Kongsberg Maritime

Powerware UPS 2kVA and 3kVA

Mk IV, Installation and User's
Manual

Supplier: PowerWare
Reference: 1021485
Version: C

179747/H
Installation and Users Manual
for UPS 2kVA and 3kVA

1021485 Rev. C PDF/TA Page 1

 CONTENTS

1. Introduction
2. Safety Information
3. Installation
3.1 General Information
3.2 Location of the Unit
3.3 Logistics
3.4 Handling
3.5 Procedures
3.6 Storage of UPS
3.7 Storage of Battery
4. Technical specifications
4.1 General
4.2 Input
4.3 Output
4.4 Environmental
4.5 Mechanical
4.6 Battery

DRAWINGS
Main schematics Drawing UPS with distribution board 1021435
Dimensional Drawing 1023060
Dimensional Drawing 1023832

1021485 Rev. C Page 2

1. INTRODUCTION

This UPS is to be used only in restricted access locations.

The UPS operates automatically and protects connected equipment against
disturbances and power failures of the vessels mains. During mains power failure the
UPS will continue to operate independently for at least 30 minutes by means of internal
battery.
The UPS is an uninterruptible power supply unit for general use on board vessels.
The UPSs are delivered in three variants depending on the input voltage and output
capacity as follows:
120V / 3kVA
230V / 2kVA
230V / 3kVA
The UPSs are delivered completely assembled in crates and are ready to be installed
without any pre-assembly.

2. SAFETY INFORMATION

Since the UPS unit operates on line power and contains a bank of high-current backup
batteries, the information in this chaper is important to all personnel involved. Please
read the safety manual provided with this UPS.

WARNING!

Do not open the UPS cabinet. Some components inside the UPS cabinet
carry high voltage. To touch them may prove fatal. All operations inside the
unit must be carried out only by authorized personnel only.

This UPS contains its own energy source (batteries). The output may carry
live voltage even when the UPS is not connected to an AC supply.

Users operations
The only users operations permitted are:
Starting up and shutting down the UPS unit
Operating the users interface

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 Connecting data interface cables
These operations must be performed according to the instructions in this manual. During
any of these operations the user must take greatest care and perform only the prescibed
operations. Any deviation from the instructions could be dangerous to the operator.

WARNING!

The UPS contains high voltage and current which can injure or kill
personnel and damage equipment.
All repairs and service should be performed by authorized personnel only.
There are no serviceable parts inside the UPS.

WARNING!

Batteries may contain high energy and voltages, and caustic, toxic and
flammable substance.
Because of the battery string the output receptacles may carry high
voltage even when the AC supply is not connected to the UPS.
Read the shut down instruction of the Users and Installation manual.

WARNING!

Do not discard batteries or battery material in the public disposal system.

Follow all applicable local regulations for storage, handling and disposal of
batteries and battery material
Never dispose batteries in fire. Batteries may explode when exposed to
flame.
Never open or damage batteries. Released electrolyte is harmful to the skin
and eyes, and may be extremely toxic.

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3. INSTALLATION

3.1 General Information

The UPS is a 2kVA / 3kVA UPS with 30 minutes backup time. The UPS includes a main
switch, built-in batteries, power distribution, a bypass switch and an Emergency Shut
Down (ESD) function. For cabinet layout refer to figure 1.

Power Earth Mains ESD Bypass

switch
distribution failure trip switch

UPS

Batteries

Figure 1.

1021485 Rev. C Page 5

3.2 Location of the Unit
Avoid direct sunlight or other elements that can cause overheating of the unit.
Make sufficient space around the unit for ventilation and service. The unit must not be
installed in a small, closed and unventilated cabinet.

3.3 Logistics
General safety precautions should be followed when working on the UPS.

3.4 Handling
Appropriate equipment should be used and care must be taken when handling the UPS
units.

3.5 Procedures
3.5.1 Mechanical Installation
The UPS shall be fastened to the floor through two 5 mm mounting rails. Diameter of
bolts is 8 mm, see the attached dimensional drawing no. 1023060.

3.5.2 Electrical Installation

For electrical installation remove the cabinet top plate.
Connect the power and signal cables to appropriate connectors.
Install (or replace) the batteries.
Refer to the Main Schematic drawing 1021435 and figure 2 and 3.

