7400 Single Phase 1+N UPS 3.3 Connecting UPS Power Cables 3.3.1 Cable Entry 3.3.2 Cable Rating WARNING Ø Before cabling-up the UPS, ensure that you are aware of the location and operation of the external isolators that connect the UPS Input / Bypass supply to the mains distribution panel.

  • Page 35: Cable Connections

    12 – 14. For 110V systems Static bypass isolator is located in auxiliary cubicles which is usually in scope of Emerson Network Power (India) Pvt. Ltd. Generally it is mounted in SCVS/ SVR cubicles. The cable connection details for the same are given in figures 15 – 18.
  • Page 36 Series 7400 Single Phase 1+N UPS Connect the safety earth and any necessary bonding earth cables to the copper earth busbar located on the floor of the equipment below the power connections. Note:- The earthing and neutral bonding arrangement must be in accordance with local and national codes of practice.
  • Page 37 Series 7400 Single Phase 1+N UPS NU RU NI RI SI TI Figure 11: Cable connection 25-40kVA, 230V, 1 Ph. Figure 12: Cable connection 50kVA, 230V, 1 Ph. NS RS RI SI TI...
  • Page 38 Series 7400 Single Phase 1+N UPS RI SI TI + - Figure 13: Cable connection 60 / 80 kVA, 230V, 1 Ph. N3 NI UI VI WI Figure 14: Cable connections for 105 kVA, 230V, 1 Ph.
  • Page 39 Series 7400 Single Phase 1+N UPS RU NU NS1 RS1 NS2 RS2 Figure 15: Cable connection 25-40kVA, 110V, 1 Ph. Figure 16: Cable connection 50kVA, 110V, 1 Ph. RI SI TI RI SI TI...
  • Page 40 Series 7400 Single Phase 1+N UPS RS RI SI TI Figure 17: Cable connection 60 / 70 kVA, 110V, 1 Ph. N3 N2 RI SI TI Figure 18: Cable connections for 105 kVA, 230V, 1 Ph.

  • Page 41: Battery Circuit Breaker Boxes

    Series 7400 Single Phase 1+N UPS 3.5 Battery Circuit Breaker Boxes U P S C A B I N E T NU RU NI RI SI TI A battery circuit breaker box houses the battery circuit breaker and its controller board and is used to connect the battery to the UPS in installations where the batteries are not contained in the standard battery cabinet.
  • Page 42 Series 7400 Single Phase 1+N UPS U P S C A B I N E T Figure 20: Battery C/B box connections for a typical 105 kVA 230V 1 PH UPS Usually the ‘box’ is fitted as close as possible to the batteries.
  • Page 43 Series 7400 Single Phase 1+N UPS...

  • Page 44: Optional Equipment

    4 Optional Equipment Several items of optional equipment are available for fitting to the 7400 series UPS for the use by the customer as required. These options are: IBM AS400 Interface IBM AS400 Interface with 4-way output Output Interface Board Remote Alarms Board.

  • Page 45: As400 Interface Board Outputs

    UPS internal low voltage supplies. When fitting the AS400 interface board to the 7400 series, ensure that link SH - 1 is in position 1 - 2. single module.
  • Page 46 Series 7400 Single Phase 1+N UPS A S 4 0 0 I N T E R F A C E P a r t N o . 1 0 0 2 1 5 1 2 0 0 0 3 A S 4 0 0 O u t p u t s...

  • Page 47: Way As400 Interface Board (#100201120004)

    UPS internal low voltage supplies. When fitting the AS400 interface board to the 7400 series, ensure that link SH-1 is in position 1-2.
  • Page 48 Series 7400 Single Phase 1+N UPS Control Inputs TB - M1 Synchro Inverter R L 7 R L 9 R L 6 R L 8 RL10 A S 4 0 0 P a r t N o . 1 0 0 2 0 1 1 2 0 0 0 4...

  • Page 49: Output Interface (Remote Alarms) Board (#100215120007 100215120002)

