ABB PCS100 UPS-I User Manual
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ABB PCS100 UPS-I User Manual

Industrial uninterruptable power supply
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2UCD120000E001 I
PCS100 UPS-I
Industrial Uninterruptable Power Supply
User Manual
© Copyright 2022 ABB, All rights reserved.

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Summary of Contents for ABB PCS100 UPS-I

  • Page 1 — 2UCD120000E001 I PCS100 UPS-I Industrial Uninterruptable Power Supply User Manual © Copyright 2022 ABB, All rights reserved.

  • Page 2: About This Document

    When such events occur in critical control operations, they can cause the complete shutdown of a facility. T he PCS100 UPS-I is an industrial strength uninterruptible power supply designed to solve these problems. It is a robust single conversion UPS for industrial or commercial loads. It is used to protect sensitive loads from sags, surges and outages using Ultracapacitor or battery energy storage.

  • Page 3: Document Information

    ABB Ltd. The hardware and software described in this manual are provided under a license and may be used, copied, or disclosed only in accordance with the terms of such license.

  • Page 4: Hardware Revision

    PCS100 UPS-I User Manual Hardware Revision This User Manual applies to PCS100 UPS-I systems with: Ultracapacitor Energy Storage Enclosures Mk2 – Utility Disconnect Enclosure Mk2 – Software Revision This manual applies to PCS100 AVC-40 systems with software revision R2JX.

  • Page 5: Safety

    PCS100 UPS-I User Manual — SAFETY Safety Instructions Attenzione: Tensione pericolosa! Fare riferimento alle istruzioni per l’uso. Prima di intervenire su questo dispositivo, scollegare e isolare tutte le fonti di alimentazione. Attenzione! L’installazione deve essere eseguita esclusivamente da un installatore qualificato.
  • Page 6 PCS100 UPS-I User Manual Advertencia: ¡Tensión peligrosa! Внимание: Опасное электрическое напряжение! Consulte las instrucciones de funcionamiento. Обратитесь к инструкциям по эксплуатации. Antes de trabajar con este dispositivo, desconecte y bloquee la corriente. Отключите питание и обесточьте устройство перед началом работ.

  • Page 7: Safety Notices

    CAUTION – Trained Operators All operations on the PCS100 UPS-I must only be carried out by a trained Operator familiar with the contents of this manual. Hazardous conditions could arise from incorrect adjustment.
  • Page 8 PCS100 UPS-I User Manual DANGER – Protective Covers Normal operation of this product requires any protective covers to be in place and doors secured closed. DANGER – Personal Protection Equipment Ensure safety glasses are worn while working if any part of the unit could be energized.

  • Page 9: Table Of Contents

    Safety Notices ........................................... 7 Overview ..................................13 1.1. User Benefits ........................................13 1.2. Features ..........................................13 1.3. PCS100 UPS-I Advantages Compared to Alternative Solutions......................13 1.4. Applications and Industries ..................................14 1.5. PCS100 Power Protection Portfolio ................................14 Functional Description ............................. 15 How it works........................................15...
  • Page 10 Menu Page ..........................................61 7.1.7 Summary Page ........................................... 61 Utility Disconnect Status LEDs................................. 62 PCS100 Inverter Display Boards ................................64 Operating PCS100 UPS-I ............................66 Starting and Stopping PCS100 UPS-I ..............................66 8.1.1 GDM Control ..........................................66 8.1.2 Remote Control.......................................... 68 8.1.3 Start/Stop Configuration ......................................
  • Page 11 17.9 Supply transformer ....................................135 Service and technical support ..........................136 ABB Power Conditioning provide global service and support of installation and commissioning of PCS100 products ..... 136 18.1 Comprehensive Global Services Portfolio ............................136 18.2 Custom Tailored Service Contracts............................... 136 18.3 Life Cycle Management ....................................
  • Page 12 PCS100 UPS-I User Manual 19.2 Recycling Information ....................................138 19.3 Waste Electrical and Electronic Equipment Information (WEEE) ....................138 19.4 Glossary ........................................138 19.5 Open-Source Software ..................................... 139 19.6 Detailed Single-Line Diagram ................................. 140 19.7 Torque settings and Bolt order ................................141...

