IOTA IISCN3P Series Three-Phase Central Inverters User Manual

 IISCN3P Series Three-Phase Central Inverters
User Manual

30 & 60 minute run time 24.0 kW – 50.0 kW
120 minute run time 20.4 kW – 42.5 kW
IOTA Engineering
Service: 610-868-5400
www.iotaengineering.com

CAUTION
READ THE ENTIRE MANUAL AND REVIEW ALL DOCUMENTATION BEFORE ATTEMPTING SYSTEM INSTALLATION
FOR SERVICE OR INSTALLATION INFORMATION:
TELEPHONE: 610-868-5400 (24 HR. HOTLINE)
FAX: 610-954-8227
FOR YOUR PROTECTION
PLEASE COMPLETE AND RETURN THE WARRANTY REGISTRATION CARD IMMEDIATELY.

This unit contains LETHAL VOLTAGES. All repairs and services should be performed by AUTHORIZED SERVICE PERSONNEL ONLY! There are NO USER-SERVICEABLE PARTS inside this unit.

IMPORTANT SAFEGUARDS

When using electrical equipment, you should always follow basic safety precautions, including the following:

1. READ AND FOLLOW ALL SAFETY INSTRUCTIONS.
2. Do not install the system outdoors.
3. Do not install near gas or electric heaters or in other high-temperature locations.
4. Use caution when servicing batteries. Depending on battery type, batteries contain either acid or alkali and can cause burns to the skin and eyes. If battery fluid is spilled on the skin or in the eyes, flush with fresh water and contact a physician immediately.
5. Equipment should be mounted in locations where unauthorized personnel will not readily subject it to tampering.
6. The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition and void the warranty.
7. Do not use this equipment for other than its intended use.
8. Qualified service personnel must perform all servicing of this equipment.

SAVE THESE INSTRUCTIONS

The installation and use of this product must comply with all national, federal, state, municipal, or local codes that apply. If you need help, please call Service.

User’s Guide
An on-site permanent log of the inspection, testing, and maintenance of the emergency electrical power supply system shall be maintained in accordance with the Manufacturer’s operating manual. The log shall include:
The date on which the inspection, testing, and maintenance exercise was carried out
The name of the person(s) who performed the inspection, testing, and maintenance.
A note of any unsatisfactory condition observed or discovered, and the steps are taken to correct the condition

CHAPTER1 INTRODUCTION

Keep this manual and the System Installation Guide in the folder mounted inside the unit.

This unit is a microprocessor-controlled PWM (Pulse Width Modulated) pure sine wave-based DC to AC power inverter utilizing IGBT technology. It integrates a fully automatic 3rate battery charger, a solid-state transfer system, control circuitry, self-testing and recording digital meter display, and maintenance- free sealed lead calcium type batteries. The system components are carefully matched to make the unit a completely self-contained, fully automatic standby power source for operation on all types of lighting loads. The batteries are sized and tested per CSA C22.2 No. 141-15, the Standard for Unit Equipment for Emergency Lighting and Life Safety Code ANSI / NFPA 101, providing emergency power for a minimum of 30, 60, or 120 minutes.

If the duration of a power failure is greater than the battery’s storage capability, the inverter will automatically shut down when the battery voltage reaches 85% of the nominal DC voltage. This feature protects the battery from being permanently damaged from a deep discharge that could cause cell reversal. This battery protection feature is called “Low Voltage Disconnect” or L.V.D.

When the AC power is restored after a full discharge, the system will be ready for another power failure within 24hrs. If another power failure occurs before the 24-hour  recharge time, the run time will be decreased.
The front panel display incorporates an alphanumeric 2×20 LCD character display, LED status indicators, and a 4 x 4 keypad. All user interface functions are available from the front panel assembly.
Utilizing a small footprint, this unit is for use with any lighting load including quartz, HID, incandescent, fluorescent, and halogen.

