Sect 9

Section 9: Optional Equipment
Chapter 1 - Alarm Interface Board 4590055P

1.1 General description ................................................................................... 9-1
1.1.1 Remote control inputs .................................................................. 9-2
1.1.2 AS400 Interface ........................................................................... 9-2
1.1.3 Alarm outputs ............................................................................... 9-3
1.1.4 X2 Extension ................................................................................ 9-3
Chapter 2 - Remote Alarm Interface 4590056Q
2.1 Introduction .............................................................................................. 9-5
2.2 Alarm outputs ........................................................................................... 9-6
2.3 Alarm inputs ............................................................................................. 9-6
Chapter 3 - Remote Alarm Monitor 4305001Z
3.1 General description ................................................................................... 9-9
3.1.1 Connections .................................................................................. 9-9
3.2 Detailed circuit description .................................................................... 9-11
3.2.1 Power supply .............................................................................. 9-11
3.2.2 Alarm indications ....................................................................... 9-11
3.2.3 Audible alarm control ................................................................ 9-12
Chapter 4 - Battery cabinets
4.1 General introduction ............................................................................... 9-15
4.2 Type D' (85 Ah) Battery cabinet assembly and installation ................. 9-15
Chapter 5 - Battery Breaker Boxes
5.1 Introduction ............................................................................................ 9-23
5.2 Circuit breaker details ............................................................................ 9-23
5.3 Battery Circuit Breaker Interface Board (4520067-T) ........................... 9-25
5.3.1 Circuit breaker close operation ............................................... 9-25
5.3.2 Auxiliary contacts ...................................................................... 9-25
5.3.3 Temperature sensor .................................................................... 9-25
Chapter 6 - Input Harmonic Filters
6.1 General Introduction ............................................................................... 9-27
6.1.1 Specification .............................................................................. 9-27
6.1.2 Notes on connection ................................................................... 9-27
Chapter 7 - RS232 Comms Kit 4645101T
7.1 Hardware and Installation Requirements ............................................... 9-31
7.2 UPS Hardware and Software Configuration .......................................... 9-32
7.2.1 Master UPS Set-Up .................................................................... 9-32
7.2.2 Slave UPS Set-Up ...................................................................... 9-33
7.2.3 Installing the Software program ................................................. 9-33
7.2.4 Running the Software ................................................................ 9-35
7.2.5 Accessing the Data ..................................................................... 9-37
S-8.FM5 - Issue 2 Dated 21/08/97
SECTION 9 - Optional Equipment
ii
7200 Series UPS Service Manual
S-8.FM5 - Issue 2 Dated 21/08/97
Section 9:
Chapter 1 - Alarm Interface Board 4590055P
1.1
General description
The Alarm Interface board is fitted in the right hand side of the unit, on the front
lower face (see Figure 9-1) near the auxiliary terminal block (X3), and is connected to the UPS control electronics (UPS Logic board) by a ribbon cable (W10)
which is normally stowed in the cable loom when not in use. The board has several functions as described below:
4530025T
Figure 9-1: Alarm Board location
4550007H
Alarm Board
s8-c1.fm5 - Issue 1 Dated 21/08/97
9-1

CHAPTER 1 - Alarm Interface Board 4590055P
1.1.1
Remote control inputs

The Interface Board has facilities to accept three remote control inputs, as shown
in Figure 9-2. The external control signals (12Vd.c. or 12Va.c.), which are optocoupled to the electronics, should be connected to terminal block X5 as shown in
Figure 9-2.
Important
The control voltages applied to these terminals must be generated by an external

power source and not taken from the UPS internal low voltage supplies.
The remote input to X5 pins 1 and 2 is not used. The input to pins 3 and 4 enable
the inverter to be shut down remotely transferring the load to the bypass supply.
The third remote input, to X5 pins 5 and 6, is most often used in conjunction with
a stand-by generator which may be activated when the input mains supply fails.
The effects of this input can be configured from the Operator Control Panel to a
combination of the following; reduce the input current limit; reduce the battery
current limit; inhibit the inverter/bypass synchronisation.
1.1.2
AS400 Interface
The AS400 Interface connects the five most operationally critical UPS alarms to
an IBM AS400 computer, which is designed to monitor such alarms and respond
to their appearance.
Connection to the AS400 is provided on the Interface Board via a terminal block
X3. These alarm signals are provided by volt-free relay contacts, maximum contact rating is 50 Vcc @ 1 Amp.
The alarms in question are:
Load On Static Bypass [AS400BY>
When high, this signal energises relay K6 and connects X3 pin 5 to pin 1 (0V).
This occurs when the maintenance bypass switch is open and a transfer-to bypass request is present (alarm [#18]).
Low Battery Warning [AS400BL>
This alarm is enabled only if the maintenance bypass switch is open, the load is
on-inverter [#01], and the rectifier is stopped [#22] for any reason. The alarm
then activates when the battery voltage falls below the minimum programmed
Low Battery Level [#56] (usually set to occur at 355Vdc).
Maintenance Bypass Breaker Open [AS400ON>
This occurs when the maintenance bypass switch is open.
Mains or Rectifier Failure [AS400UE>
This alarm is enabled only if the maintenance bypass switch is open and the load
is on-inverter [#01]. The alarm then activates when the rectifier is stopped
[#22] for any reason.
9-2
1.1.3

Alarm outputs
In addition to the AS400 alarm outputs the Interface Board also contains a number
of relays whose contacts provide a set of volt-free alarm outputs that are connected to terminal block X4 - as shown in Figure 9-2. These outputs can be used to
drive an external alarms monitoring device. Maximum contact rating on M1 terminals = 50 Vcc @ 1 Amp. Note:- When using the above contacts for remote
alarm annunciation, the power supply for the remote indicators must be obtained
from an external power source and not taken from the UPS internal low voltage
supplies.
The alarms in question are:
Bypass Supply Failure [MNS_KO>
When high, this signal energises relay K1 and connects X4 pin 14 to pin 15. This
alarm is active when the bypass voltage is low (undervoltage alarm [#12]), the
bypass voltage is high (overvoltage alarm [#11]) or absent (alarm [#10]); or the
bypass-side static switch is selected blocked [#17] via the Operator Control Panel
menuing system.
Low Battery Warning [BATED>
alarm is active when the battery breaker is open [#05], the bypass fuse is open
[#57]) or the Low Battery alarm is active [#56]). The Low Battery alarm threshold
is programmable via the Operator Control Panel menuing system, and is usually
set at 360Vdc (i.e. 1.82V/Cell).
Load -on Bypass [MNS_L>
alarm is active when the Static Switch bypass-side SCRs are triggered by the UPS
Logic Board (alarm [#18]).
Maintenance Bypass Breaker closed [SW_BYP>
alarm is active when the Maintenance Bypass breaker is closed as sensed via the
UPS Logic Board (alarm [#06]).
Load on Inverter [INV_L>
alarm is active when the inverter output contactor is closed, as controlled by the
UPS Logic Board (alarm [#01]).
1.1.4
X2 Extension
The X2 connection on the board is provided to interface the UPS systems with the
remote alarms board part number 4590056Q which contains additional alarms.
9-3

