Perfect power systems EXT Series User manual
Perfect Power System
Phone: (800)-786-6915
FAX no: (800)-246-2346
Technical Assistance: service@800pwrsrvc.com
Document No.: 725-MAN, Rev.B
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Due to continuous product improvement, this document is subject to change without prior notice
Emergency Lighting Inverter
EXT Series(Outdoor)
Single-Phase, 2.1KW ~ 17KW
Installation and Operation Manual
725-MAN Rev B Page 2 of 89
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manual may be reproduced, copied, translated or transmitted, in any orm or by any means, without
the prior written permission o the company.
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Systems. assumes no responsibility or its use, nor or any in ringement o rights o third parties which
may result rom its use. THIS DOCUMENT IS PROVIDED “AS IS” AND ANY EXPRESS OR IMPLIED
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Trademarks
All trademarks and registered trademarks are the property o their respective owners.
Harsh Environment Series Installation and Operation Manual
Document No.: 725-MAN, Rev.B
August 5, 2019
725-MAN Rev B Page 3 of 89
Table of Contents
Table of Contents............................................................................................................. 3
Introduction .................................................................................................................... 5
Scope and Audience................................................................................................................... 5
Sa ety and Warnings .................................................................................................................. 5
Warranty Registration and Warranty Certi icate Request ........................................................ 5
Service ........................................................................................................................................ 5
Chapter 1. Safety .................................................................................................... 6
Chapter 2. Overview ............................................................................................. 1
2.1 Product Description ........................................................................................................... 10
2.2 Product Features ................................................................................................................ 11
Chapter 3. Hardware Overview ............................................................................. 13
3.2 Key Components ................................................................................................................ 14
3.3 Functional Description (Typical) ........................................................................................ 17
3.4 Theory o Operation .......................................................................................................... 19
Chapter 4. Installation ........................................................................................... 21
4.1 Delivery Space Requirements ............................................................................................ 21
4.2 Site Considerations ............................................................................................................ 24
4.3 Delivery and Handling ........................................................................................................ 28
4.4 Storing the System ............................................................................................................. 37
Chapter 5. Operation ............................................................................................. 39
5.1 Starting the Unit or the First Time .................................................................................... 39
Chapter 6. Maintenance ........................................................................................ 42
6.1 Sa ety Precautions ............................................................................................................. 42
6.2 Preventative Maintenance ................................................................................................ 43
6.3 FRU Replacement............................................................................................................... 46
6.4 Calling or Service .............................................................................................................. 53
Chapter 7. Troubleshooting ................................................................................... 54
7.1 Reset Instructions .............................................................................................................. 55
7.2 Troubleshooting Guide and System Alarms ...................................................................... 55
7.3 Using the LCD Display Panel .............................................................................................. 57
Table of Contents
725-MAN Rev B Page 4 of 89
Chapter 8. Specifications ....................................................................................... 6
APPENDIX A - Battery Connections .............................................................................. 65
APPENDIX B - Options ................................................................................................. 73
B.2 Internal Manual Bypass Switch (Make Be ore Break) ....................................................... 74
B.3 Form “C” N/O Contacts or Alarms .................................................................................... 74
B.4 Dry Contact, N/O or N/C Contact with Isolated Common ................................................. 74
B.5 Battery Breaker alarm ....................................................................................................... 75
B.6 External Wrap-around Manual Bypass Switch (same Input and Output Voltage) ............ 75
B.7 Audio Alarms with Silence Switch ..................................................................................... 78
B.8 Remote Status Panel .......................................................................................................... 78
B.9 Transient Voltage Surge Suppressor (TVSS) ...................................................................... 79
B.10 O line Inverter Operation ............................................................................................... 79
B.11 Normally ON/OFF Output Aux. Circuit Breakers ............................................................. 79
B.12 Main Input CB Standard/Higher KAIC .............................................................................. 79
B.13 Main Output CB Standard/Higher KAIC ........................................................................... 79
B.14 Power Flow Mimic ........................................................................................................... 79
B.15 Global Monitoring Systems (GMS) .................................................................................. 80
B.15.1 Local Monitoring via PC with RS-232 ..................................................................... 83
B.15.2 Local Monitoring via PC with RS-485 ..................................................................... 83
B.15.3 RJ45 Ethernet connection ...................................................................................... 83
B.16 Simple Network Management Protocol .......................................................................... 84
B.17 Battery Thermal Runaway Control .................................................................................. 85
B.18 Heater Strip with Adjustable Thermostat ........................................................................ 86
B.19 Battery String Monitoring (Wireless) ............................................................................... 86
B.20 Battery (Individual) Monitoring (Wireless) ...................................................................... 86
Index .............................................................................................................................. 88
725-MAN Rev B Page 5 of 89
Introduction
This manual tells you how to install, start and operate your unit and lets you know how to get more
in ormation or special situations, and provide contact in ormation
Scope and Audience
This guide is intended to be used as a re erence or users responsible or installing, operating, and
maintaining this equipment.
