user manual carg bats universal

8/7/2019 User Manual Carg Bats Universal

http://slidepdf.com/reader/full/user-manual-carg-bats-universal 1/15

GE Consumer & IndustrialPower Protection

User manualDigital Energy™ Universal Battery Charger

for use with GEDE UPS

NetPro 3000, LP 11/31T/31

Manufactured by:

GE Consumer & Industrial SAGeneral Electric CompanyCH – 6595 Riazzino (LocarnoSwitzerlandT +41 (0)91 / 850 51 51F +41 (0)91 / 850 51 44www.gedigitalenergy.com



GB

User manualUBC - Universal Battery Charger130-290Vdc, 2/4/6/8A

Please read these instructions carefully before installation and start-up of the Universal BatteryCharger. Keep this manual in a safe place for future reference.

CONTENTS

1 Important safety instructions............................... ..................................... ............................ ...........2

1.1 Save these instructions1.2 Safety rules

2 Introduction .................................... .................................... ..................................... ......................... ........32.1 Introduction2.2 Intended use2.3 Transport / storage

3 Installation.................................................................................................................................................43.1 Installation rules3.2 Installation procedures

3.2.1 Connecting the UBC to a NetPro 3000 UPS3.2.2 Connecting the UBC to an LP 11/31T Series UPS3.2.3 Connecting two UBC units to an LP 31 Series UPS

3.3 Settings: voltage and current3.3.1 Setting the charge voltage3.3.2 Setting the charge current

4 Operation................................................................................................................................................124.1 Start-up and normal operation4.2 Use: status and alarm Indications

4.2.1 Status indication during normal operation4.2.2 Alarm indication4.2.3 Protection

5 Maintenance..........................................................................................................................................13

6 Troubleshooting...................................................................................................................................13

7 Technical specifications .................................... ..................................... ............................ ..............14

© General Electric Digital Energy. All rights reserved; reproduction without permission prohibited. This manual may be subject tochange; no liability can be accepted for any error or omission.

modifications reservedOPM_UBC_130_290_XXX_1GB_V010 1 User manual UBC 130-290V 1.0 (GB)



1 - Important safety instructions

1.1 Save these instructions

This manual contains important instructions that should be followed during installation and

maintenance of the UBC. It also gives all necessary information about the correct use of the UBC.Before attempting to install and start up the UBC, carefully read this manual. Keep this manual nextto the unit for future references.

Full understanding of and compliance with the safety instructions and warningscontained in this manual are

THE ONLY CONDITIONto avoid any dangerous situation during installation, operation and maintenance work,and to preserve the maximum reliability of the UPS system.

GE refuses any responsibility in case of non-observance, unauthorized alterations or improper use of the delivered UBC.

While every care has been taken to ensure the completeness and accuracy of this manual, GEaccepts no responsibility or liability for any loss or damage resulting from the use of the informationcontained in this document.

This document shall not be copied nor reproduced without the permission of GE.

Due to technical improvements, some of the information contained in this manual may be changedwithout notice.

1.2 Safety rules

CAUTION! RISK OF ELECTRIC SHOCK. The UBC contains potentially hazardous voltages. Do not open the unit, there are nouser serviceable parts inside.

All maintenance and service work should be performed by qualified service personnel.

CAUTIONThere may be damage to the equipment if procedures and practices are not strictlyobserved and followed.

NOTEDo not attempt to service the UBC unless you have had proper training. Refer allmaintenance and servicing to properly qualified, skilled and competent servicepersonnel.

Qualified, skilled personnel are persons who (because of their training, experience, and position aswell as their knowledge of appropriate standards, regulations, health and safety requirements andworking conditions) are authorised to be responsible for the safety of the equipment, at all timeswhilst carrying out their normal duties and are therefore aware of, and can report, possible hazards(observe IEC 364, DIN VDE 0105 and national wiring regulations and accident prevention rules).