  • Page 13: Overview

    — 1 OVERVIEW The ABB PCS100 UPS-I is a high performance high efficiency UPS system that ensures protection from power quality events, enabling continuous power supply to modern industrial processes. To supply continuous power during utility events the PCS100 UPS-I uses a modular energy storage and inverter system.

  • Page 14: Applications And Industries

    – Plastic film manufacturing – 1.5. PCS100 Power Protection Portfolio The PCS100 UPS-I is part of the PCS100 Power Protection portfolio, as shown below. Each product is tailored to address specific power quality problems: PCS100 AVC PCS100 UPS-I PCS100 RPC...

  • Page 15: Functional Description

    When the utility voltage is normal, the load is supported directly by the utility. When a sag, surge or outage occurs, the PCS100 UPS-I immediately transfers the load onto its inverter. Power is provided by battery or Ultracapacitor energy storage.

  • Page 16: Operation

    Figure 2-2: PCS100 UPS-I Single line diagram 2.3 Operation The following diagrams show how the PCS100 UPS-I behaves when a utility disturbance occurs, and what happens when the Fail-Safe Bypass is operating. Note: The following diagrams show a Fail-Safe Bypass. In some PCS100 UPS-I models the Fail-Safe Bypass is integrated and for other models it is optional.

  • Page 17: Utility Disturbance Occurs

    When the voltage returns within user defined limits the PCS100 UPS-I synchronizes with the utility voltage then closes the Utility Disconnect. If required the PCS100 UPS-I can softly transfer the load from the inverter to the utility or generator using the generator walk-in function. Once the load is transferred, power to the load is again supplied by the utility.

  • Page 18: Voltage Operating Range

    2.3.5 Fail-Safe Bypass Operation In an expected or unexpected PCS100 UPS-I shutdown, load current will be transferred to the Fail-Safe Bypass (where fitted). This provides an additional level of security by placing a mechanical contact in parallel with the Utility Disconnect.

  • Page 19: Typical Applications

    Figure 2-8: PCS100 UPS-I installation protecting the complete factory Figure 2-9 shows typical PCS100 UPS-I installation where the PCS100 UPS-I is used to protect a specific load. The PCS100 UPS-I is installed within the LV distribution system, i.e. on the feeder supplying the specific load to be protected.

  • Page 20: Model Definition

    Termination Side The location of the power terminals when viewed from the front of the PCS100 UPS-I. For 900 A and lower current systems the termination is always on the Left (L). For > 900A systems the termination is always on the Right (R).

  • Page 21: Options

    Empty Battery Energy Storage Enclosure Table 3-1: PCS100 UPS-I available options 3.1 Rating label The information relating to a specific PCS100 UPS-I is shown on its rating label inside the master inverter enclosure door. Example rating label is shown below.

  • Page 22: Pcs100 Ups-I Model Range

    PCS100 UPS-I User Manual 3.2 PCS100 UPS-I Model Range The following Table 3-2 gives the models available. This model range does not include energy storage. For complete information with Ultracapacitor or Battery Energy Storage refer to document 2UCD120000E002 PCS100 UPS-I Technical Catalogue.
  • Page 23 380 V operation is achieved by setting a 400 V PCS100 UPS-I to 380 V. 415 V or 440 V operation is achieved by setting a 480 V PCS100 UPS-I to 415 V or 440 respectively. This configuration is done at the factory and must be specified when ordering.
  • Page 24 120% of rated current for 60 s every 10 minutes 150% of rated current for 30 s every 10 minutes 200% of rated current for 10 s every 10 minutes 300% of rated current for 5 s every 10 minutes Table 3-3: PCS100 UPS-I model range table definition explanations...

