Instruction & Operating anual with Drawings

DAR AL RIYADH HOLDING CO. LTD.

SWCC AL-JUBAIL

PURCHASE ORDER # 2003J1464-R03

SCI PROJECT # S82594 Volume 1 of 1

AMTEK SOLID AMTEK SOLID

Section 1 80KVA UPS STATE CONTROLS
STATE CONTROLS

Section 2 80KVA REMOTE MANUAL BYPASS SWITCH

Pocket DRAWINGS

MANUAL REV. B

SOLIDSTATE CONTROLS

875 Dearborn Drive, Columbus, Ohio 43085

Telephone: (614) 846-7500, Fax: (614) 885-3990

An IS0 9001 &-tified Company!

INDEX
 AMETEK - Solidstate Controls. Operations Manual - ProcessPowerTMSeries Uninterruptible Power Supply

Table of Contents

1.0 Introduction ...................................................................................................................................... 1

1.1 General Description.. ...................................................................................................................... 1
1.2 Safety.. ............................................................................................................................................ 1
2.0 Specifications ................................................................................................................................... 2
2.1.1 Electrical .................................................................................................................................. 2
2.1.2 Physical ................................................................................................................................... 4
2.1.3 Environmental ......................................................................................................................... 4
3.0 Installation ........................................................................................................................................ 5
3.1 Receiving ........................................................................................................................................ 5
3.1 .l Unpacking and Inspection.. .................................................................................................... .5
3.1.2 Storage.. .................................................................................................................................. 5
3.1.3 Site Selection.. ......................................................................................................................... 5
3.2 Installation ....................................................................................................................................... 6
3.2.1 Equipment Required.. .............................................................................................................. 6
3.2.2 Input/Output Power Connections ............................................................................................ 6
3.2.3 Battery Connections ................................................................................................................ 6
3.2.5 Alarm Interface Connections.. ................................................................................................. 6
3.2.6 Conductor Terminations .......................................................................................................... 7
4.0 Operation .......................................................................................................................................... 8
4.1 Start-up and Shutdown ................................................................................................................... 8
4.1 .I Starting Sequence.. ................................................................................................................. 8
4.1.2 Shutdown Sequence ............................................................................................................... 8
4.2 Keypad ............................................................................................................................................ 8
4.2.1 Float/Equalize Operation.. ....................................................................................................... 9
4.2.2 Battery Test ............................................................................................................................. 9
4.2.3 lnverter Reset.. ........................................................................................................................ 9
4.2.4 Static Switch Reset ................................................................................................................. 9
4.2.5 Alarm Silence .......................................................................................................................... 9
4.2.6 LCD Display ............................................................................................................................ 9
4.2.7 Mimic Screen.. ......................................................................................................................... 9
4.2.8 Measurement Screens .......................................................................................................... 10
4.2.9 Alarm Status Screen ............................................................................................................. 1 1
4.2.10 Date & Time Screen.. ............................................................................................................ 11
4.2.1 1 Set-up Screen ....................................................................................................................... 12
4.3 Historical Event File.. .................................................................................................................... 12
4.4 Communicating with a Host using MODBUS RTU Protocol ....................................................... 14
4.4.1 Using MODBUS RTU Protocol.. ............................................................................................ 14
4.4.2 Virtual Address Map.. ............................................................................................................ 14
5.0 Theory of Operation ....................................................................................................................... 16
5.1 Rectifier/Charger .......................................................................................................................... 16
5.2 lnverter .......................................................................................................................................... 18
5.3 Static Switch ................................................................................................................................. 18
5.4 Manual Bypass Switch ................................................................................................................. 19
5.5 Supervisor Annunciation and Control.. ......................................................................................... 19
6.0 UPS Monitor Software ................................................................................................................... 20
7.0 Maintenance .................................................................................................................................... 23
7.1 Preventive Maintenance.. ............................................................................................................. 23
7.1 .I Torque Specifications.. ......................................................................................................... .24
7.2 Diagnostics ................................................................................................................................... 25
7.2.1 No Charger Output Voltage and/or Current.. ....................................................................... .25
7.2.2 Low Charger Output Voltage.. .............................................................................................. .25
7.2.3 High Charger Output Voltage.. ............................................................................................. .25
7.2.4 High Charger Output Current.. ....................... . ..................................................................... .25
7.2.5 Low Charger Output Current.. .............................................................................................. .25
7.2.6 Charger Inoperative . Fuses Open or Input Breaker Tripped ............................................... 25
7.2.7 Charger Output Voltage Not Adjustable.. ............................................................................. .25
7.2.8 High Ripple Voltage on Charger Output ................................................................................ 26
7.2.9 No AC Output Voltage ........................................................................................................... 26
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 AMETEK - Solidstate Controls. Operations Manual - ProcessPowerTMSeries Uninterruptible Power Supply

7.2.10 Low lnverter Output Voltage.. ............................................................................................... .26