Figure 9-2: Interface Board inputs/outputs
X5
6
ON_GEN
On generator = apply 12V
5
4
INV_OFF
3
2
Inverter off = apply 12V

Not Used
X4
RL-K1
15
14
MNS_KO
Mains or Rectifier Failure
13
RL-K2
12
11
BATED
Low Battery (pre-alarm)
10
RL-K3
9
8
MNS_L
Load on Bypass
RL-K4
X2
6
5
SW_BYP
Load on Maintenance
Bypass
RL-K5
INV_L
Load on Inverter
X3
RL-K6
Load on Bypass
Low Battery
Maintenance Bypass
Open
Mains or Rectifier Failure
AS400BY
RL-K7
AS400BL
RL-K8
AS400ON
RL-K9
AS400UE
Common (0V)
Maximum Contact Rating = 50Vcc @ 1 ampere
9-4
Section 9:
Chapter 2 - Remote Alarm Interface 4590056Q
2.1
Introduction
The Remote Alarms Interface board is fitted in the right hand side of the unit and
is connected (piggy back style) directly via connector X1 onto the Alarm Interface
Board (4590055P) connector X2. This board therefore can only be used in conjunction with the Interface Board (4590055P).
All alarms are generated via software routines on the UPS Logic Board and output
from the micro data bus via a series of controlled output buffers. The signals then
pass via a piggy-back connection through the Alarm Interface Board (4590055P)
to the Remote Alarm Interface Board where they energise appropriate relay coils
via N-P-N switching transistors i.e. any UPS Logic flag (e.g. [OVL>) going high
(+5V) will energise the relay coil.
4530025T
Figure 9-3: Location of Alarm Interface Boards
4550007H
Alarm Interface Board

Part Number 4590055P
Remote Alarm Interface Board
Part Number 4590056Q
9-5

CHAPTER 2 - Remote Alarm Interface 4590056Q
2.2
Alarm outputs
The Remote Alarms Interface board output relays all have changeover contacts
which can be used to provide make or break volt-free alarm outputs via terminal blocks X2 and X3 - as shown in Figure 9-4. The contacts are rated at 50Vdc
@ 1 amp and can be connected to an external remote alarms signalling system.
Important
2.3
The power supply for any remote indicators must be provided from an external
power source. Under no circumstances should the UPS internal low voltage supplies be used for this purpose.
Alarm inputs
Any of the following UPS Logic Board alarm flags (e.g. [OVL>) going high (+5V)
will energise the relay coil.
Battery discharging alarm [BAT-DSC>
When high, energises relay K1 and connects X2 pins 14 and 15.

This alarm is enabled when the battery breaker is closed and the battery fuse in
intact and then active when rectifier block (alarm #22) signal is present.
Inverter overload alarm [OVL>

This alarm is active when either the 150% current limit (alarm # 33) or the overload timer (alarm 66) is enabled.
Overtemperature alarm [OVT_DIS>

This alarm is active when a rectifier overtemperature (alarm # 24) or an inverter
overtemperature (alarm #34) is enabled.
Inverter unsynchronised alarm [SYN_KO>

This alarm is active when the R phase of the bypass supply and inverter are displaced by more than 11 (alarm #35).
Common alarm [ALL_GEN>

This is a general alarm facility and is activated from any of the following:
9-6
Bypass-side static switch is blocked (inhibited) by hardware (alarm #16)

Inverter is unsynchronised (alarm # 35)
Overtemperature is active (alarm #24 or # 34)
Battery is discharging (alarm #52)
Maintenance Bypass Breaker is closed (alarm #06)
Low Battery/ Open Battery warning (alarm #05 or #56 or #57)
Bypass supply failure (alarm #10 or #11 or #12 or #17)
Overload is active (alarm #33 or #66)

Battery overtemperature alarm [OVT_BAT>
Excessive ambient air temperature within the battery cabinet (not programmed).
Bypass-side Static Switch blocked [CS_KO>

This alarm is active if the UPS Logic Board is hardware-blocking a transfer to
bypass (alarm #16) e.g. Emergency power off (#63); Open SCR (#15); Bypass
phase rotation error (#14), PCB Power supply failure; UPS Logic Board Q1 selected to inhibit.
Rectifier input voltage failure [MNS_REC>

This alarm is active when the rectifier input voltage drops below -20% of nominal; as sensed by the Rectifier Logic Board (H9 illuminated).
Ambient air overtemperature [OVT_AMD>
Excessive ambient air temperature within the UPS cabinet (not programmed).
Rectifier inhibited [CHG_INH> or [OUT_01>
Rectifier shut-down (not programmed).
9-7

Figure 9-4: Remote Alarms Interface Board Part No 4590056Q
X2
RL-K1
BAT_DSC
15
14
Battery on Load
13
RL-K2
OVL
12
11
Overload
10
RL-K3
OVT_DIS
9
8
Overtemperature
RL-K4
Connect piggy-back to X2 of 4590055P
SYN_KO
6
5
Inverter Unsynchronised
X1
RL-K5
ALL_GEN
3
2
Common Alarm
X3
RL-K6
OVT_BAT(N/A)
15
14
13
RL-K7
CS_KO
12
11
Battery Cabinet
Ambient overtemp
Not Used
Bypass Static Switch