  • Page 25: Technical Specification

    PCS100 UPS-I User Manual — 4 TECHNICAL SPECIFICATION NOTE: These specifications apply to the standard PCS100 UPS-I range and may be superseded by special variations stated on the PCS100 UPS-I rating label or User Manual Addendum. 4.1 Utility – Input Rated Supply Voltage 220 V (208 –...

  • Page 26: Load - Output

    110% for 30 s Inverter <10% of rated kVA Load Imbalance See 9.7 for more detail. Contact ABB where load imbalance is greater than 10% of rated kVA <5% of rated current Neutral Current See 9.7 for more detail. Contact ABB where neutral current is greater than 5% of rated current 4.3 Inverter Supply...

  • Page 27: Fail-Safe Bypass

    20 ms Closing Time 2200 & 4200 A 80 ms Cooling Convection 4.5 Coupling Transformer Capacity Rating 110% of PCS100 UPS-I kVA rating for 30 s Note: Optimized for short-term performance. Type UL Insulation Class N (200 °C) Design Temperature Temperature rises 60 °C for short-term full load...

  • Page 28: Energy Storage - Batteries

    Overload Capacity 100% Rated Power 240 kW per string Autonomy Period 30 s @ 240 kW For more information refer to ABB Document 2UCD120000E018 Operating Temperature 15 °C to 25 °C (recommended) Design Life 10 years at 25 °C Cycle Life >...

  • Page 29: Enclosure

    PCS100 UPS-I User Manual 4.10 Enclosure Enclosure rating IP20 / NEMA 1 Material Electro-galvanized steel Panel Thickness Side and 1.5 mm Rear Panel Thickness Door 2 mm Finish Standard epoxy-polyester powder coating textured finish Color RAL7035 Enclosure Access Hinged doors with key lock 4.11 User Interface...

  • Page 30: Subassemblies

    Energy Storage (Ultracapacitor or battery) that supplies power to the load during a utility – disturbance Together, these sub-assemblies are referred to as the PCS100 UPS-I system. Small PCS100 UPS-I models have multiple sub-assemblies in one enclosure. Large PCS100 UPS-I models may have one sub-assembly housed in multiple enclosures.

  • Page 31: Utility Disconnect

    • 2200 A • 4200 A The type of Utility Disconnect used on a particular model varies depending on the PCS100 UPS-I current rating. See Table 3-2: PCS100 UPS-I model range. PCS100 UPS-I Utility Disconnect Rating (A) Rated Power (kVA)

  • Page 32: 2200 A And 4200 A Utility Disconnect

    2200 A and 4200 A Utility Disconnect The 2200 A and 4200 A Utility Disconnect are separate enclosures that also include the main input and output terminals for connecting the PCS100 UPS-I to the utility and the load. DANGER – Hazardous Voltages An Operator must not open doors or panels marked as containing hazardous voltages.

  • Page 33: Coupling Transformer Enclosure

    Isolation of the inverter common mode voltages from the utility. – CAUTION The star point of the coupling transformer must be connected to the supply neutral. The star point is the neutral reference while the PCS100 UPS-I inverter is discharging.

  • Page 34: Float Charger

    The Float Charger also allows Ultracapacitor based systems to start from a completely discharged state. Note: For the smallest PCS100 UPS-I systems without a separate Coupling Transformer Enclosure (frame size 1xB) the Float Charger is installed in the Termination Enclosure.

  • Page 35: Pcs100 Inverter

    Each inverter module has a unique identification number (1 - 32) which is displayed on the front of the module. The inverter cooling fans are switched off most of the time. They switch on when the PCS100 UPS-I is discharging and remain switched on for about 30 seconds afterwards.

  • Page 36: Auxiliary Master Module

    ABB recommend installation of a maintenance bypass for this purpose. 5.1.11 Intergrated Fail-Safe Bypass The PCS100 UPS-I with 900 A Utility Disconnect have an integrated Fail-Safe Bypass inside the Utility Disconnect module in the form of normally closed contactors. 5.1.12...
  • Page 37 The energy required to open or close the switch-disconnector is supplied via an internal spring which is charged by an integrated motor. The PCS100 UPS-I will not attempt to open the FSB unless the ACB closing spring is charged. This ensures that the FSB can re-close immediately whenever required.