HOW TO USE THIS MANUAL

This manual tells you how to start, operate, and communicate with your unit and lets you know how to get more information for special situations.
Please record your unit’s model number, serial number, and part number below. You can find these numbers on the labels on the inside panel.
Model Number __
Serial Number __
Part Number ___

Service and Support
We are committed to outstanding customer service. A service technician is available 24 hours a day, 365 days a year. Service is also available 24 hours a day to give you access to technical notes and product information. You can also visit our website.
NOTE: Please have your unit’s Serial and Model numbers available when you call; this number is located behind the right door.
Contact SERVICE one of the following ways:
Service Number: 610-868-5400
Service Fax: 610-954-8227
Website: iotaengineering.com 

CHAPTER 2 ENVIRONMENT

Make sure the environment is a clean, cool, dry place with normal ventilation.

Storage Temperature
Store the batteries (in the system or battery cabinet) at -18 to 40°C (0 to 104°F). Batteries have a longer shelf life if they are stored below 25°C (77°F). Keep stored batteries fully charged. Recharge the batteries every 90–180 days. The system or battery cabinet without batteries may be stored at -20 to 70°C (-4 to 158°F).

Ventilation
The air around the unit must be clean, dust-free, and free of corrosive chemicals or other contaminants. Do not place the system or batteries in a sealed room or container.

Operating Temperature
The system can operate from 20° to 30°C (68° to 86°F) and up to 95% relative humidity. The batteries’ service life is longer if the operating temperature stays below 25°C (77°F).

Batteries
The temperature should be near 25°C (77°F) for optimum battery performance. Batteries are less efficient at temperatures below 18°C (65°F), and high temperatures reduce battery life.
Typically, at about 35°C (95°F), battery life is half of what it would be at a normal temperature of 25°C (77°F). At about 45°C (113°F), battery life is one- fourth of normal.
Make sure that heaters, sunlight, air conditioners, or outside air vents are not directed toward the batteries. These conditions can make the temperature within battery strings vary, which can cause differences in the batteries’ voltages. Eventually, these conditions affect battery performance.
If the batteries are not in the system, remember that the batteries should be installed as close as possible to the unit to reduce DC wiring costs and improve battery performance.
Do not allow tobacco smoking, sparks, or flames in the system location because hydrogen is concentrated under the vent cap of each cell of the battery. Hydrogen is highly explosive, and it is hard to detect because it is colorless, odorless, and lighter than air.
Every type of battery can produce hydrogen gas, even sealed maintenance-free batteries.
The gas is vented through the vent caps and into the air, mainly when the unit is charging the batteries. The batteries produce the most hydrogen when maximum voltage is present in fully charged batteries; the batteries do not produce hydrogen during float charging. The amount of current that the charger supplies to the batteries (not the battery ampere-hour) determine how much hydrogen is produced.

High Altitude Operation
Maximum elevation is 3000m (10,000 ft). Derating on output power is 4% per 300m (1000ft) above 3000m (10,000 ft).

CHAPTER 3 STARTUP AND SHUTDOWN PROCEDURE

Refer to the Installation Manual to secure the unit and install AC and DC wiring.

STARTUP PROCEDURE

For the initial startup of the system, follow the instructions in the Startup and Warranty Validation Form.
Failure to do so will void the warranty.

CAUTION: HAZARDOUS VOLTAGES – ONLY QUALIFIED SERVICE PERSONNEL SHOULD PERFORM THE PROCEDURE.

1. Verify that the installation switch located on the inverter chassis is in the OFF position. Verify that the AC input is disconnected.
2. Press and hold the DC Pre-charge switch located on the inverter chassis for approximately five seconds and then turn on the battery breaker.
3. Energize the Mains AC input by turning on the unit’s input circuit breaker and/or the Distribution Panel breaker located upstream from the inverter.
4. Turn the installation switch to the On position. The Front Panel display should now be illuminated and a slight hum should be heard from the inverter transformer. The unit is now charging and the output should be energized.

SHUTDOWN PROCEDURE

1. Interrupt the AC Mains to the machine by the Distribution Panel Breaker or the machine’s input circuit breaker. The Inverter should then start.
2. Turn the installation switch located on the inverter chassis to the off position. The inverter should stop.
3. Disconnect the main battery breaker.