Blocked
10
RL-K8
MNS_REC
9
8
7
RL-K9
OVT_AMB (N/A)
5
4
RL-K10
CHG_INH
OUT_01
9-8
Rectifier input volts

failure (-20%)
UPS Cabinet
Ambient overtemp
Not Used
3
2
Not Used
Section 9:
Chapter 3 - Remote Alarm Monitor 4305001Z
3.1
General description
When used in conjunction with the Alarms Interface Board (4590055P) described
previously, the Remote Alarm Monitor (R.A.M.) enables the auxiliary alarm signals to be displayed at a remote station up to 200 metres from the main equipment.
The R.A.M. can be mounted either horizontally or vertically and contains a
mains-driven power supply to power the alarm LEDs. The following alarm indications are displayed:
Table 9-1: LED Indications
Panel
Indication
Colour
Normal
state
green
ON
Normal operating condition indicating that

the load is being supplied by the inverter.
This is not an alarm' indicator.
Utility Failure:
red
OFF
When lit, it indicates that the input mains are

out of tolerance or rectifier has failed.
Battery low:
red
OFF
When lit, it indicates that the battery voltage

is below minimum or that the battery circuit
breaker is open.
Bypass ON:
red
OFF
When lit, it indicates that the load is being

fed from the bypass supply possibly due to a
UPS failure.
Maintenance:
red
OFF
When lit, it indicates that the UPS has been

selected to operate on the maintenance
bypass and the load is unprotected.
Alarm:
red
OFF
This is a common alarm' and is lit when any

of the red leds described above are lit.
Inverter ON:
Interpretation
An audible warning accompanies any of the above alarm conditions. This is, however, subject to a short time delay when activated in conjunction with the Utility
Failure' and Bypass ON' alarms, to prevent the warning being activated by transient conditions. Pressing the reset' push-button cancels the audible warning but
the alarm indications remain until the condition returns to normal operation.
3.1.1
3.1.1.1
Connections
Power supply
The R.A.M. contains a single phase 220-240Va.c. mains-driven power supply.

Power is applied through a standard three-pin mains connector located in the
R.A.M. back panel (plug provided) - using 3-core 0.5mm cable (minimum). The
supply is rated at approximately 4 Watts and fused at 1A.
To guarantee that the R.A.M. remains active following a mains failure, it is advised that the power supply is fed from the UPS output (critical bus).
S8-c3.fm5 - Issue 2 Dated 21/08/97
9-9

CHAPTER 3 - Remote Alarm Monitor 4305001Z
3.1.1.2
Alarm connections
A soldered 9 pin D-type connector (provided with the option kit) fits into the 9
pin socket on the back of the RAM and should be wired to the Alarms Interface
Board (4590055P), fitted in the UPS, using 9 core, 0.22mm. (minimum) shielded
cable as shown. The maximum recommended distance is 200 metres.
Figure 9-5: Remote Alarm Monitor connection details
X4
Mains
SupplyFailure
RL-K1
Low
RL-K2
Battery
(pre-alarm)
Load on
RL-K3
Static bypass
supply
15
14
13
12
11
10
9
8
7
Load on
RL-K4
Maintenance
Bypass
6
5
RL-K5
3
2
Load on
Inverter
1
220/240V a.c. 50 Hz
5
4
9
INVERTER
ON
ON
9-10
UTILITY
FAILURE
BATTERY
LOW
3 2
8
1
6
ALARM
BYPASS
MAINTENANCE
3.2

Detailed circuit description

The following description refers to the R.A.M. circuit diagram SE-4530021P.
3.2.1
Power supply
The 220/240Vac power supply is stepped down by isolation transformer T1,
whose secondary output is then rectified by D1/D2 and smoothed by C13 to provide an unregulated nominal +12V supply rail which is used by the audible alarm
annunciator. This rail is also connected to a standard three-terminal +5V regulator
whose output is smoothed by C14 and then provides a stable +5V rail that is used
by the remainder of the boards electronic circuits. The supply is not fused onboard but a 1A fuse should be fitted in the external connector.
3.2.2
Alarm indications
All the alarms are activated via volt-free relay contacts on the Alarms Interface
Board (4590055P) (See Figure 9-5).
Load-on-inverter
This indication (not an alarm, as it is normally on) is connected to CN1 pin 5 and
is 0V when the load is connected to the inverter (i.e. the output contactor is
closed). The 0V supply to pin 5 is obtained from pin 4. This alarm input drives
the indicator led LS1 only (normally ON) and is not connected to the audible
alarm circuit.
Load-on-Bypass
This alarm is connected to CN1 pin 9 and is 0V when the load is connected to the
bypass supply (i.e. the bypass-side static switch is closed). The 0V supply to pin
9 is obtained from pin 2. This alarm input drives the indicator led LS4 immediately and also activates the audible alarm circuit via IC1 pin 4 after a delay of approximately 11 seconds. which is introduced to avoid nuisance alarms.
Load-on-Maintenance Bypass
This alarm is connected to CN1 pin 8 and is 0V when the maintenance bypass
contactor is closed. The 0V supply to pin 8 is obtained from pin 1. This alarm
input drives the indicator led LS5 and inhibits the audible alarm operation when
the Maintenance Bypass isolator is closed (IC1 pin 3 = low).
Low battery
This alarm is connected to CN1 pin 7 and is 0V when the battery is at its lowvoltage threshold i.e. approaching its end-of-discharge voltage. The 0V supply
to pin 7 is obtained from pin 3. This alarm input drives the indicator led LS3 immediately and also activates the audible alarm circuit via IC1 pin 2 after a delay
of approximately 11 seconds, which is introduced to avoid nuisance alarms.
Utility Failure
This alarm is connected to CN1 pin 6 and is 0V when the mains supply voltage is
low (-20%). The 0V supply to pin 6 is obtained from pin 3. This alarm input drives
the indicator led LS2 immediately and also activates the audible alarm circuit via
IC1 pin 1 after a short (11sec) delay to avoid nuisance alarms.
9-11

Summary alarm
The summary alarm is produced by a four-input and gate within IC1 (See Figure
9-6) whose output pin 19 goes low if either one of the above four alarm conditions
are present. This output illuminates LS6 and also places a logic high on IC1 pin
5, which resets the audible alarm automatically when the alarm condition is removed (described later).
Figure 9-6: Internal logic diagram of IC1
Utility Fail
Load-on-bypass
Battery Low
Maint. Bypass
17 RES-C1
18 RES-C2
13 OC2
12 OC1
19 ALARM
(LS6)
ID1
ID2
8
9
IC1
IC2
6
7
RAL 5
RES 14
Stop 11
3.2.3
16 Buzzer
15 N.I.U.
Audible alarm control