  • Page 38: Energy Storage

    The amount of energy storage required depends on the load kW rating, and autonomy period (seconds). The autonomy period is the period of time the PCS100 UPS-I can supply rated load from its energy storage. The required number of enclosures increases with the PCS100 UPS-I rating and autonomy period. Each energy storage enclosure includes its own DC circuit protection.
  • Page 39 PCS100 UPS-I User Manual DANGER – Stored Charge Stored charge is present after the device is switched off. When the PCS100 UPS-I is powered down lethal voltages (+/- 375 Vdc) will remain in the energy storage element and the complete PCS100 UPS-I should be considered live.

  • Page 40: Utracapacitor Monitor Board

    Non- faulty string operation is not influenced. In any event a warning is issued on the PCS100 UPS-I GDM and service personnel can determine the cause of the warning from inspection of the Monitoring Board.

  • Page 41: Status Lamps

    PCS100 UPS-I User Manual Internal Mimic Panel and Status LEDs: The Mimic Panel represents the capacitors fault outs. It identifies the capacitor/(s) causing the warning or fault and indicates the fault type with the number of red flashes. Additional Status LEDs indicate any other warning or fault (EPO, enclosure overtemperature, supply status, etc.)

  • Page 42: Mimic Panel

    PCS100 UPS-I User Manual Ultracapacitor Monitor Board is 1) Check fan supply voltage. If not 24V replace fuse not powered and/or Ultracapacitor Monitor Board Table 6-2: Status Lamps states description 6.1.2.2 Mimic Panel Ultracapacitor module’s overvoltage overtemperature inputs connected UPPER BANK...

  • Page 43: Status Leds

    PCS100 UPS-I DC bus voltage breaker UB string DC voltage not within +/-30 Wait for string to charge V from PCS100 UPS-I DC bus voltage LB MAIN LB string DC circuit breaker is in Resolve tripping condition tripped state...

  • Page 44: Ultracapacitor Energy Storage Autonomy Time

    Ultracapacitor Energy Storage consists of one or more 300 kW Ultracapacitor strings. Multiple strings are connected in parallel for increased kW or autonomy (ride through) time. Based on the system rating PCS100 UPS-I systems offer autonomy according to Table 6-6. PCS100 UPS-I...
  • Page 45 2400 2400 EC08 Table 6-6: PCS100 UPS-I Ultracapacitor Energy Storage specifications The Storage Load vs. Autonomy Period graph below shows dependency of autonomy period versus loading of Ultracapacitor Energy Storage on ambient temperatures on 25 ºC and below. Figure 6-5: Storage Load vs. Autonomy Period Graph Care should be taken to ensure the Ultracapacitor Energy Storage enclosure temperature does not exceed 25 ºC.

  • Page 46: Calculation Of Autonomy Time

    PCS100 UPS-I User Manual Recommended temperature operating zone Operating Temperature (ºC) Figure 6-6: Design Life vs. Operating Temperature graph 6.1.4 Calculation of Autonomy Time The autonomy period for a load level other than those given in the tables can be calculated using the following information and graphs.
  • Page 47 PCS100 UPS-I User Manual PCS100 UPS-I model selection Based on application load requirements and PCS100 UPS-I Ultracapacitor model tables, the closest larger kVA rating PCS100 UPS-I model can be selected. Frame Size Type Code 5.9 99.0 25 / 10 1xB 1xC...

  • Page 48: Battery Energy Storage

    0.8 PF. A single Battery Energy Storage enclosure contains 1 battery string. DANGER – Stored Charge Stored charge is present after the device is switched off. When the PCS100 UPS-I is powered down lethal voltages (+/- 375 Vdc) will remain in the energy storage element and the complete PCS100 UPS-I should be considered live.