2 - Introduction

2.1 Introduction

The GE (General Electric) Digital Energy™ Universal Battery Charger is a compact and modern

battery charging system which incorporates the most advanced power electronics technology toprovide exceptional performance.The UBC is intended to provide additional battery charging capacity to a UPS (Uninterruptible PowerSupply) equipped with battery extension pack(s). The unit can be applied in those circumstanceswhere the regular built-in battery charging capacity of the UPS is considered to be insufficient,given the frequency of power failures and the capacity of the back-up batteries. It is designed tomatch the battery characteristics of the following GE Digital Energy UPS models: NetPro 3000 andLP Series 11 / 31T / 31. Please note that two UBC units are required in a system with an LP 31UPS. Off factory the UBC is wired for use with a NetPro 3000 UPS.

Mains

Battery extensionpack

LoadUPS

Battery extensionpack

UBCin case of LP 31 UPS

Fig. 1 Typical installation with UBC, UPS and battery extension pack(s)

2.2 Intended use

• The UBC is intended to provide additional battery charging capacity to a UPS system equippedwith battery extension pack(s). It is designed to match the battery characteristics of the followingGE Digital Energy UPS models: NetPro 3000 and LP Series 11 / 31T / 31.

• The UBC is not intended to be used as a standalone battery charger.• The technical data as well as information concerning connection requirements can be found on

the rating label and in this document and shall be strictly observed.

2.3 Transport / storage

• No liability can be accepted for any transport damage when the equipment is shipped in non-original packaging.

• Store the UBC in a dry location. Storage temperature must be within -20 +45°C (-4 +104 °F)




3 - Installation

The shipping box contains a UBC - Universal Battery Charger, an IEC male-female mains power cord,a DC cable for use with a Digital Energy LP Series UPS and this manual. Inspect the UPS for damageafter unpacking. If any damage is present please immediately notify the carrier and place of purchase.

WARNING! In case of recognizable damage:DO NOT connect any voltage to the unitDO NOT put the unit into operation

IMPORTANTBefore making any connection and switching on the UBC, please check that yourmains supply is 220 - 240 Volts and 50 Hz

3.1 Installation rules

• The UBC is intended to be used in normal domestic and office situations.• Protect the UBC, according to the wiring rules, with a 16A D-type fuse.• The UBC must be powered from a single phase grounded wall outlet. Do not use extension cords.• Avoid locations that are excessively humid, near water, near heat sources or in direct sunlight.• The ambient temperature should not exceed 40°C (104°F).• It is important that ventilation air can move freely around and through the unit. Do not block the

air vents.• Do not touch electronic components. They may be electrostatic sensitive and are for that reason

easily damaged due to improper handling.

• To avoid potential health risks, electrical components should not be mechanically damaged ordestroyed.

• The sum of the leakage currents of the UBC, UPS and the connected loads should not exceed3.5mA.

3.2 Installation Procedures

This sections describes the installation of the UBC in combiantion with the following UPS models:

3.2.1 NetPro 3000 UPS

3.2.2 LP 11/31T Series UPS

3.2.3 LP 31 Series UPS




3.2.1 Connecting the UBC to a NetPro 3000 UPS


1. Make sure that the load protected by the UPS hasbeen switched off.Switch off the UPS, and unplug it from the wall outlet.

2. If you do not want to install a remote alarm (for detailssee section 4.2.2), proceed with step 3. To install aremote alarm read chapter 1 and proceed as follows:

3c

3a

3

Fig. 2a

3a

4

3

6

5

1a

7

1

2

UBC

NetPro 3000 VABattery pack

Fig. 2 Connections for NetPro 3000 UPS

2.1 Remove the screw from the front / bottom side of the UBC cabinet2.2 Remove the 4 screws at the rear side of the UBC cabinet holding the I/O plate2.3 Slide out the I/O plate till it is locked

2.4 Install the remote alarm on the alarm relay contact (15 on fig. 11). Lead the cablethrough the hole in the lower middle of the back panel of the UBC.