Alarm latch operation
The audible warning device is controlled from a latch within IC1, as show above.
The alarm is activated by a logic high applied to any of the input pins 6, 7, 8 or 9:
this sets the latch, which drives IC1 pin 16 high and energises the warning
device by turning on TR1. Once set, the latch will activate the audible alarm until
it is reset by a logic high input to IC1 pin 5, 11 or 14.
The signals to IC1 pins 6, 7, 8 and 9 are driven by the four alarm signals produced
at pins 12, 13, 17, and 18 which are connected to the latch set inputs via timing
and debounce circuits.
For example: pin 6 is driven by the Maintenance Bypass alarm output at pin 12
and debounced by R7 and C9. Pin 7 is driven by the Battery Low alarm output at
pin 13 and debounced by R8 and C8. Pins 8 and 9 are driven via controlled time
delays which are introduced to overcome nuisance audible warnings in response
to Load On Bypass and Utility Failure alarms on pins 17 and 18 respectively.
9-12

Time delays
The time delays are implemented by IC2 and IC3. IC2 is a dual binary counter,
both sections of which are clocked by a free-running 555 timer, IC3, at approximately 1.4 second intervals. The circuit is best understood by considering the following operation of IC2a in response to the Load-on-bypass alarm output from
IC1 pin 18.
Under normal conditions, IC1 pin 18 is logic high which applies a permanent reset
to IC2 pin 7 and holds it at zero-count i.e. Q0 to Q3 all low. If a Load-on-bypass
alarm condition arises, the reset condition is removed and IC2 will count up on
successive clock pulses applied to its enable input (pin 2). On the eighth clock
pulse the Q3 output will switch high, which disables further counting and flags
the alarm condition to IC1 in 9 via debounce circuit R10/C6. Hence, the Load-onbypass alarm output from IC1 pin 18 must be present for approximately 11 seconds before it annunciates the audible warning. If the alarm condition disappears
before the completion of eight clock cycles IC2 is reset to zero by the logic high
signal being reapplied to pin 7.
The second section of IC2 works in an identical manner for the Bypass Mains Fail
alarm output at IC1 pin 18.
Alarm latch reset
As explained above, the audible alarm latch can be reset by any one of three signals applied to IC1 pins 5, 11, 14 (high to reset).
The input to pin 5 is driven directly from the summary alarm output at pin 19 and
resets the audible alarm automatically when Load On Bypass, Battery Low and
Utility Failure alarm conditions all revert to normal, provided the maintenance
bypass breaker is open. If the maintenance bypass breaker is closed the Load On
Bypass, Battery Low and Utility Failure alarms are prevented from activating the
audible warning. That is, if the UPS is undergoing maintenance there will be no
audible warnings at the Remote Alarms Monitor station; but once maintenance is
complete, and the load is transferred back to the normal UPS supply, the audible
warning is automatically re-enabled.
The input to pin 14 is driven from a power-up reset debounce circuit which ensures that the audible warning is inhibited when power is first applied.
The input to pin 11 is driven from the mimic panel reset button (PS1) which
allows the operator to reset the audible warning once the alarm has been recognised. Note that the mimic display alarm leds will not reset until the alarmed condition has reverted to normal.
9-13

9-14
Section 9:
Chapter 4 - Battery cabinets
4.1
General introduction
HAZARD
WARNINGS
Only qualified personnel should install or service batteries.

Batteries may present a risk of shock or burn from high short circuit currents.
Eye protection should be worn to prevent injury from accidental electrical arcs.Remove rings, watches and all metal objects.
Only use tools with insulated handles.
Wear rubber gloves.If a battery leaks electrolyte, or is otherwise physically damaged, it should be placed in a container resistant to sulphuric acid and disposed
of in accordance with local regulations.If electrolyte comes into contact with the
skin the affected area should be washed immediately.
Batteries MUST be disposed of in accordance with local environmental laws.
There are three types of battery cabinet offered with the Series 7200 UPS which
are graded according to their recommended ampere hour capacities. Type B is
rated at 38 Ah; Type C is rated at 50 Ah and Type D is rated at 85 Ah. The cabinets
are of the same height as the UPS and can be sited on either side of the UPS cabinet. Where higher autonomy times are required additional cabinets can be added
to the system.
Due to the type and size of cells which can be used in battery installations it would
be impracticable to provide specific installation instructions in this manual. However as a general guide: Always install the batteries starting from the bottom and work upwards.
Leave the inter row links identified as (C) and connections to the circuit
breaker until last (see Figure 9-8, Figure 9-10 and Figure 9-12).
After each connection is made fit the insulation shroud for that terminal
into position.
Please refer to the battery manufacturers instructions and the drawings
supplied with the module for specific installation instructions.
Figure 9-7 to Figure 9-12 give suggested layouts for the three types of cabinet.
The following instructions refer to a Type D (85 Ah) cabinet installation. Installation of the other cabinets would follow a similar method. If you use a different
type of battery these instruction may be invalid due to the terminal orientation of
the cells in use and their terminal fixture.
4.2
Type D' (85 Ah) Battery cabinet assembly and installation

The battery cabinet can be fitted with either a 100 Amp circuit breaker for use
with 30-40 kVA modules, or with a 160 Amp circuit breaker for use with 60kVA
modules. It houses thirty-four maintenance free batteries connected in series to
provide a 460V battery bank. The batteries are housed on rails and there are
eleven sets of rails in the complete cabinet as shown in Figure 9-11.
Before proceeding with the following instructions please study Figure 9-11 and
Figure 9-12, note that batteries should be fitted from the lower level up and the
9-15