  • Page 49: Models Without Batteries

    The PCS100 UPS-I can be supplied from the factory without batteries. Empty battery enclosures can be ordered to fit ABB specified batteries. Third-party sourced batteries may be used, however, battery systems must meet ABB’s battery performance and protection requirements. For information on these requirements, refer ABB document 2UCD120000E013.

  • Page 50: User Interface

    The primary user interface for configuration of the PCS100 UPS-I is via the Graphic Display Module (GDM) which is mounted in the door of the master inverter enclosure. It allows local control of the PCS100 UPS-I and shows the system status and provides access to the operating parameters and event history.
  • Page 51 PCS100 UPS-I User Manual Navigation & Control Panel Status Bar Page selected in Navigation Panel Figure 7-1: PCS100 UPS-I GDM showing the Status page...

  • Page 52: Navigation Panel

    Press the navigation buttons on the Navigation & Control panel to provide access to the following 5 pages. Navigation Buttons Status page Event log page Product page Press the navigation buttons to access the required page 4. Menu page Summary page Figure 7-2: PCS100 UPS-I GDM pages...

  • Page 53: Status Page

    This current is mainly capacitive and is generally useful for plants which have a lagging power factor. The status page of the PCS100 UPS-I in RUN status is shown on Figure 7-3. The status page of the PCS100 UPS-I in bypass mode is shown on Figure 7-4.

  • Page 54: Status Bar

    Figure 7-5: PCS100 UPS-I Status Bar example PCS100 UPS-I Status. Refer to Table 7-4 for a complete list of status messages. See also Figure 7-6 Fault or Warning description. The event code number can be found in the event log. Refer to section 11 for complete event descriptions.
  • Page 55 UPS-I has been running on energy storage for longer than parameter 520 Maximum Active Time. Discharge overload The PCS100 UPS-I has returned to the utility supply. The UPS-I is at current limit for an extended period or the heatsink is hot. Storage empty Load is operating from the utility supply.
  • Page 56 Inverter IDLE Storage is Utility Utility greater voltage is voltage is than 650 back within back within thresholds. thresholds. 2UCD004820E441 Figure 7-6: PCS100 UPS-I state flow diagram For Status message descriptions see Table 7-4. For Event descriptions see Table 11-2...

  • Page 57: Event Log Page

    PCS100 UPS-I User Manual 7.1.4 Event Log Page The PCS100 UPS-I incorporates an event log that stores a chronological list of events. This is useful for diagnosing PCS100 UPS-I operation and system power quality events. 5 event records per page Figure 7-7: GDM Event Log Page Accessing the event log page uploads the most recent event records with the most recent events at the top.
  • Page 58 A Warning condition has ended. Warning End events are only recorded for events where the “System” in the origin. (see Table 7-7). Warning Start A Warning condition has started. The PCS100 UPS-I can still function but it may have a reduced capacity. Table 7-6: System Event Types...

  • Page 59: Additional Event Information

    The Modules section displays which of the PCS100 modules in the PCS100 UPS-I are reporting the event. The Description field contains an extended description of the event.

  • Page 60: Product Page

    PCS100 UPS-I User Manual 7.1.5 Product Page The product page records information about the product and site. Date and Time Site Information Hour meters Product Information Network Settings Figure 7-9: GDM Product page The information displayed in Product Page: Item...

  • Page 61: Menu Page

    7.1.6 Menu Page The menu provides access to the PCS100 UPS-I and GDM parameters for viewing and/or adjustment. It is organized into menus and sub menus which contain the parameters. Each folder and parameter is indexed by three characters to the left of the name.