7.2.1 1 lnverter Failure ..................................................................................................................... .26
7.2.12 lnverter Won’t Start .............................................................................................................. .26
7.2.13 Won’t Transfer to lnverter.. ................................................................................................... .26
7.2.14 Transferred to Bypass.. ........................................................................................................ .26
7.2.15 Out of Sync.. .......................................................................................................................... 26
8.0 Product Support Services ............................................................................................................. 27
8.1 Services Available (optional) ....................................................................................................... .27
8.1.1 On-Site Start-Up.. .................................................................................................................. 27
8.1.2 Preventive Maintenance Agreement.. .................................................................................. .27
8.1.3 Maintenance Training Program.. .......................................................................................... .27
8.2 Warranty Coverage ...................................................................................................................... 27
8.2.1 First Year Standard Warranty .............................................................................................. .27
8.2.2 Extended Warranty (optional) .............................................................................................. .27
8.3 Returned Material Authorization (RMA) ...................................................................................... .28
8.4 Recommended Spare Parts ......................................................................................................... 28
Bills of Material ........................................................................................................................................ 29

iv
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 ETEK”
875 Dearborn Dr., Columbus, Ohio 43085
FAX: (6141885-3990
Field Service: l-800-222-9079 / (614) 8467500
SOLIDSTATECONTROLS
FACTORY ACCEPTANCE TEST FORM FOR PPRO80-48-22-12-60

JOB NUMBER: A11055-S82594 SERIAL NUMBER: S82594OlllA D A T E : 03/17/2004

TESTED By: GUSTAV0 MARQUARDT SIGN.: &a

SUPERVISED BY: JORGE L. GARIN

CUSTOMER APPROVAL By: SIGN.:

TABLE OF CONTENTS

TABLE OF CONTENTS .......................................................................................... 2

ELECTRICAL SPECIFICATIONS ....................................................................... 4
TEST PROCEDURE ............................................................................................... 5
1. Preliminary visual inspection: ....................................................................... 5
2. Paint inspection ............................................................................................ 5
3. Continuity test ............................................................................................... 5
4. Dielectric test and insulation resistance......................................................... 5
4.1. Insulation resistance value before dielectric test ................................... 5
4.2. -
Dielectric test 2000VCA/50hz, one minute ............................................ 6
4.3. Insulation resistance value after dielectric test.. .................................... 6
5. Rectifier Performance test*. ........................................................................... 7
5.1. DC Output voltage-............................................................................... 7
5.2. DC Voltage regulation test-. ................................................................ 7
5.3. Rectifier Current limit*. ......................................................................... 9
5.4. Output ripple voltage ......................................................................... i0
6. lnverter Performance test ........................................................................... 11
6.1. lnverter steady state voltage regulation ............................................... 11
6.2. Dynamic regulation .............................................................................. 12
6.3. Overload .............................................................................................. 12
7. Static switch ................................................................................................ 12
Burn in .................................................................................................................. 13
8. Temperature measurement ........................................................................ 1 3
9. Functional test ................................................................................................. 15
10. Analog variables display indications .............................................................. 1 6
REPORT 1 ............................................................................................................ 17
REPORT 2 ............................................................................................................ 18
REPORT 3 ............................................................................................................ 19

Al 1055 - S825940111 A-Test Procedure.doc Sh. 2 of 19

INDEX

SOLIDSTATE CONTROLS
FACTORY ACCEPTANCE TEST FORM FOR
875 Dearborn Dr., Columbus, Ohio 43085
FAX: (614) 885-3990
Field Service: l-800-222-9079 I(614) 846-7500
PPRO80-48-22-12-60

JOB NUMBER: Al 1055 - 582594 S825940111B D A T E : 03/H/2004

TESTED By: SERGIO MARTINEZ

SUPERVISED By: J O R G E L . GARIN SIGN.:

CUSTOMER APPROVAL By: SIGN.:

TABLE OF CONTENTS

TABLE OF CONTENTS ..........................................................................................

ELECTRICAL SPEClFlCATlONS.. ..................................................................... 4
TEST PROCEDURE ............................................................................................... 5
1. Preliminary visual inspection: ....................................................................... 5
2. Paint inspection ............................................................................................ 5
3. Continuity test ............................................................................................... 5
4. Dielectric test and insulation resistance* ........................................................ 5
4.1. Insulation resistance value before dielectric test ................................... 5
4.2. Dielectric test 2000VCA/50hz, one minute ............................................ 6
4.3. Insulation resistance value after dielectric test ...................................... 6
5. Rectifier Performance test-............................................................................ 7
5.1. DC Output voltage-............................................................................... 7
5.2. DC Voltage regulation test: ................................................................ 7
5.3. Rectifier Current limit*.......................................................................... 9
5.4. Output ripple voltage ......................................................................... i’0
6. lnverter Performance test-........................................................................... 11
6.1. lnverter steady state voltage regulation ............................................... 11
6.2. Dynamic regulation .............................................................................. 12
6.3. Overload .............................................................................................. 12
7. Static switch ................................................................................................ 12
Burn in .................................................................................................................. 13
8. Temperature measurement ........................................................................ 1 3
9. Functional test ................................................................................................. 15
10. Analog variables display indications .............................................................. 16
REPORT 1 ............................................................................................................ 17
REPORT 2 ............................................................................................................ 18
REPORT 3 ............................................................................................................ 19