CAUTION: HAZARDOUS VOLTAGES STILL EXIST AT THE BATTERY TERMINAL BLOCK AND WITHIN THE SYSTEM. AUTHORIZED SERVICE TECHNICIANS MUST DISCHARGE DC CAPACITORS AND TURN OFF UTILITY POWER BEFORE SERVICING EQUIPMENT.
CAUTION: DO NOT LEAVE THE SYSTEM SHUT DOWN FOR A PROLONGED LENGTH OF TIME. LEAD-BASED BATTERIES WILL EXPERIENCE PERMANENT DAMAGE FROM LACK OF CHARGING AFTER A FEW MONTHS.

MAINTENANCE BYPASS PROCEDURE

CAUTION:
HAZARDOUS VOLTAGES – ONLY QUALIFIED SERVICE PERSONNEL SHOULD PERFORM THE PROCEDURE.
MAINTENANCE BYPASS SHOULD NOT BE PERFORMED WHEN THE SYSTEM IS IN BATTERY EMERGENCY MODE.

System Into Bypass Mode

1. Open the left-hand door. Locate Maintenance Bypass Switch.
2. Turn Maintenance Bypass Switch from normal mode (UPS) to bypass mode (BYPASS).
3. Locate the Installation Switch behind the left-hand door on the right-hand wall. Turn the Installation Switch to the (OFF) position.
4. Locate Input Circuit Breaker (CB1) behind the left-hand door. Turn the Input Circuit Breaker to the (OFF) position.
5. Remove screws to open the right-hand doors. Locate the Main Battery Circuit Breaker on the lower left-hand wall. Turn Main Battery Circuit Breaker to the (OFF) position.

CAUTION:
HAZARDOUS VOLTAGES STILL EXIST AT THE BATTERY TERMINAL BLOCK AND WITHIN THE SYSTEM. AUTHORIZED SERVICE TECHNICIANS  MUST DISCHARGE DC CAPACITORS BEFORE SERVICING EQUIPMENT.

WARNING:
DO NOT LEAVE THE SYSTEM SHUT DOWN FOR A PROLONGED LENGTH OF TIME.
LEAD-BASED BATTERIES WILL EXPERIENCE PERMANENT DAMAGE FROM LACK OF CHARGING.
Remove all Battery Fuses from all Battery Cabinets.
System On-Line From Bypass Mode

1. Verify that the Installation Switch is in the (OFF) position.
2. Install all Battery Fuses in all Battery Cabinets.
3. Press and hold the DC Pre-charge switch located behind the right-hand door for approximately five seconds and then turn the Main Battery Circuit Breaker to the (ON) position.  If the circuit breaker trips, the batteries are not connected properly. Call service immediately.
4. Turn the Input Circuit Breaker (CB1) to the (ON) position.
5. Turn the Installation Switch behind the left-hand door on the right-hand wall to the (ON) position. The Front Panel Display will now be illuminated and a slight hum should be heard from the inverter transformer. The unit is now charging the batteries.
6. Turn the Maintenance Bypass Switch from bypass mode (BYPASS) to normal mode (UPS).
   The emergency equipment is now protected by the inverter system.

CHAPTER 4 OPERATION

The following is a description of the status LEDs located on the front panel.

AC Present
When the AC Mains is present, the LED will illuminate. If a power failure was long in duration, or the AC mains was disconnected by some other means (Circuit breaker open)  the AC Present LED would not be illuminated. When the control circuit senses that the line has dropped below an acceptable level (Black Out, Brown Out, or Transient), the inverter will energize for at least one minute. So, if the power failure was a momentary glitch, the AC present LED would be illuminated but the inverter would be running.

System Ready
When the system has adequate battery voltage to transfer, the System Ready LED will illuminate.
This feature prevents damage from multiple deep discharges of the battery.

Battery Charging
When the AC Mains is connected to the line and the battery is charging under normal conditions, the Battery Charging LED will illuminate.

Battery Power
When the inverter is producing output power (battery is being discharged), the Battery Power LED will be illuminated.

Fault
This is a summary Fault indication. When there is a fault condition present, the Fault LED will illuminate. To view which fault is present, use the keypad and LCD display feature.
The front panel display will provide the user with a variety of information. It has a full complement of Meter functions, Control functions, and Program functions.

CHAPTER 5 FRONT PANEL DISPLAY

The front panel consists of a 2 x 20 alphanumeric LCD display with LED Backlighting, 5 Status LED indicators and a 4 x 4 keypad for the user interface.