  • Page 62: Utility Disconnect Status Leds

    PCS100 UPS-I User Manual 7.2 Utility Disconnect Status LEDs Utility Disconnect Status LEDs show local status information about the Utility Disconnect. This information is generally not reproduced on the GDM. LED 1 SCRs Disable SCRs Disable LED 1 LED 2...
  • Page 63 LED 3 Open FSB Command exists from the master to open the FSB. This will occur when the PCS100 UPS-I is Online and there are no faults. LED 7 FSB Open The FSB is open (feedback from the ACB aux contacts)

  • Page 64: Pcs100 Inverter Display Boards

    PCS100 UPS-I User Manual 7.3 PCS100 Inverter Display Boards The PCS100 Inverter modules contain their own display boards which contain the RUN and OK LEDS, as well as 2 x 7 segment LED displays. The 7 segment displays show the individual module identification number (1 – 32), however if there is an error condition they will flash alternately every 500 ms the module identification number and an error code.
  • Page 65 PCS100 UPS-I User Manual OK LED Product Status or Description Not powered No Fault and microprocessor functioning FLASH (50% duty, 1sec period) FAULT, WARNING or module boot up stage. Table 7-13: OK LED displays RUN LED Product Status or Description...

  • Page 66: Operating Pcs100 Ups-I

    GDM Control The Start (I) / Stop (O) /Reset button in the Navigation & Control Panel allows GDM control of the PCS100 UPS-I. When the PCS100 UPS-I is stopped (Bypass) a green Start (I) button will show, and when running (RUN) a red Stop (O) button will show.
  • Page 67 Start Button Figure 8-2: Start button The Start button is visible when the PCS100 UPS-I status is Static Bypass (Off). Press the Start button and press “Yes” at the confirmation screen. The PCS100 UPS-I will transition to RUN operation in approx. 1sec.

  • Page 68: Remote Control

    The PCS100 UPS-I is configured for GDM control by default in the factory. The PCS100 UPS-I can also retain its previous run status following a power cycle. The default setting is that the run status will be retained, therefore the PCS100 UPS-I will return to the previous state after the next power up.

  • Page 69: Advanced Functional Descriptions

    9 ADVANCED FUNCTIONAL DESCRIPTIONS 9.1 Voltage Event Detection The PCS100 UPS-I is classified as a single conversion UPS of the type VFD according to IEC62040-3. That is, the voltage and frequency are protected but are dependent on the supply in normal operation.

  • Page 70: Rms Detection

    The thresholds for this detection are set by parameters 530 RMS Sag Threshold and 531 RMS Surge Threshold with the supply voltage set point parameter 121 Utility Voltage. When the RMS detection is triggered the PCS100 UPS-I will display “127 Discharge RMS” in the event log. 9.1.2...

  • Page 71: Frequency Detection

    PCS100 UPS-I set points. The PCS100 UPS-I is classified as VFD SX 211 for rated powers below 450 kVA and VFD SS 211 for rated powers above 450 kVA according to IEC 62040-3.

  • Page 72: Redundancy

    Energy Storage 9.3 Redundancy The PCS100 UPS-I inverter consists of multiple 150 kVA PCS100 inverter modules connected in parallel. If one inverter module fails the PCS100 UPS-I will reconfigure itself to operate with the remaining modules. A maximum of 50% of the modules can fail before the PCS100 UPS-I will trip out.

  • Page 73: Energy Storage Description

    PCS100 UPS-I system. The PCS100 Inverters send power from the utility supply to replenish the Energy Storage following any significant discharge operation. Once the PCS100 UPS-I is On Line the PCS100 Inverter fast charging will charge energy storage from 554 V to the maximum storage voltage.

  • Page 74: Generator Walk-In

    Figure 9-2: PCS100 UPS-I combined with stand-by generator The PCS100 UPS-I needs to support the need to transfer load back to a generator supply from the energy storage mode of operation. However, a step transfer of load to generator (or weak utility supply networks) will result in the voltage and/or frequency disturbance on the generator terminals exceeding the transfer threshold.

  • Page 75: Fan Control Service

    Figure 9-3: PCS100 UPS-I Generator Walk-in functionality timing diagram 9.6 Fan Control Service To extend the life of the PCS100 UPS-I Inverter module cooling fans they do not run continuously. The temperature of the inverter electronics is monitored and triggers a fan operation to circulate cooling air. All module temperatures are monitored and the worst case is used to trigger the fans.