2.5 Slide the I/O plate back into the unit and tighten the 4 screws at the backside and 1screw at the bottom side of the UBC.

3. Connect the DC cable plug (1, fig. 2) from the battery pack to the DC socket (2, fig. 2) of theUBC.

4. Connect the DC cable plug (3, fig. 2) from the UBC to the DC socket (4, fig. 2 and 2a) of the UPS.You will hear a click when the cable is properly installed. Block the DC connector: install thesmall locking plate (3c, fig. 2a) that came with the battery pack, and fasten it with the screw

provided.

5. BEFORE connecting the UBC to mains: Check the dip switch setting at the back side of the UBC(7, fig. 2) for NetPro 3000 usage, please refer to section 3.3.

6. Use the mains power cord provided with the UBC (6, fig. 2) and connect it to the input socket(5, fig. 2)

7. Connect the mains power cords of the UBC and UPS to a working, grounded AC wall socketoutlet.

8. Switch on the UPS, refer to the user manual of the UPS for further instructions.

9. The green LED ‘on’ (12, fig. 10) of the UBC illuminates. Depending on the condition of thebatteries LED “charging” (14, fig. 10) may illuminate as well.




3.2.2 Connecting the UBC to an LP 11 / 31T Series UPS

The UBC is standard wired for use with a NetPro 3000 UPS.If you want to use the UBC in combination with an LP 11/31T Series UPS you first have to makesome small modifications to the UBC.

1. Make sure that the load protected by the UPS has been switched off.Switch off the UPS

2. Switch all MCBs (2, fig. 3) to ‘off’ position (down) and open the battery fuse holder (9, fig. 3).Please refer to the operating manual of the UPS for additional information.

3. Open the battery fuse holder of the battery extension cabinet as well (9a, fig. 3)

4. Read chapter 1.Prepare the UBC for use with an LP 11/31T Series UPS:

4.1 Remove the screw from the front / bottom side of the UBC cabinet

4.2 Remove the 4 screws at the rear side of the UBC cabinet holding the I/O plate4.3 Slide out the I/O plate till it is locked4.4 Disconnect cable 3a from connector J231 and earth stud PE (fig. 5), remove the pull

relief (11, fig. 5) and remove cable 3a.4.5 A DC cable was delivered with the UBC. Install the red DC+ and black DC- wires of this

cable (3b, fig. 3/6) to connector J231 (fig. 6)4.6 Connect the yellow-green earth wire of cable 3b to the earth stud “PE”, according to fig.

6 and 7.4.7 Place the metal pull relief (11, fig. 6) for cable 3b according to fig. 6 and fig. 8.4.8 Connect the plug of the DC cable coming from the battery extension cabinet (1d, fig.

3/6) to connector 1c inside the UBC (fig. 6).4.9 Place the metal pull relief for this cable according to fig. 6/8.

4.10 A remote alarm (for details see section 4.2.2) can be installed on the alarm relaycontact (15 on fig. 11). Lead the cable through the hole in the lower middle of the backpanel of the UBC.


4.12 BEFORE connecting the UBC to mains: set the dip switches at the back side of the UBC(7, fig. 3) for LP Series UPS usage. Please refer to section 3.3.

5. Connect the DC cable plug (3d, fig. 3) from the UBC to the DC socket of the UPS (8, fig. 3).

6. Use the mains power cord provided with the UBC and connect it to the input socket (5, fig.3).

7. Connect the mains power cord of the UBC (6, fig. 3) to a working, grounded AC wall socketoutlet.

8. Switch on the UPS and close the battery fuse holders of UPS (9, fig. 3) and battery cabinet(s)(9a, fig. 3). Please refer to the operating manual of the UPS for additional information.




LP 5-6 kVA

9

UBC

3b

3d

2

LP battery cabinet

14Ah

9a

1d

1e

8

LP 8-10 kVA

2

8

9

56

7

Fig. 3 Connections for LP 11/31T Series





3.2.3 Connecting two UBC units to an LP 31 Series UPS

The UBC is standard wired for use with a NetPro 3000 UPS.If you want to use the UBC in combination with an LP 31 Series UPS you first have to make somesmall modifications to the UBC. Please note that two UBC units are required in a system with anLP 31 UPS.