CHAPTER 4 - Battery Cabinets
battery interconnecting links starting with the (A) links and the last connection
must be the (G) link.
1.
Unpack each battery and check its terminal voltage with a DVM. If any battery terminal voltage is less than 2.13 volts per cell (12.8V per 6 cell block)
it must be recharged before continuing with the battery cabinet assembly.
2.
Gain full access to the battery cabinet interior, remove the battery fitting
hardware stowed, ensure the interior is clean of any transit debris.
3.
Starting at the rear of the lower level fit the nine batteries on this level.
4.
Connect the inter-battery (A) links (6 off) and the inter-row (B) link (1 off).
Connect one end of the inter-level (C) links (2 off) to the positive terminal
of the right hand rear battery in both cabinets and safely stow the other end.
5.
Fit the thirteen batteries into place on the middle level.
6.
Connect the inter-battery (A) links (9 off) then the inter-row (B) links (2
off). Connect one end of the inter-level (C) links (2 off) to the positive terminal of the right hand rear battery in both cabinets and safely stow the
other end.
7.
Fit the twelve batteries into place on the top level.
8.
Connect the inter-battery (A) links (8 off) followed by the inter-row (B)
links (2 off).
9.
Take the previously stowed inter-level (C) link connected to the bottom
level of the right hand cabinet and connect it to the negative terminal of the
left hand front battery on the middle level. Then repeat for the left hand cabinet.
10. Take the previously stowed inter-level (C) link connected to the middle
level of the right hand cabinet and connect it to the negative terminal of the
left hand front battery on the top level. Then repeat for the left hand cabinet.
11. Ensure the battery circuit breaker is selected to the OFF position.
12. Locate the (D) link (1 off) and connect it between the positive terminal of
the front right hand battery on the upper level in the right hand cabinet and
the left hand input connection of the battery circuit breaker.
13. Locate the (E) link (1 off) and connect it between the positive terminal of
the front right hand battery on the upper level in the left hand cabinet and the
centre +ve output connection of the battery circuit breaker.
14. Locate the (F) link (1 off) and connect it between the negative terminal of
the front left hand battery on the lower level in the right hand cabinet and the
right hand -ve output connection of the battery circuit breaker.
15. Locate the (G) link (1 off) and connect it between the negative terminal of
the front battery on the lower level in the left hand cabinet and the left hand
output connection of the battery circuit breaker.
16. Connect the battery power cables and Circuit Breaker Controller Board control cables between the battery cabinet and UPS cabinet if they are not yet
connected - see Figure 9-12. To maintain EMC standards the Battery cabinet
must be bonded to the UPS cabinet and the control cables must be screened
and run in a separate trunking from the power cables.
9-16

17. Fit the safety screen to the front of the battery cabinet and close the doors.
9-17

Figure 9-7: 38Ah Battery cabinet - Battery Assembly and Layout
Battery Supply
to UPS
Battery CB
Controller Board
(4520067T)
BATTERY CABINET FRONT VIEW (DOOR OPEN)

AND SIDE VIEW
+ve
PLAN VIEW OF BATTERY CABINET BOTTOM ROW
9-18

Figure 9-8: 38Ah Battery cabinet - Battery Layout and Connection Detail
Double positive pole method
B
A
A
A
A
B
A
C
A
A
B
A
NT
F RO
A
A
B
A
C
A
A
F
Battery CB
Battery Supply to
UPS Cabinet
9-19

Figure 9-9: 50Ah Battery cabinet - Battery Assembly and Layout
Battery CB
Controller Board
(4520067T)
Battery Supply
to UPS
BATTERY CABINET FRONT VIEW (DOOR OPEN)

AND SIDE VIEW
PLAN VIEW OF BATTERY CABINET TOP ROW
9-20

Figure 9-10: 50Ah Battery cabinet - Battery Layout and Connection

A
C
B
A
E
A
A
A
NT
FRO
B
A
A
F
Battery CB
B
A
Battery Supply to
UPS Cabinet
9-21

Battery CB
Controller
Board
(4520067T)
Battery Supply
to UPS
BATTERY CABINET FRONT VIEW (DOORS OPEN)
A
A
PLAN VIEW OF BATTERY CABINET MIDDLE ROW
9-22


Half Potential method
9-23

9-24
Section 9:
Chapter 5 - Battery Breaker Boxes
5.1
Introduction
The battery circuit breaker box houses the battery circuit breaker and its controller
board, as shown in Figure 9-13. It is used to connect the battery to the UPS in installations where the batteries are not contained in a standard battery cabinet and
is usually fitted as close to the batteries as possible.
Two types of Battery Breaker Boxes are available: these are similar in design and
listed below:
100 Amp C/B Part No 4641027 B for use with 30 - 40 kVA models.
160 Amp C/B Part No 4641028 C for use with 60kVA+ model.
The battery circuit breaker box offers the following features:
Battery temperature compensation.

Undervoltage cut-off (battery trip) controlled by the UPS.
Low battery safety cut-off.
Battery circuit breaker status information to the UPS.
Over current protection.
Three pole circuit breaker - which can be connected in either a Doublepositive pole or half-potential configuration.
The connections are similar to the connections made to the battery cabinet.
Safety Notes:
1. The Battery Circuit Breaker Box must be earthed.

2. Remove the battery fuse in the UPS before making the battery circuit breaker
power connections.
5.2
Circuit breaker details

The circuit breaker main contacts are typically rated at >22kA @ 380Vac and
7.5kA @ 500Vdc for 10 milliseconds. The auxiliary contacts are rated at 5A
@220Vac.
The circuit breaker coil is rated at 110Vdc. Typically, it closes at a coil voltage of
93Vdc and drops-out when the coil voltage falls to 40Vdc.
The coil resistance is approximately 9kOhms.
9-23
SECTION 9 - Battery Breaker Boxes

CHAPTER 5 - Battery Breaker Boxes
Figure 9-13: Battery box layout and connections

Power cables
To
to Battery
Temperature
Sensor
Maximum dimensions in mm:

Height
470
Width
300
Depth
146
Control Board 4520067T terminal block X1

connections to the UPS auxiliary terminal block X3
Red
Black
4520067T
BCB
System
UPS
X1-5
Temperature Sensing Signal
X3-2
X1-4
Temperature Sensing Signal
X3-3
X1-3
Control Signal Common
X3-4
X1-2
CB Status Control
X3-5
X1-1
CB Control Signal
X3-6
Temp Sensing Signal to UPS

Earth
Power cables
Control/Monitoring Signals
To UPS
Temperature Sensor
To Battery
0835047F
0540032M
Screened Cable
X10 X2
X5
4520067T
<V
X6
X8
X9
Black
Red
X3
X4
X1
1 2 3 4 5
Screened Cable
To UPS
9-24
To UPS auxiliary
terminal block X3
5.3

Battery Circuit Breaker Interface Board (4520067-T)

The purpose of this board (see diagram SE 4520067 T) is to provide an interface
between the UPS control logic and the circuit breaker itself. The board provides
galvanic isolation for the close signal to the circuit breaker coil, and also
presents a path for the circuit breakers auxiliary contacts and temperature sensor
signals back to the UPS.
5.3.1
Circuit breaker close operation