    Series 7400 Single Phase 1+N UPS 4.3 Output Interface (Remote Alarms) Board (100215120007 & 100215120002) 4.3.1 Alarm Outputs 4.3.2 Remote Control Inputs Two remote alarm boards, shown in figure 23 & 24, similar in function and differing only in their connections to the terminal...
  • Page 50 Series 7400 Single Phase 1+N UPS MAINS VOLTAGE OK RECTIFIER ACTIVE OVER TEMPERATURE MAINT, BYPASS ENABLED STATIC BYPASS ISOLATOR CLOSED (SPLIT BYPASS) OUTPUT SWITCH CLOSED SYNCHRO INHIBIT INVERTER ON/OFF BATTERY OK PRE-ALARM END OF DISCHARGE INVERTER OK SYNCHRO OK LOAD ON UPS...
  • Page 51 Series 7400 Single Phase 1+N UPS Remote Alarm Monitor (RAM) for Single Module & “1 + 1” UPS System. This will contain following items: 1. Remote Alarm Monitor for Single Module #270154000001. 2. Remote Alarm Monitor for 1+1 Module #270154000003.
  • Page 52 Series 7400 Single Phase 1+N UPS Figure 25: Remote alarm monitors for single module and 1+1 configuration...
  • Page 53 Series 7400 Single Phase 1+N UPS OUTPUT INTERFACE PCB MOUNTED IN UPS SYSTEM MAINS OK (BYPASS) RECTIFIER ACTIVE BATTERY END OF DISCHARGE INVERTER SYNCHRO LOAD ON LOAD ON BYPASS OVER TEMPERATURE OVERLOAD MAINT. BYP. ENABLED STATIC BYPASS ISOLATOR CLOSED OUTPUT SWITCH...
  • Page 54 Series 7400 Single Phase 1+N UPS OUTPUT INTERFACE PCB MOUNTED IN MODULE 1 MAINS OK MIMIC STATUS LED – MAINS (BYPASS) OK (BYPASS) RECTIFIER MIMIC STATUS LED – RECTIFIER ACTIVE ACTIVE BATTERY MIMIC STATUS LED – BATT. BREAKER OK END OF...
  • Page 55 Series 7400 Single Phase 1+N UPS...

  • Page 56: Maintenance

    Series 7400 Single Phase 1+N UPS C h a p t e r 5 C h a p t e r 5 Maintenance 5.1 Introduction 5.2 Safety Precautions 5.3 Scheduled Maintenance 5.3.1 Daily Checks This chapter contains the procedures necessary to effect general maintenance of the UPS module and battery.

  • Page 57: Weekly Checks

    Series 7400 Single Phase 1+N UPS 5.3.2 Weekly Checks 5.3.3 Annual Service Carry out the following checks from the mimic panel and log the results: 1. Measure and record the battery float charge voltage. 2. Measure and record the battery charge current.

  • Page 58: Extended Service

    Series 7400 Single Phase 1+N UPS 5.3.4 Extended Service 5.3.5 Battery Maintenance 6. Carry thorough components and sub-assemblies, paying particular attention to the following - Electrolytic capacitors - Check for signs of leakage, buckling etc. Magnetic components - Check for signs of overheating, security of fixture and signs of delamination.
  • Page 59 Series 7400 Single Phase 1+N UPS...

  • Page 60: Troubleshooting

    Series 7400 Single Phase 1+N UPS C h a p t e r 6 C h a p t e r 6 Troubleshooting 6.1 Troubleshooting UPS systems 6.1.1 Operating Parameters and Limitations 6.1.2 General Troubleshooting Procedure The UPS contains complex electronic control circuits that require a firm understanding in order to carry out comprehensive fault diagnosis and repair of the equipment.
  • Page 61 Series 7400 Single Phase 1+N UPS Corrective Action When all the indications have been noted, you should refer to the following fault interpretation charts and carry out the actions detailed against any led whose status is abnormal. unsure as to how to undertake the actions detailed - or if several...
  • Page 62 Series 7400 Single Phase 1+N UPS NORMAL NUMBER STATE ACTIONS TO BE TAKEN IF ABNORMAL If this led is OFF it signifies a problem either with the incoming mains supply or the rectifier section. accompanying alarm messages. Check the following: a) Input isolator is closed.
  • Page 63 Series 7400 Single Phase 1+N UPS NORMAL NUMBER STATE LS5** LS6** ACTIONS TO BE TAKEN IF ABNORMAL If this led is OFF it signifies that the inverter is not producing its correct output voltage. Check the following: a) If [OVERTEMPERATURE] OR [OVERLOAD] alarm...

  • Page 64: Display Panel Message Interpretation

    Series 7400 Single Phase 1+N UPS Display Panel Message Interpretation DISPLAY MESSAGE EMERGENCY STOP INVERTER OFF OR FAILED OVERTEMPERATURE OVERLOAD BATTERY C/B OPEN OUTPUT C.B. OPEN RECTIFIER OFF FAILED The following table lists the various messages displayed on the operator panel together with a description of their interpretation.
  • Page 65 Series 7400 Single Phase 1+N UPS DISPLAY MESSAGE UPS ON MAINTENANCE BYPASS INVERTER UNSYNCHRONISED BATTERY ON LOAD MAINS FAILURE LOAD ON BYPASS INTERPRETATION This is a status warning that the load is being powered through the maintenance bypass line and is unprotected from mains supply abbreviations.

  • Page 66: Annexure

    Series 7400 Single Phase 1+N UPS A N N E X U R E Inter Connection cable details Any system essentially needs UPS module. However many customers need auxiliary Transformers, Battery Current Sharing Kit, 1+1 Paralleling kit, Bypass SCVS / SVR or Bypass Line Transformers. In case any of the auxiliary cubicle or combination of them is required &...
  • Page 67 Series 7400 Single Phase 1+N UPS...

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