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Al 1055 - S825940111 B-Test Procedure.doc Sh. 2 of 19

 Solidstate Controls, Inc. Operations Manual - Manual Bypass Switch

Table of Contents

1 .O Introduction ...................................................................................................................................... 1
1 . 1 General Description ........................................................................................................................... 1
1.2 Safety ................................................................................................................................................. 1
2.0 Specifications ................................................................................................................................... 2
2.1 Electrical .............................................................................................................................................. 2
2.2 Manual Bypass Switch Transfer Characteristics.. ............................................................................... 2
2.3 Environmental.. .................................................................................................................................... 2
2.4 General Specifications ........................................................................................................................ 2
3.0 Installation ........................................................................................................................................ 5
3.1 Receiving ............................................................................................................................................ 5
3.1 .l Unpacking and Inspection.. ..................................................................................................... 5
3.1.2 Storage.. .................................................................................................................................. 5
3.1.3 Site Selection.. ......................................................................................................................... 5
3.2 Installation .......................................................................................................................................... 6
3.2.1 Equipment Required.. ............................................................................................................. .6
3.2.2 Input/Output Power Connections ........................................................................................... .6
3.2.3 Cabinet Ground ....................................................................................................................... 6
3.2.4 Alarm Interface Connections.. ................................................................................................ .6
3.2.5 Conductor Terminations.. ........................................................................................................ 8
4.0 Operation .......................................................................................................................................... 9
4.1 User Interface Panel .......................................................................................................................... 9
4.2 System Controls ................................................................................................................................. 9
4.2.1 Indicators.. ............................................................................................................................... 9
4.2.2 Alarms ..................................................................................................................................... 9
4.3 Operating Procedures.. .................................................................................................................... 10
4.3.1 Starting .................................................................................................................................. 10
4.3.2 Shut-Down.. ........................................................................................................................... 10
4.3.3 Safe Transfer of the Manual Bypass Switch ......................................................................... 10
4.4 Optional Equipment.. ........................................................................................................................ 10
4.4.1 S800 MBS with Padlock.. ...................................................................................................... 10
4.4.2 S800 MBS with Solenoid Lock.. ............................................................................................ 11
4.4.3 AC Output Circuit Breaker . 8801 (option 18). ...................................................................... 11
4.4.4 Bypass Source AC Input Circuit Breaker . 8800 (option 95). ............................................... 11
4.4.5 Manual Switch Position Alarm (option 90) ............................................................................ 11
4.4.6 Voltmeter with Selector Switch (option 89) ........................................................................... 11
4.4.7 Breaker Padlock (option 93). ................................................................................................. 11
5.0 Theory of Operation ....................................................................................................................... 12
5 . 1 Manual Transfer Switch Design.. ..................................................................................................... 12
5.2 Sync Monitor Board ......................................................................................................................... 1. 3
6.0 Maintenance .................................................................................................................................... 14
6.1 Preventive Maintenance.. ................................................................................................................. 14
6.1 .l Torque Specifications ................................................................................................................. 15
6.2 Diagnostics....................................................................................................................................... 16
7.0 Product Support Services ............................................................................................................. 17
7 . 1 Services Available (optional). ........................................................................................................... 17
7.1.1 On-Site Start-Up .................................................................................................................... 17
7.1.2 Preventive Maintenance Agreement.. ................................................................................... 17
7.1.3 Maintenance Training Program.. ........................................................................................... 17
7.2 Warranty Coverage .......................................................................................................................... 17
7.2.1 First Year Standard Warranty ............................................................................................... 17
7.2.2 Extended Warranty (optional) ............................................................................................... 17
7.3 Returned Material Authorization (RMA). ........................................................................................... 18
7.4 Recommended Spare Parts.. ........................................................................................................... 18

...
III

SOLIDSTATECONTROLS
FACTORY ACCEPTANCE TEST FORM FOR
875 Dearborn Dr., Columbus, Ohio 43085
FAX: (614) 885-3990
Field Service: l-600-222-9079 / (614) 646-7500
PPR080-48-22-12-60

JOB NUMBER: Al 1055 - S82594 SERIAL NUMBER: 3825940111B

TESTED By: SIGN.: h/a

SUPERVISEDBY: ..bW= L. dAe& SIGN.:

CUSTOMER APPROVAL By: SIGN.:

TABLE OF CONTENTS

TABLE OF CONTENTS .......................................................................................... 2

TEST PROCEDURE ............................................................................................... 4
1. Preliminary visual inspection: ....................................................................... 4
2. Paint inspection ............................................................................................ 4
3. Continuity test ............................................................................................... 4
4. Dielectric test and insulation resistance: ....................................................... 4
4.1. Insulation resistance value before dielectric test ................................... 4
4.2. Dielectric test 2000VCA/50hz, one minute ............................................ 4
4.3. Insulation resistance value after dielectric test ...................................... 4
5. MBS Performance test: ................................................................................ 5

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Al 1055 - S825940115-Test Procedure.doc Sh. 2 of 5