The circuit breaker (CB) coil is connected to terminals X5 and X6, and its energising voltage is obtained from the rectifier output (DC bus), which is connected
to X4(+) and X3(-). The battery bus positive voltage at X4 is thus connected directly to one side of the CB coil at X5. It also provides a stabilised 13V rail at
opto-isolator V6 collector, due to the action of R4, R5 and zener V3.
When the UPS control logic issues a battery circuit breaker close command, it
applies a logic high signal between X1-1(+5V) and X1-3(0V). This turns ON
opto-isolator V6, whose emitter now pulls-up V4s gate to the 13V rail and causes
it to turn ON. With V4 turned ON, the CB coils connection at X6 is effectively
connected to the battery bus negative voltage at X3 via R7, R5 and V4.
V2 is a flywheel diode for the CB coil and protects V4 against large regenerative
currents. V1 and V5 similarly protects the opto-isolator against reverse voltage
transients.
5.3.2
Auxiliary contacts
The circuit breakers auxiliary contacts are connected to X8 and X9. These contacts are normally open and close when the circuit breaker is closed to provide
a CB status input to the UPS control logic.
Note: the line to X9 from X1-3 is connected to the 0V rail within the UPS.
5.3.3
Temperature sensor
The temperature sensor is connected to the battery charge control logic where it
reduces the charge voltage proportionally with battery temperature if it rises
above 25C. The sensor is connected between X2 and X10 and should produce a
voltage in the region of 2.98Vdc between these points at 25C.
9-25

9-26
Section 9:
Chapter 6 - Input Harmonic Filters
6.1
General Introduction
An optional input harmonic filter can be added to the 7200 series UPS to improve
the UPS input power factor and reduce the amount of electrical noise reflected
into the input three phase supply.
The filter components are contained within the UPS cabinet therefore extra cooling is required (see Figure 9-15). The filters are matched to the UPS capacity, resulting in different part numbers for each system as follows:
30kVA filter
40 kVA filter
60kVA filter
6.1.1
Specification
Input voltage
Input voltage tolerance
Nominal frequency
Input frequency tolerance
UPS input current distortion
UPS input power factor
6.1.2
4641015 P
4641016 Q
4641017 R
380-400-415, three phase

15%
50Hz
5%
10% max
>0.9
Notes on connection
This option is normally factory fitted with the harmonic filter becoming an integral part of the UPS as shown in the block diagram Figure 9-14 and the component location diagram Figure 9-15. Therefore, connection of the input power
supplies does not change from that shown in section 2 Figure 2-5.
Note:- The input Neutral connection must always be connected to the bypass
input N3' on the UPS.
9-27

CHAPTER 6 - Input Harmonic Filters
Figure 9-14: Block diagram of Input Filter and UPS

Q3
Maintenance Bypass Power Switch
Q2
Bypass Power Switch
ac input
L5
supplies Q1
RECTIFIER
Rectifier
Input Power
Switch
L6
C21
to
C29
Optional Input
Harmonic Filter
40/60kVA units
additional fan
connections
E8
STATIC
SWITCH
INVERTER
BATTERY
E7
30kVA units
additional fan
connections
E1
E1
E4
Figure 9-15: Harmonic Filter Component Part Locations

REAR VIEW
f
TOP VIEW - Section A-A

c
g
L6
L5
C29
C26
C23
C28
C25
C22
C27
C24
C21
a
L6
L6
Fan Identifier from Diagram
T1
L1
Model
a
30kVA
E1
E2
E3
E4
40kVA
E1
E2
E3
E4
E5
E6
E7
E8
60kVA
E1
E2
E3
E4
E6
E6
E7
E8
Fans (g) and (h) are additional when the

input harmonic filter is added.
9-28
Section 9:
Chapter 7 - RS232 Comms Kit 4645101T
The RS-232 Communications kit offers the necessary cable assembly and fixings
for connection into the communications socket (X8) on the operator logic board
(part no. 4550005F) to a DB25 male connector (X4), located adjacent to the cable
access panel as shown in Figure 9-16.
Using the wiring configurations shown in Figure 9-17 the UPS can be connected
to either a personal computer or a modem.
Additional software will be required to gain maximum advantage from the features offered.
Caution
Note:-The communications wiring for this option must be kept separate from the
power wiring. This is to maintain the integrity of Safety Extra Low Voltage'
(S.E.L.V.) circuits.
Figure 9-16: Installing the RS232 communication cable
W9
4550005F
X5
X8
X4
4645101T
X4
9-29

CHAPTER 7 - RS232 Comms Kit 4645101T
Figure 9-17: RS232 connections to PC or Modem

DB25M
1
DB25F
TD
RD
RTS 4
CTS 5
DSR 6
GND 7
DCD 8
DTR 20
20
RI
Wiring details for

connection of UPS
to Modem via
DB25 socket.
22
22
X4
UPS
MODEM
DB25M
DB25F
1
TD
1
2
TD
RD 3
3 RD
RTS 4
GND 7
4 RTS Wiring details for

connection of
5 CTS
UPS to personal
6 DSR
computer via
DB25 socket.
7 GND
DCD 8
8 DCD
DTR 20
20 DTR
CTS 5
DSR 6
22 RI
RI 22
X4
UPS
PC
DB25M
DB9F
1 DCD
RD
RD 3
TD
RTS 4
4 DTR
TD
GND 7
Wiring details for

connection of
UPS
to personal
5 GND
computer via DB9
6 DSR
socket.
7 RTS
DCD 8
8 CTS
DTR 20
CTS 5
DSR 6
RI
RI 22
X4
UPS
9-30
PC
7.1

Hardware and Installation Requirements

1. Qty 1 Part N 4645101T Interface Option for Master unit.
a) Fit the DB25 way Female connector to X8 of the operator logic PCB Part
N 4550005F. As shown in Figure 9-16.
2. IBM compatible PC for connection to the RS232 port X4 on the option PCB
Part N 4645101T.
Minimum specification:
a) Processor 386 or higher.
b) 512kB of RAM.
c) DOS version 3.1 or higher.
d) Windows 3.1 or Windows 95.
3. RS232 Cable to connect to the D type 25 pin plug X4 on the option board
Part N 4645101T and the D type 25 or 9 way plug PC Communication port,
as shown in Figure 9-17.
Note
Each end of the cable will require D type sockets. The maximum length is to be
no longer than 15 meters.
4. Associated installation software provided with the option kit Part N