Safety and Warnings
This guide uses the ollowing symbols to draw your attention to certain in ormation.
Symbol Meaning Description
Note Notes emphasize or supplement important points o the main text.
Tip Tips provide help ul in ormation, guidelines, or suggestions or per orming
tasks more e ectively.
Caution Cautions indicate that ailure to take a speci ied action could result in damage
to the hardware.
DANGER The Danger symbol warns users o possible injury or death i instructions are
not ollowed.
Electrostatic
Sensitive
This symbol warns users that the equipment is sensitive to electrostatic
discharge (ESD) and could be damaged i users do not take appropriate
precautions such as using a grounded wrist strap when touching or handling
the equipment.
Warranty Registration and Warranty Certificate Request
Visit our web site at: www.800pwrsrvc.com under download tab
Service
I you require assistance, ill out a Service Report Form at www.800pwrsrvc.com, email us at
service@800pwrsrvc.com, or call our 24-hour toll ree hot line (800-797-7782). Please have the
unit’s SERIAL NO. rom the Start-Up label located on the top le t corner o the ront door or speed
assistance.
725-MAN Rev B Page 6 of 89
Chapter 1. Safety
This chapter contains sa ety precautions to observe when operating or servicing electrical
equipment. The symbols shown are used extensively throughout this manual. Always heed these
precautions because they are essential to the sa e operation and servicing o this product.
Safety
725-MAN Rev B Page 7 of 89
DANGER: This Equipment is intended to be permanently connected. Only actory-trained
or authorized personnel should
attempt to install or repair the unit or its batteries system.
Improper installation has proven to be the single most signi icant cause o start-up
problems. High AC and DC electrical voltages are present throughout the unit(s) and
incorrect installation or servicing could result in electrocution, ire, explosion, or
equipment ailure.
DANGER: Read this manual in its entirety be ore per orming the installation, start-up,
operation, or maintenance o the UPS unit or battery systems. Failure to do so could
result in electrocution, ire, explosion, or equipment ailure.
DANGER: All power connections must be completed by a licensed electrician who is
experienced in wiring this type o equipment. Wiring must be installed in accordance with
all applicable national and local electrical codes. Improper wiring may cause damage to
the equipment, injury or death o personnel. Veri y that all high and low voltage input
power circuits are de-energized and locked out be ore installing cables or making any
electrical connections.
DANGER: Exercise extreme care when handling unit and battery cabinets to avoid
equipment damage or injury to personnel. Cabinets weigh several hundred pounds.
DANGER: Test li t and balance the cabinets be ore moving. Maintain minimum tilt rom
vertical at all times. The bottom structure will support the unit only i the orkli t orks are
completely underneath the unit.
DANGER: Observe all battery sa ety precautions during installation or service o the unit
or batteries. Even with the battery circuit breaker in the o position, the danger o
electrocution may still be present. The battery power to the unit must be locked and
tagged “o ” be ore per orming any service or work on the unit. The battery
manu acturer’s sa ety in ormation and material sa ety data sheet are located in a pocket
attached to the inside o le t door o each unit. Failure to ollow those instructions and
the instruction listed above and elsewhere in this manual could result in an explosion,
ire, equipment ailure, or electrocution.
Safety
725-MAN Rev B Page 8 of 89
DANGER: All power to the unit must be locked and tagged "o " be ore per orming any
service or work on the unit. ailure to do so could result in electrocution.
DANGER: In case o ire involving electrical equipment, only carbon dioxide ire
extinguishers, or those approved or use on electrical equipment, should be used. Use o
water on ires involving live high voltage electrical circuits could present an electrocution
hazard.