Input Alarm ESD trip

Figure 2.
terminals TB1 terminals TB2 terminals TB3

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 Output MCBs

Figure 3

3.5.3 Connections of Mains

Connect the input mains cable to the terminal block TB1.
Connect the output mains cables directly to the MCBs.
Connect the PE wire to the PE bar.
Connect all armour / screens of cable to the PE bar.

3.5.4 Connection of Alarms

All alarms are by default connected in series in terminal block TB2, i.e. only one common
alarm is given for any specific alarm to terminals D1 and D19. Connection in series is
made between terminals D1, D2-D4, D5-D7, D9-D10, D11-D14, D15-D18, D19.

If specific alarm indication are required the jumper connection must be disconnected and
a new connection made according to the table 1.

3.5.5 Connection of Remote ESD trip

The ESD (Emergency Shut Down) trip is located on the upper right part of the cabinet.
This trip will disconnect the batteries in emergency case.
ESD function is activated by an external 24V DC signal connected to terminal block TB3
and marked with 0V and +24V. An alarm contact is wired to terminals D17, D18, D19,
refer to table 1. The ESD trip is to be manually reset after trip.

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 3.5.6 Operation of the Mains Input Switch S1 and Starting and
Shutting down the UPS
When the Mains Input Switch S1 is turned On, the mains is connected to UPS. When
S1 is turned Off, the mains is disconnected from UPS.
Note! UPS will not shut down, when S1 is turned Off.
UPS will be started by pushing the start button ( I ) in UPS front panel couple of seconds.
UPS will be shut down by pushing the same start button ( I ) also couple of seconds.
Note! If Remote ESD trip is activated before UPS is shut down, UPS should be started
manually with the start button in UPS front panel.

Refer to figure 4.

Function Terminal no. System state

Line failure D1 D2 Line OK D1 D2
D1 D3 Line failure D3
Low battery D4 D5 Battery normal D4 D5
D4 D6 Battery low D6
UPS on / ok D7 D9 UPS on / ok D7 D9
UPS alarm D7 D8 UPS alarm D8
Earth failure D11 D10 Opens at earth failure D11 D10
D12 D13 Closes at earth failure D12 D13
Manual Bypass D15 D14 Opens when bypassed D15 D14
D15 D16 Closes when bypassed D16
Emergency Safety D18 D19 Opens when activated D18 D19
Device D18 D17 Closes when activated D17

Table 1. All contacts are shown in OK position.

3.5.7 Operation of the Manual Bypass Switch S2

The manual bypass switch S2 is located on the upper right part of cabinet. It allows the
user to isolate the UPS unit and batteries from the load for servicing the UPS system.
The information of the position of the Manual Bypass Switch is wired to terminals D14-
D15-D16, refer to table 1.

Refer to figure 4.

1021485 Rev. C Page 8

Figure 4.

NOTE!

Force the UPS first to static bypass before manual bypass

1021485 Rev. C Page 9

 NOTE!

The manual bypass switch should be operated only by a qualified and

trained personnel. An error in the procedure may result in a breakdown of
load feeding.

To operate the manual bypass switch, follow these instructions:

To disconnect the UPS:

1. Make sure the load is fed by the Mains input of the UPS and not from the batteries
2. Force the UPS to internal bypass by selecting Manual bypass GO ON from UPS
setting in the LCD menu (see UPS configurations page 19 in Users and Installation
Manual of UPS, p/n 1017934)
3. Turn the manual bypass switch into Bypass position.
Note, the UPS will not protect the load, when manual bypass is used.

To connect the UPS:

1. If there has been performed maintenance on the UPS unit or the batteries, make
sure that the connections are done correctly.
2. Make sure the manual bypass switch is in "Bypass" position.
3. Start the UPS and force it to internal bypass by selecting Manual bypass GO ON
from UPS setting in the LCD menu
4. Turn the manual bypass switch into Normal position
5. Select Manual bypass OFF from UPS setting in the LCD menu

3.5.8 Earth Failure Unit

The earth failure unit is located on the upper right part of cabinet. The earth failure unit
sum up the load current, - phase + neutral. Adjust the earth fault alarm level to 30 mA
and the alarm delay to zero. If the current differs from zero more than 30mA, it gives an
alarm out to terminals D10, D11, D12 and D13. For more detail refer to table 1, figure 4
and drawing 1021435.

