DOC1682

ROTORK UPS MANUAL ORDER P11407 ROTORK 5KWMEGA-PAK UPS SYSTEM MANUAL

IMPORTANT NOTE: PLEASE READ THIS MANUAL THOROUGHLY TO UNDERSTAND THE OPERATION AND ASSEMBLY PROCEDURES FOR THIS SYSTEM. ALSO ATTACHED ARE THE FACTORY MANUALS FOR MAIN INDIVIDUAL COMPONENTS.

1. INTRODUCTION The ROTORK 5KW MEGA-PAK UPS SYSTEM is designed to provide a maximum 5KW @120VAC in Colombia, using a 5KW MODULAR INVERTER for uninterrupted AC output and also a 25A-24V SENS charger to charge (2) 8G8D batteries wired for 24 volt operation.

2. BATTERY WIRING The (2) 225Ahr batteries are wired in series to provide 24 volt output. The RED wire is POSITIVE and the BLACK wire is NEGATIVE. Refer to the attached drawing.

3. 7KW Inverter
The 5KW inverter provides 120VAC. The program settings on the inverter have seen set by ROTORK, There are terminals on the backplane in enclosure for 120VAC load connections, and also 24VDC load connection .

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4. BATTERY INSTALLATION OR REPLACEMENT This AC-UPS system is furnished with (4) 8G8D amp Hour deep cycle gel type batteries, wired to provide 265Ahr @24VDC. They NEVER require water, and removing the caps will void warranty. When installing new or replacement batteries, slide the new batteries on to the shelves with the terminals to the outside side of the cabinet, as shown in the photos and attached battery schematic drawing. Note battery position and polarity of the battery terminals. Whenever handling batteries, remove all rings and jewelry, and treat them with the utmost respect, batteries can hurt you in a lot of ways! They can shock you if you touch the terminals, burn you if your tools or jewelry bridge the terminals, chemically burn you if they are opened or damaged, and they will definitely break your bones if you drop them, SO BE CAREFUL!!

5. MAINTENANCE The batteries require no water or maintenance and a semiannual inspection. If any corrosion should occur at the battery terminal, schedule a down time period to clean them. If you remove the cables to clean the terminals, the system will not operate, so use caution and common sense. Remove any corrosion with a stainless steel wire brush, avoiding any skin contact with the corrosion, as it is caustic and poisonous. After cleaning the cable lugs and terminals, replace and tighten the bolts, wait 30 minutes, then retighten, Always use split ring lock washers on the battery terminals to retain terminal pressure even if the battery post yields.

6. MAJOR TASKS TO COMPLETE INSTALLATION The following are major steps to complete installation. (1) Mount enclosure to a suitable concrete base. (2) Make customer 24VDC connections as required. (3) Make 120VAC input and 120VAC output electrical connections in electronics compartment.

7. TESTING THE SYSTEM Once all of the input and output electrical connections have been made, you are ready to test the system.

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(1) Turn on the AC circuit breaker for the BATTERY CHARGER, located on the front panel of the unit. (2) Turn on the battery circuit breaker for the BATTERY CHARGER, located on the front panel of the unit. (3) Turn on the 5KW INVERTER power switch on, located on the front panel of the inverter. (4) If desired, turn on the 10A circuit breaker for the desired 24VDC output.

8. TROUBLE-SHOOTING THE SYSTEM The following list of items should be checked if there is a problem with the system, such as failing to work, or the batteries not holding a charge. (1) (2) (3) (4) (5) (6) Is there 120VAC power to the unit? Are the battery charger circuit breakers on and in good working condition? Is the inverter power switch on and green lights showing? Are customer load connections made? Is the Load circuit breaker on and in good working condition? Are all wire terminations on the din rail terminals tight and fully connected?

For trouble shooting convenience the circuit breakers have screw contacts in them for a digital meter probe. You can trouble shoot 90% of the system at the backplane To check breaker: first put your meter in either diode check or ohm check position, place probe on terminal screw above and below the circuit breaker and check for continuity. It should show almost no resistance in the OHM mode and beep in the diode mode. (Only one check is necessary, not both). To check voltage, put the + probe at the breaker, - probe on the negative terminals. To check current, turn off the circuit breaker to be checked, set meter to current and use the meter to jump across the open breaker. This shunts the solar array current through your meter and you should be able to read current directly on your meter. You can check the battery voltage and load current the same way, but DO NOT check the battery current through your meter. If you short the batteries, you will blow your meter fuse, and possibly damage your meter or melt the test leads. 9. WARRANTY SUMMARY Rotork warrants this system to be free from defects in materials and workmanship for a period of 5 years from date of purchase. Batteries carry a pro-rated 3-year warranty. This warranty does not cover abuse, neglect, improper installation, acts of God or vandalism. Please contact Rotork for any warranty issues.

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10. PICTURES ROTORK 5KW MEGA-PAK UPS SYSTEM

July 2009 Shown is a TYPICAL powder coated aluminum Mega-box enclosure. The unit has aluminum mounting brackets which attach to the concrete pad.

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Shown is the assembled backplane electronics rack, with the inverter. The inverters range for 3kW to 7kW in size. (Shown is the 7kw unit)

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Shown is the 25A-24V battery charger. Note: the charger AC input circuit breaker and 24VDC output circuit breaker are located on the front panel.

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Shown is the AC power input terminals and AC surge arrestor, the alarm contacts, and the circuit breaker and terminals for the 24VDC optional output power.

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Shown is the typical battery compartment that holds 8G8D size batteries. The battery are clamped in position and are wired, for this system (SO#27858), for 24V operation. Refer to attached drawing for wiring schematic.

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Shown are the TYPICAL terminals in all Rotork systems, for the battery low voltage alarm, located in the center of the din rail. FOR ALARM WIRING, THE FOLLOWING APPLIES: BLACK WIRE: FAIL RED WIRE: OK GREEN WIRE: COMMON There is a 10A circuit breaker and negative terminal for 24VDC power, on the right, if desired. Also shown is the inverter disconnect pull out fuse holder and push button switch to energize the inverter capacitors when batteries are installed.

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Origin: S. Cannan Date: 7/16/2009