  • Page 76: Neutral Current

    PCS100 UPS-I User Manual 9.7 Neutral Current The PCS100 UPS-I transformer has a partially rated neutral which should not exceed 5% of the UPS-I rated current. Neutral current may be caused by load imbalance or utility voltage imbalance. The PCS100 UPS-I will generate Event Code 12 when the neutral current exceeds 5% of the rated current. The...

  • Page 77: Parameters

    PCS100 UPS-I User Manual — 10 PARAMETERS 10.1 Parameter Setting (Menu Page) Parameter setting is performed by the GDM Menu pages, as shown Figure 10-1. Menu Page is organized into menus and sub menus which contain the parameters. Each parameter is indexed by three characters to the left of the name.

  • Page 78: Parameter Access Control

    PCS100 UPS-I User Manual 10.1.2 Parameter Access Control There are 2 menu levels on the PCS100 UPS-I. Menus are security protected by a password to stop unauthorized access. 10.1.2.1 Operator menu Parameters in the Operator menu are suitable for adjustment by the operator. It is made accessible by entering operator password to parameter 011 Password.

  • Page 79: Parameter Index

    PCS100 UPS-I User Manual 10.2 Parameter Index Menu number & name Parameter number & name Page 000 General Login Reset Power Quality Date and Time Set Parameter System Reboot Show Faults 100 Electrical Settings System Current Sag Recording Thres Module Voltage...

  • Page 80: Parameter Listing

    Some parameter visibility depends on the login level of the user. NOTICE – Trained Operators All operations on the PCS100 UPS-I must only be carried out by a trained Operator familiar with the contents of this manual. Hazardous conditions could arise from incorrect adjustment.
  • Page 81 PCS100 UPS-I User Manual Range: True / False Setting Up: Select “True” to clear the PQ events. The parameter will automatically return to “False” once the events have been cleared. Note: This parameter does not clear the events recorded in the Event Log.

  • Page 82: Menu 000 Electrical Settings

    Nameplate voltage rating of PCS100 UPS-I Setting: Setting up: Set to the supply voltage. Note This setting also adjusts the output voltage when the PCS100 UPS-I is operating from the backup energy storage. Parameter: 122 Utility Frequency Function: Set to frequency of Supply...
  • Page 83 Factory Setting: Note: At full load the PCS100 UPS-I inverter output voltage will be increased by this amount to compensate for the voltage drop across the coupling transformer resistance. The compensation voltage will reduce linearly to zero at zero load.

  • Page 84: Menu 200 Name Settings

    PCS100 UPS-I User Manual 10.3.3 Menu 200 Name Settings 200 Name Settings This menu contains the settings that are displayed on the Product Page. See section Error! Reference source not found. Parameter: 211 Company Function: Company name entry which is displayed on the Product Page (see section Error! Reference source not found.) and the downloaded event log.

  • Page 85: Menu 300 Product Revision

    PCS100 UPS-I User Manual 10.3.4 Menu 300 Product Revision 300 Product Revision This menu displays the various PCS100 UPS-I software numbers and revisions. Parameter: 311 System Product Function: Displays the product main software number Range: For PCS100 UPS-Is this is “7301”...

  • Page 86: Menu 400 Gdm Services

    Function: Displays the status of the Modbus TCP Service Range: Should display “Running” Note: After a software upgrade the PCS100 UPS-I needs to be rebooted twice to initialize the Modbus Parameter: 441 NTP Status Function: Displays the status of the NTP (Network Time Protocol) client service.

  • Page 87: Menu 500 Ups Settings

    Parameter used to meet UL safety requirements for UPS implementations that do not have an input contactor. For a PCS100 UPS-I without an ‘SCR off’ detection board this parameter must be set to 15 seconds or less if UL safety requirements are to be met.
  • Page 88 Setting: Note: If the input RMS voltage raises above the value of this parameter the PCS100 UPS-I will transfer to backup storage. Response time is about one half cycle i.e. 10 ms for a 50 Hz supply or 6.2 ms for 60 Hz Setting up: Set to the highest supply variation that the load can withstand.
  • Page 89 Local control refers to the GDM. A GDM operator can override an active Remote start signal by pressing the GDM stop button. This causes the PCS100 UPS-I to trip (fault code 106). The GDM reset button will cause the system to start if a Remote start signal is still present.