Figure 5.1 Front Panel Display

Control Panel Keypads

Table 5.1 Keypad Functions

values. To enter passwords, press [PROGRAM], enter the password, and press [ENTER].  NOTE: A password must be entered to change parameters.
Enter (Grey)| This key records or enters a task you perform using the control panel keys.
[ ◄ ]| This key functions as Left scroll key
[ ► ]| This key functions as Right scroll key
[ 0 ]| This key works as a number key; it is also used to display active alarms when in CONTROL Mode.
[ 1 ] through [ 9 ]| These keys work as number keys.

Meter Functions

Meter functions are available by pressing the METER keypad to get to the Meter
Menu and then press the desired function keypad. (See figure 5.1)

Table 5.2 Meter Functions

Normally Off loads is connected, it will read the sum of Normally On and Normally Off outputs.| I OUT
Battery Voltage| Measures Battery Voltage| V BATT
Battery Current| Measures the Battery Current. When in charge mode, the current will be positive. When in  Inverter mode, the current will be negative.| I BATT
VA Output| Multiplication of the output voltage and output current| VA OUT
Inverter Watts| Multiplication of the battery voltage and the battery current| INV. WATTS
Inverter Minutes| Total minutes the system has run on inverter| INV. MIN
Temperature| Measures the ambient temperature of the electronics enclosure.| TEMP
System Days| Total days the system has been in service.| SYS. DAYS

Control Functions

Control functions are available by pressing “CONTROL” to get to the Control Menu and then pressing the desired function.

Table 5.3 Control Functions

• TEST LOG – View the Test Log of the last 75 monthly or Yearly Tests. View the Date, Time, Duration, Output Voltage, Output Current, Temperature and Fault Status.
  Use the left and right scroll keys to change the event number.
  Use the ENTER key to select desired event number.
  Use the left and right scroll keys to view event information about the event.
  Use the TEST LOG key to return to the event number.

• EVENT LOG – Identical to the TEST LOG except this log records the past 75 events.

• TEST – Pressing the TEST key will initiate a 1-minute test. This test will be recorded in the Event log since it is not part of the scheduled monthly or yearly test.

• ALARM – View the Alarm log of the last 50 alarms. View the Date, Time, and Alarm.
  Use the left and right scroll keys to change the alarm number.
  Use the enter key to select the alarming number.
  Use the left and right scroll keys to view information about the alarm.
  Use the ALARM key to return to the event number.

• BUZZER – Pressing this key silences the audible buzzer from a fault condition or an intermittent beep when the inverter is under battery power. If a fault caused the buzzer to alarm and the alarm is silenced, the buzzer will return after 24 hours or after the fault is cleared.

Program Functions

User Program Functions
All program functions are password protected. The password for the user level is 1234. When the PROGRAM keypad is pressed, the display will prompt the user for the password.  After the password is entered (1234 + ENTER key), the user can change the Date, Time, Month Test Date, Month Test Time, Yearly Test Date and Yearly Test Time, Load  Reduction Fault, Low VAC Alarm, High VAC Alarm, Ambient Temp Alarm and Near Low Battery settings.
Time is always in the 24-hour standard. Example 4:00 PM is 16:00.

Table 5.4 Program Functions

• Near Low Battery Voltage is in VVVV (Volts). The last digit entered is after the decimal place.
  I.E. (430 + ENTER) will register 43.0VDC. Please refer to table 5.5.

• Load Reduction Fault is in AAAA (Amps). The last digit entered is after the decimal place.
  I.E. (480 + ENTER) will register 48.0 Amps. If the output current under battery power is 10 percent below this number, the alarm will be set.

• Low AC Voltage Alarm is in VVVV (Volts). The last digit entered is after the decimal place.
  I.E. (1200 + ENTER) will register 120.0 Volts. If the Input AC Voltage goes below this number the alarm will be set.

• A high AC Voltage Alarm is similar to Low AC Voltage Alarm.

• The ambient Temperature Alarm is in DDD (Degrees Centigrade). I.E. (75 + ENTER) will register 75 deg. C. When the ambient temperature internal to the inverter enclosure goes above the set point the alarm will be set.