1. Make sure that the load protected by the UPS has been switched off. Switch off the UPS.

2. On the UPS, switch all MCBs (2, fig. 4) to ‘off’ position (down).Open the battery fuse holders (9b, fig. 4).Please refer to the operating manual of the UPS for additional information.

3. Open the battery fuse holder of the battery extension cabinet (9c, fig. 4)

4. Read chapter 1. Prepare the UBC’s for use with an LP 31 Series UPS (for each UBC unit followsteps 4.1 through 4.12):4.1 Remove the screw from the front / bottom side of the UBC cabinet.

4.2 Remove the 4 screws at the rear side of the UBC cabinet holding the I/O plate.4.3 Slide out the I/O plate till it is locked.4.4 Disconnect cable 3a from connector J231 and earth stud PE (fig. 5), remove the pull

relief (11, fig. 5) and remove cable 3a.4.5 Using a 10mm2 3-wire (red - black - yellow/green) DC cable: Install the red DC+ and

black DC- wires of this cable (3b, fig. 4/5/6) to connector J231 (fig. 6). Please note thatthis cable 3b has no connector.

4.6 Connect the yellow/green earth wire of cable 3b to the earth stud “PE”, according to fig.6 and 7.

4.7 Place the metal pull relief (11, fig. 6) for cable 3b according to fig. 6 and fig. 8.4.8 A DC cable was delivered with the UBC. Connect the plug (1d, fig. 6) of this DC cable (1e,

fig. 4/6) to connector 1c inside the UBC (fig. 6).

4.9 Place the metal pull relief for this cable according to fig. 6/8.4.10 A remote alarm (for details see section 4.2.2) can be installed on the alarm relay

contact (15, fig. 11). Lead the cable through the hole in the lower middle of the backpanel of the UBC.


4.12 BEFORE connecting the UBC to mains: set the dip switches at the back side of the UBC(7, fig. 4) for LP Series UPS usage, please refer to section 3.3.

5. Connect the DC cable (3b, fig. 4) from UBC 1&2 to the battery terminals of the UPS (10a, fig. 4).Please refer to the operating manual of the UPS for additional information.

6. Connect the DC cable (1e, fig. 4 from UBC 1&2 to the battery terminals of the batteryextension cabinet (10b, fig. 4). Please refer to the operating manual of the UPS for additionalinformation.

7. Use the mains power cord provided with UBC 1&2 and connect it to the input socket (5, fig. 4).

8. Connect the mains power cord of UBC 1&2 (6, fig. 4/5) to a working, grounded AC wall socketoutlet.

9. Switch on the UPS and close the battery fuse holders of the UPS and battery cabinet(s) (9b/c,fig. 4). Please refer to the operating manual of the UPS for additional information.





2

1b

3a

PE

11PE

Fig. 5 Cable connections to filter PCB (for NetPro 3000)

1c 1d

11

3b

batterypack1

1a

3

UPS

batterycabinet

1e

3d (LP 11/31T)

UPS

Fig. 6 Cable connections to filter PCB (for LP 11 / 31T / 31 Series)

3a/b11

1e/3a/3b

Fig. 7 PE Earth stud wire sequence Fig. 8 Pull relief assembly



4 - Operation

4.1 Start-up and normal operation

There is no need to switch on the UBC: as soon as the mains cord of the UBC has been pluggedinto a working, grounded AC wall socket the UBC starts up.

During installation you have properly set the nominal charge voltage and - current, according tothe UPS system. For more information please refer to section 3.3. In the charging mode the UBCcharge voltage will follow the UPS charge voltage. This way the advantages of the superiorbattery management features of the UPS are fully used:

automatic boost mode - reduces the battery recharge time

temperature compensated battery charging - reduces the battery charge voltage withincreasing temperature. As a result poor charging of the batteries under low temperature

conditions and overcharging of the batteries under high temperature conditions are prevented.