DANGER: Extreme caution is required when per orming maintenance. Lethal voltages
exist within the equipment during operation. Observe all warnings and cautions in this
manual. Failure to comply may result in serious injury or death. Obtain quali ied service
or this equipment as instructed.
DANGER: Be constantly aware that the unit system contains high DC as well as AC
voltages. With input power o and the battery disconnected, high voltage at the ilter
capacitors and power circuits should discharge within 30 seconds. However, power circuit
ailures can occur, so you should always assume that high voltage might still exist a ter
shutdown. Veri y that power is o using AC and DC voltmeters be ore making contact.
DANGER: Some components within the cabinets are not connected t
o chassis ground. Any
contact between loating circuits and the chassis is a lethal shock hazard.
DANGER: Internal battery strapping must be veri ied by the customer prior to moving this
unit. This unit contains non-spillable batteries. Keep the unit upright. Do not stack. Do not
tip. Always ollow the battery manu acturer’s sa ety in ormation, located in a pocket
attached to the inside o the le t door o your unit, to prevent an accident that could result in
injury or death.
Safety
725-MAN Rev B Page 9 of 89
DANGER: Lead-acid batteries contain hazardous materials. Batteries must be handled,
transported, and recycled or discarded in accordance with ederal, state, and local
regulations. Because lead is a toxic substance, lead-acid batteries should be recycled rather
than discarded.
Do not dispose o batteries in a ire, the batteries may explode.
Do not open or mutilate the batteries. Released electrolytes are harm ul to the skin and eyes
and may be toxic.
A battery can have a high short circuit current and present a risk o electrical shock. The
ollowing precautions should be observed when working on batteries:
1. Remove watches, rings, or other metal objects.
2. Use tools with insulated handles.
3. Wear rubber gloves and boots.
4. Do not lay tools or metal parts on top of batteries.
5. Disconnect charging source prior to connecting or disconnecting battery
terminals.
6. Determine whether battery is inadvertently grounded. if so, remove the
source of the ground. Contact with any part of a grounded battery can
result in electrical shock. The likelihood of such shock will be reduced if
such grounds are removed during installation and maintenance.
7. Lead-acid batteries can present a risk of fire because they generate
hydrogen gas. The following procedures should be followed:
8. Do not smoke when near batteries.
9. Do not cause flame or spark in battery area.
10.
Discharge static electricity from your body before touching batteries by first
touching a grounded surface.
725-MAN Rev B Page 10 of 89
Chapter 2. Overview
This chapter provides an overview o the Single-Phase Lighting Inverter Standard Series.
2.1 Product Description
The Harsh Environment Single-Phase Lighting Inverter is manu actured to provide critical power or
lighting during a power outage. The Lighting Inverter meets or exceeds the li e sa ety codes o UL924
and UL1778. These codes were established to allow emergency lighting inverters to provide critical
power to the lighting circuits during a power ailure.
I input power to the inverter is lost during a power outage, the system draws clean sine wave
power automatically rom its internal battery supply without any interruption. Power is provided or
90 minutes, su icient time or sa e and orderly evacuation rom the acility.
An optional output trans ormer allows multiple output voltages as well as input voltages that are
di erent rom output voltages. They are available in 3kva to 17kw with input or output voltages o
120, 208, 240, 277 or 480 VAC, single phase. This in ormation is shown on the nameplate located on
the inside ront door o the unit and should be recorded on page 5 o this manual.
The internal valve regulated lead-acid (VRLA), maintenance- ree batteries provide 90 minutes o
backup power. When input power is restored, the Lighting Inverter resumes normal operation
automatically and begins recharging the batteries immediately.
An internal bypass circuit maintains power to the load in case an internal unit ailure occurs.
Comprehensive monitoring capabilities include a Liquid Crystal Display (LCD) panel and ive dry relay
contacts or remote monitoring.
Table 2-1 lists the cabinet dimension, and Figure 2-1 shows them.
Table 2-1. Harsh Environment Series Cabinet Dimensions
kVA/KW Cabinet Size (Including Battery)
(W x H x D in Inche )
Cabinet Type
3KVA ~ 5KW 39” x 73.5” x 20” See Figure 4-1
6.5kVA ~17 KW 51” x 77.5” x 33.5” See Figure 4-2
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