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3.5.9 Replacement of Batteries

WARNING!

Batteries may contain high energy and voltages, caustic, toxic and
flammable substances.
Do not discard batteries or battery material in public disposal systems.
Follow all applicable local regulations for storage, handling and disposal of
batteries and battery material
Never dispose batteries in fire. Batteries may explode when exposed to
flame.
Never open or damage batteries. Released electrolyte is harmful to the skin
and eyes, and may be extremely toxic.

The batteries are not hot-swappable.

To replace the batteries follow these instructions:
1. Transfer load into by-pass according to the procedure section 3.5.7 Operation of
the Manual Bypass Switch S2.
2. Remove front cover by removing 8 pcs of phillips drive screws.
3. Remove fastening brackets for the batteries by unscrewing them in the front end
of the cabinet. The bracket is now free and can easily be removed by lifting the
front end while pulled straight out.
4. Pay attention not to short-circuit the batteries. Even used batteries may contain
high energy and should be handled carefully.
5. Disconnect all battery connection cables and label the positive and negative
output cables.
6. Pull out the old batteries and install the new ones. Make sure that the new
batteries are according to specificatons in section 4.6. To prevent overheating of
battery bank, please install spacers between the batteries.
7. Reinstall the fastening brackets by entering the inner fastening clamp and secure
the brackets by mounting the screws on the outer end.
8. Fit all connection cables to the batteries and tighten the battery terminals with a
torque wrench key. For batteries with M5 bolt insertion type and M5 bolt and nut
type use fastening torque 20~30 kg x cm or 17.3~26.0 lbs x inch.
9. Cross-check battery polarity and make absolutely sure that the battery bank is
terminated with correct polarity to the UPS. Verify that there is no connection
between any battery terminals and ground.

1021485 Rev. C Page 11

10. Reinstall the front cover with all fastening screws.
11. Start the UPS according to the procedure section 3.5.7 Operation of the Manual
By-pass switch S2

3.6 Storage of UPS

Store the UPS in a stable position and protect it from rain. Keep the UPS in upright
position. Do not store the UPS under direct sunlight, in high temperatures (+60C or
higher) or in a high humidity atmosphere.

3.7 Storage of Battery

During storage of the batteries, recharge batteries at least every six months (when
ambient temperature is +25C or lower). Shorten the interval of recharging to half by
every 10C rise of ambient temperature. Rate of self-discharge of battery doubles every
10C rise of ambient temperature. If the battery has been stored for a longer period in a
discharged state, it may not be able to recharge to full capacity of it.
If the battery is stored for a year or longer without being recharged, its service life may
be shortened.
Typical battery life time is six years at ambient temperature of 25C and ten years at
temperature of 20C.

1021485 Rev. C Page 12

4. TECHNICAL SPECIFICATIONS

4.1 General
Rated power 2000 VA, 3000 VA at p.f. 0,7
Technology On-line, double conversion topology with
automatic and maintenance bypass
4.2 Input
Phase Single phase with ground
Input Voltage 90 to 144 VAC / 176 to 264 VAC
Frequency 50/60Hz
Frequency window from mains 45 65Hz
Synchronization window +/- 3Hz
Input current (230VAC/2kVA) 7,7A
(230VAC/3kVA) 12,0A
(120VAC/3kVA) 24,0A
Input Power factor 0.97
4.3 Output
Output Voltage 120VAC / 230VAC
Voltage regulation +/- 2%
Voltage distortion < 5% THD at full non-linear load
< 3% THD at full linear load
Frequency regulation +/- 0,25% (battery mode or free running)
Overload capacity 100 125% 1 min
125 150% 10 sec
Efficiency 0,86
Output fuse breakers 6 Amps.

4.4 Environmental
Ambient temperature +0C +40C
Recommended temperature +15C +25C
Storage temperature -15C +50C
Cooling Forced air cooling
Humidity 0 95%, non-condensing

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Audible noise < 50 dB normal and battery mode
4.5 Mechanical
Width x Depth x Height 612 x 586 x 662 mm
Weight with batteries 115 kg
Colour Grey NCS S 4500-N
Protection IP22

4.6 Battery
Type Panasonic LC-X1224AP
Number of batteries 8
Nominal voltage 12 V
Rated capacity 24 Ah

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