4645101T on a 1.44 3.5 floppy diskette and user manual Part N 4645101T.
5. RS485 cables to interconnect each additional Slave unit in a series string
with the Master unit, via the 9 pin D type plug X4 on each units operator
logic PCB Part N 4850005F. As shown in Figure 9-18.
Note
The maximum number of UPS in the complete string must not exceed 8.
9-31

Figure 9-18: Master Slave communication cable connections

UPS 3 Slave
RS485 cable
linking X4 to
X4 on next unit
Maximum of 8
UPS 2 Slave
UPS 1 Master
RS485 cable
linking X4 to X4
RS485 cable
linking X4 to X4
RS232 cable Max length=15meters
7.2
UPS Hardware and Software Configuration
7.2.1
Master UPS Set-Up

Hardware
1. Ensure that Link X26 7-8 on the UPS logic PCB Part N 4550007H is closed
to over-ride the password security system.
2. Ensure that Links X20 2-3; X21; X22; X25 1-2 are closed on the operator
logic PCB Part N 4550005F to enable the RS485 port X4 to communicate to
the Slave Units if required.
Software
1. Ensure that version 3.0 Software or better is installed on both the UPS logic
and Operator logic PCBs, by checking the appropriate mimic screens.
2. Using the appropriate Mimic Panel buttons and FUNCTION menu map gain
access to the following windows and set as appropriate.
9-32

a) PC CONN Select LOCAL and press ENTER.

b) RESET Select YES and press ENTER.
c) UPS TYPE Select MASTER and press ENTER.
d) GROUP Select 1 and press ENTER.
e) UPS Select 1 and press ENTER.
3. Return to the main menu by pressing ESCAPE.
4. If required remove Link X26 7-8 to re-enable the password security system.
7.2.2
Slave UPS Set-Up

Hardware
1. Ensure that Link X26 7-8 on the UPS logic PCB Part N 4550007H is closed
to over-ride the password security system.
2. Ensure that Links X20 2-3; X21; X22; X25 1-2 are closed on the operator
logic PCB Part N 4550005F to enable the RS485 port X4 to communicate to
the Slave Units if required.
Software
1. Ensure that version 3.0 Software or better is installed on both the UPS logic
and Operator logic PCBs, by checking the appropriate mimic screens.
2. Using the appropriate Mimic Panel buttons and FUNCTION menu map gain
access to the following windows and set as appropriate.
a) PC CONN Select LOCAL and press ENTER.
b) RESET Select YES and press ENTER.
c) UPS TYPE Select SLAVE and press ENTER.
d) GROUP Select 1 and press ENTER.
e) UPS Select 2 for the second unit and press ENTER.
f) UPS Select 3 for the second unit and press ENTER.
g) Repeat steps e) and f) for each additional slave unit as require, selecting
number 2 to 8 up to a maximum of 8 units.
3. Return to the main menu by repeatedly pressing ESCAPE.
4. If required remove Link X26 7-8 to re-enable the password security system.
7.2.3
Installing the Software program

1. Start the PC as normal and switch to the DOS operating system.
The DOS prompt will show C:\> (indicating that the root directory of the hard
drive has been selected)
2. Insert the operating software floppy diskette supplied with the option kit into
the PC 3.5 drive.
3. Access the floppy drive by typing A: at the C:\> DOS prompt and pressing
ENTER .
9-33

4. Install the 7200 software by typing the following at the DOS prompt.
A:\>installa C: C: /E
A:\>
installa
A drive
DOS
prompt
command
Note: this
is an Italian command
C:
space
C:
Target
drive letter
for installation
space
/E
Driver letter
containing the
Autoexec.bat
file normally C:
space
Enter upper case letter

for language selection.
D = German
I = Italian
E = English
F = French
S = Spanish
5. The attention message screen shown in Figure 9-19 will be displayed.

6. Follow the instructions on the screen to either:
a) Continue the installation by pressing any key.
b) Or exit the installation by pressing CONTROL C
Figure 9-19: Installation attention screen
!!! Attention!!!
If necessary the following directory is created:
C:\AL30\
If the environment is already present, all old files there are destroyed except:
C:\AL30\ initmdm.str
C:\AL30\remoto.opt
That remain unchanged
In order to use in future the default filters present on floppy disk, is sufficient overwrite them on the hard disk in the directory C:\AL30
The database file REMDATA.DB, isnt modified
Press key CTRL C for finish or any key to continue
Press any key to continue...
7. When the software installation has been successfully installed the PC will
give the following message shown in Figure 9-20.
Figure 9-20: Installation successfully completed
ALAMO30 V_3.0 1996
Installation completed
Thank you for your choice by Emerson SICE
Restart the system in order to use the programme
9-34

After the software has been successfully installed the directory C:\AL30\ will be
created on the selected drive, and will contain the following files.
locale.cfg
remoto.cfg
upsico.dll
locale.exe
7.2.4
remoto.exe
setpat.exe
tsrups.exe
localm.lng
locmenu.lng
locmsr.lng
locpar.lng
remmenu.lng
remoto.opt
winups.pif
mkdups.rec
initmdm.str
Running the Software

The program can now be accessed by running the LOCALE.EXE(for local PC connection) or REMOTO.EXE (for remote PC connection) executable files, from the
new directory C:\AL30.
1. Enter the directory C:\AL30. by typing CD AL30 at the DOS prompt.
e.g. C:\>CD AL30
2. Run the programme by entering the remote or local execute command at the
DOS prompt
e.g. C:\AL30>locale.exe and pressing ENTER .
or C:\AL30>remoto.exe and pressing ENTER .
3. The PC will now display the message shown in Figure 9-21 indicating that
the programme is running.
Figure 9-21: Software program active indication message
Information UPS
123776
About
LIEBERT - - UPS Network
Local Connection
Version 3.0 _ 1996
OK
4. Press ENTER .
The PC will then set up the communication to the UPS units and indicate that
there is a transmission in progress with a bargraph prompt on the display. As
shown in Figure 9-22.
9-35