4.2 Status and alarm indications


4.2.1 Status indication during normal operation

At start-up LED ‘on’ (12, fig. 10) lights up toindicate that the unit is operating properly.Depending on the condition of the batteries LED“charging” (14, fig. 10) may illuminate as well.

Fig. 10 Front panel

14

13

12

15

4.2.2 Alarm indications

If one (or more) of the protection circuits is (are)

active LED “alarm” (13, fig. 10) lights up. See 4.2.3for more details. The unit will not charge untilthe alarm situation has been cleared.

On the filter PCB, a normally open (NO) ornormally closed (NC) relay contact (15, fig. 11) isavailable to notify other equipment in thesystem that an alarm situation occurs.

Fig. 11 Filter PCB




4.2.3 Protection

All electrical circuits are protected against overtemperature or overload by means of protectioncircuits for transformer, heatsink, input AC voltage, output DC voltage and short circuit.

Transformer - PTC thermal over protection at 130°C.Heatsink - Fan control and PTC thermal protection. The fan speed is dependent on the

heatsink temperature. If the temperature of the heatsink exceeds 80°C theUBC system will shut down.

Input AC voltage - Minimum input voltage (mains) to start up the output converter is 190 Vac.Minimum input voltage after start up is 170Vac.

Output DC voltage - Minimum battery voltage to start up the output converter is 90 Vdc.Short circuit - The DC output of the UBC is fully protected against very low impedant

loads like a short circuit.

5 - Maintenance

The GE Digital Energy Universal Battery Charger is virtually maintenance free: take care of properenvironmental conditions and keep air inlets/outlets free of dust.

6 - Troubleshooting

The following chart is a simple troubleshooting checklist only. If the suggested solution does notsucceed, or if the information is insufficient to solve the problem, please contact your dealer orconsult www.gedigitalenergy.com.

Problem Possible cause Solution

Line cord not connected Connect line cordUBC will not switch on

Dead wall socket or mainsvoltage out of limits

Contact qualified electrician

Mains voltage out of limits Weak mains, connect to bettermains

Battery voltage too low Wait until UPS has chargedbatteries to 90 Vdc

Worn out batteries Replace the batteries in thebattery pack

Over-temperature Allow UBC to cool down

Place UBC in lower ambienttemperature

UBC is not charging batteries

Faulty wiring See figures 3-6 for properinstallation

UBC is charging while UPSsystem is “On Battery”

Faulty wiring See figures 3-6 for properinstallation



difi i d

7 - Technical specifications

RatingsInput power (W) : 2600Input fuse (A) : 20Output power (W) : 2320Output Fuse (A) : 10

Input converterAC input voltage : 220 - 240 VAC input voltage range : 100% load: 187 - 264 VMinimum start-up AC voltage : 190VInput current waveform : sinusoidal

conform or better than EN 61000-3-2 (IEC 555-2)Input current (A) at nom. inp. volt. : 16Input power factor : 1Input frequency range (Hz) : 45 - 66

Inrush current (A) : 23

Output converterDC output voltage : 290V max (dip switch setting 9 – 20 batteries 130.5 – 290V)DC output voltage tolerance : ± 2%DC output current : 8A max (dip switch setting 2, 4, 6 or 8 Ampere)DC output current tolerance : ± 10%

Overload capability : fully protected against overload and short circuits

GeneralWeight (kg) : 5Dimensions (hxwxd, mm) : 225x185x430

Enclosure / protection : steel-plastic / IP20

EnvironmentSafety : EN 50091-1-1, EN 60950, IEC 950Electromagnetic compatibility : EN 50091-2Ambient temperature : -10 to +40ºCAudible noise at 1 meter : < 45 dB(A), temperature dependentMax. relative humidity : 95% (non-condensing)

user manual carg bats universal

Documents