Table 5.5 Near Low Battery Voltage

CHAPTER 6 SPECIFICATIONS

Input Voltage
Input Frequency
Synchronizing Slew Rate
Protection
Voltage Harmonic Distortion
Power Factor| 120/208 or 277/480 or 347/600Vac 3-phase 4-wire +10% -15% 60Hz, +1- 3%, 50Hz available on request
1Hz per second nominal
Input Circuit Breaker
< 10% (For Resistive Load)
0.5 lag/lead
---|---
Output Voltage
Static Voltage
Dynamic Voltage
Harmonic Distortion
Output Frequency
Load Power Factor
Inverter Overload
Protection| 120/208 or 277/480 or 347/600 Vac 3-phase 4-wire
Load current change +/-4%, battery discharge +1-4%
+/-3% for +1-25% load step change, +/-6% for a 50% load step change, recovery within 3 cycles < 3% THD for linear load
60Hz +I-0.05Hz during emergency mode
0.5 lag to 0.5 lead
115% continuous rating; 150% for 2.5 seconds; 250% for 3 line cycles
Optional Output Circuit Breaker
Battery Type
Charger Protection Disconnect| Valve-regulated sealed lead-calcium. Contact factory for additional battery types. Microcontroller two stage charger (recharge — 24HR)
Automatic low-battery disconnect; automatic restart upon utility return. Fuse- and-FuselCircuit breaker above 24KVA
Environmental Altitude
Operating Temperature
Storage Temperature Relative Humidity| < 3000m (10,000 feet) above sea level without derating Inverter: 0° to 40°C (32° to 104°F)
Battery: 20° to 30° C (68° to 86°F) per UL924
-20° to 70°C (electronics only)
< 95% (non-condensing)
General Design
Generator Input Control Panel
Metering Alarms
Communications
Manual Maintenance Bypass
Alarm Contacts
Factory Start-up| Stand-by UPS. PWM Inverter type utilizing IGBT technology with 2ms transfer time.
Compatible with generators (10x unit size or larger)
Microcontroller 2 x 20 character display with touch pad controls & functions
5 LED indicators & alarm with status indicator
Input & Output Voltage, Battery Voltage, Battery & Output Current, Output VA, Temperature, Inverter Wattage
High/Low Battery Charger Fault, New Low Battery, Low Battery, Load Reduction Fault, Output Overload, High/Low AC Input Volts, High Ambient Temperature, Inverter Fault, Output Fault, Optional Circuit Breaker Trip
RS-232 port (DB9)
Standard
Optional Summary Form “C” Contacts
Optional factory start-up available
Physical Cabinet
Cooling
Cable Entry
Access| Freestanding NEMA Type 1
Forced Air, during emergency mode Top or Side
Front

CHAPTER 7 MAINTENANCE AND SERVICE

The Self-testing feature of the inverter ensures that the system is tested at least once per month for 5 minutes and once per year for 30, 60, or 120 minutes. If there are any problems with the self-tests, the fault log shall indicate which faults occurred. Please see the fault descriptions and troubleshooting guide.
A few simple maintenance operations performed periodically will help ensure many years of trouble-free operation. Battery terminals should be checked for tightness and corrosion. If severe corrosion is evident, maintenance is required to correct this situation.
Since the unit depends on unrestricted airflow for cooling of power handling components, it is important to keep the air vents free of any obstruction. If the environment tends to be extremely dusty, occasionally blow away any accumulation of dust on components. Please follow the shutdown procedure before cleaning.
CAUTION: Follow the shutdown procedure (See Chapter 3) before cleaning. An authorized technician only should perform Service!

Table 7.1 Preventive Maintenance Schedule

1. TEST UNIT:
NOTE: Perform manual test only when the critical load is connected but not required.
Output voltage should be present.
Confirm operations of front panel indicators.| X| |
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2. INSPECT BATTERIES:
All connections are tight.
Connections have no corrosion. (Clean if necessary).| | |
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CLEAN UNIT: NOTE: The unit must be shut down during this service.
Inspect air vents and clean if necessary.
Clean excessive dust from the inside cabinet(s).
Clean excessive dust from the fan(s).| | | X
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“X” Indicates when to perform service. Lines below the “X” are for the date of service.

TROUBLESHOOTING CHART

References

• Emergency Lighting Equipment | IOTA

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