Figure 9-22: Transmission executing bargraph

Information UPS
123776
Information
Transmission executing Wait
5. At the end of the transmission the PC will return to the default screen and
indicate all the measured parameters.
An example of a typical UPS interrogation is shown in Figure 9-23.
Figure 9-23: UPS default screen showing typical measured parameters
Information UPS
General Window
<>
Node
UPS1
UPS2
UPS3
UPS4
UPS5
UPS6
UPS7
UPS8
V out AB [V]
230
----
----
----
----
----
----
----
V out BC [V]
230
----
----
----
----
----
----
----
V out CA [V]
230
----
----
----
----
----
----
----
V out AN [V]
0000
----
----
----
----
----
----
----
V out BN [V]
0000
----
----
----
----
----
----
----
I out A
[A]
0000
----
----
----
----
----
----
----
I out B
[A]
0000
----
----
----
----
----
----
----
I out C
[A]
0000
----
----
----
----
----
----
----
I out N
[A]
0000
----
----
----
----
----
----
----
Pot. A
[kW]
0000
----
----
----
----
----
----
----
Pot. B
[kW]
0000
----
----
----
----
----
----
----
Pot. C [kW]
0000
----
----
----
----
----
----
----
mode configuration
U1 : M1V03.0 - V03.0 U2 : NC
U3 : NC
U4 : NC
U5 : NC
U8 : NC
F10: Exit
9-36
U6 : NC
U7 : NC
PgUp/Dn: Scroll measures <->: Sel UPS Enter: Receive configuration Tab: UPS
7.2.5

Accessing the Data

The information displayed in the default window Figure 9-23 is dependent on the
number of groups and individual UPS connected to the interface, it will vary according to the site configuration.
The UPS parameters are shown in the General Window and can be scrolled using
the Key board commands outlined below.
The mode configuration window will display a coded number which indicates the
UPS detail. The coded number can be interpreted as follows:
M 1 V03.0 - V03.0
M or S = Master or Slave
1 = Number of the UPS group
Vxx-Vyy = Software Version for Operator Panel - UPS logic PCB.
N.C = Not Connected
Information in the display window can be changed from the keyboard using the
following commands:
a) F10
Allows the operator to EXIT the communication software and return to the
AL30 directory DOS prompt c\AL30\>
b) PgUp/Dn
Operation of the page up and page down keys will scroll through the
parameters shown in the General Window.
c) <-> (Space Bar)
Operation of the space bar steps through each UPS shown in the mode
configuration window.
d) ENTER
Operation of the ENTER' key will initiate an interrogation of the unit
selected. The transmission in progress bargraph will appear, as the Software down loads the relevant data.
The display will then return to the Main Interrogation Menu shown in
Figure 9-24.
e) Tab
Operating the Tab key allows the UPS group to be selected.
Up to nine groups each a maximum of eight units can be supported.
9-37

Figure 9-24: Main data interrogation menu screen

Information UPS
Alarm Status
Alarm History
Event History
Programmable Parameters
Programmable Alarms
Control Commands
Modem Programming
mode configuration
U1 : M1V03.0 - V03.0 U2 : NC
U3 : NC
U4 : NC
U5 : NC
U7 : NC
U8 : NC
Esc: Back
U6 : NC
Up/Dn Arrow: Chose from menu
Enter: Excecute
Once an interrogation of the UPS system has been carried out the menu screen
shown in Figure 9-24 will be displayed. Access to the many data information
screens can now be made from the keyboard:
a) Esc
Return back to the Default Measurment screen.
b) Up/Dn Arrow
Operation of the UP and DOWN arrow keys allows selection of the data
to be viewed from the choice menu.
c) ENTER
Operating the ENTER key will execute the choice made with the up and
down arrows.
9-38

Sect 9

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Section 9: Optional Equipment

Chapter 1 - Alarm Interface Board 4590055P

SECTION 9 - Optional Equipment

7200 Series UPS Service Manual

S-8.FM5 - Issue 2 Dated 21/08/97

Chapter 1 - Alarm Interface Board 4590055P

Figure 9-1: Alarm Board location

s8-c1.fm5 - Issue 1 Dated 21/08/97

SECTION 9 - Optional Equipment

7200 Series UPS Service Manual

Remote control inputs

The control voltages applied to these terminals must be generated by an external

s8-c1.fm5 - Issue 1 Dated 21/08/97

7200 Series UPS Service Manual

SECTION 9 - Optional Equipment

s8-c1.fm5 - Issue 1 Dated 21/08/97

SECTION 9 - Optional Equipment

7200 Series UPS Service Manual

Figure 9-2: Interface Board inputs/outputs

On generator = apply 12V

Inverter off = apply 12V

Mains or Rectifier Failure

Low Battery (pre-alarm)

Mains or Rectifier Failure

Maximum Contact Rating = 50Vcc @ 1 ampere

s8-c1.fm5 - Issue 1 Dated 21/08/97

Chapter 2 - Remote Alarm Interface 4590056Q

Figure 9-3: Location of Alarm Interface Boards

Alarm Interface Board

s8-c2.fm5 - Issue 2 Dated 21/08/97

SECTION 9 - Optional Equipment

7200 Series UPS Service Manual

When high, energises relay K1 and connects X2 pins 14 and 15.

When high, energises relay K2 and connects X2 pins 11 and 12.

When high, energises relay K3 and connects X2 pins 8 and 9.

When high, energises relay K4 and connects X2 pins 5 and 6.

When high, energises relay K5 and connects X2 pins 2 and 3.

Bypass-side static switch is blocked (inhibited) by hardware (alarm #16)

s8-c2.fm5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

SECTION 9 - Optional Equipment

Battery overtemperature alarm [OVT_BAT>

When high, energises relay K7 and connects X3 pins 11 and 12.

When high, energises relay K8 and connects X3 pins 8 and 9.

Rectifier shut-down (not programmed).

s8-c2.fm5 - Issue 2 Dated 21/08/97

SECTION 9 - Optional Equipment

7200 Series UPS Service Manual

Figure 9-4: Remote Alarms Interface Board Part No 4590056Q

Bypass Static Switch

Rectifier input volts

s8-c2.fm5 - Issue 2 Dated 21/08/97

Chapter 3 - Remote Alarm Monitor 4305001Z

Normal operating condition indicating that

When lit, it indicates that the input mains are

When lit, it indicates that the battery voltage

When lit, it indicates that the load is being

When lit, it indicates that the UPS has been

This is a common alarm' and is lit when any

The R.A.M. contains a single phase 220-240Va.c. mains-driven power supply.

S8-c3.fm5 - Issue 2 Dated 21/08/97

SECTION 9 - Optional Equipment

7200 Series UPS Service Manual