  • Page 90: Menu 600 Tests

    PCS100 UPS-I User Manual 10.3.7 Menu 600 Tests Menu 600 Tests Parameter: 611 Test Fan Function: Forces the PCS100 UPS-I inverter cooling fans to switch on for the set time period Range: 0.0 to 16383.5 Units: Minutes Factory Setting: Access:...
  • Page 91 PCS100 UPS-I User Manual Parameter: 622 Discharge Min DC Function: Sets the DC voltage that will end the 620 Discharge – UD closed test. Range: 0 to 1000 Units: Volts Factory 605 Volts Setting: Access: Factory Note: Because the inverter currents become distorted while using the discharge test at lower voltages, a limit is placed on how low the test should discharge the energy storage.

  • Page 92: Menu 700 Charger Settings

    Parameter: 711 Charging Current Function: Sets the current level during charging Range: 0 to 40% Units: % of the PCS100 UPS-I rated current Factory 10% for battery systems, 20% for Ultracapacitors Setting: Access: Factory Note: Because charging feeds power into the energy storage (Ultracapacitors or batteries) which have low impedance the inverters are current controlled and the accuracy of the current may be reduced.

  • Page 93: Menu 800 Status-Currents

    PCS100 UPS-I User Manual 10.3.9 Menu 800 Status-Currents 800 Status-Currents This menu contains current measurements. Will be updated when entering the menu. Parameter: 810 Utility L1 Function: Displays the Utility RMS current in Line 1 Units Amperes Note: Current detected by CTs fitted in the utility disconnect enclosure.

  • Page 94: Menu 900 Commissioning

    905 GDM Remote Menus Function: Enables remote access to the GDM menus via the GDM Ethernet connection Access: Tech Note: If enabled, allows an operator to remotely configure the PCS100 UPS-I. Parameter: 915 Relay Test Mode Function: Turns relays on and off Range:...

  • Page 95: Menu Gdm A00 Display

    PCS100 UPS-I User Manual 10.3.11 Menu GDM A00 Display GDM A00 Display The menu contains parameters to setup the graphic display module Parameter: A31 GDM Control Enable Function: Enables or disables the local Start, Stop, Reset control Range: True / False...

  • Page 96: Menu Gdm B00 Network Settings

    True / False Access: Operator. Setting Up: To view the actual settings currently used by the PCS100 UPS-I see the Product Page in section 7.1.5. See section 12.2 for further setting up instructions. Table 10-13: Menu GDM B00 Network Settings...

  • Page 97: Menu Gdm C00 Network Status

    PCS100 UPS-I User Manual 10.3.13 Menu GDM C00 Network Status GDM C00 Network Status This menu displays the network status for the GDM Parameter: GDM C200 Network Status Function: Displays a range of Network settings Range: C11 Actual DHCP Active (true or false)

  • Page 98: Event Codes And Descriptions

    11 EVENT CODES AND DESCRIPTIONS Events, warning and faults for the PCS100 UPS-I are indicated via the GDM and recorded in the event log. A Summary of all the events, warning and faults are shown in Table 11-2: PCS100 UPS-I Event Descriptions. If the recommended action does not remedy the warning or fault then contact ABB for assistance.
  • Page 99 Desat fault (event 02). pressing Reset. S, I System LVDC PSU Voltage (1) The PCS100 UPS-I has powered (1) Check LVDC (26 V) down. If intentionally powered power supply is 26.5-27 V down this warning is normal, and (2) Check fuse F1 on the no resolution is required.
  • Page 100 PCS100 UPS-I User Manual Event Code Origin GDM Description Event Description Recommended Action Type DC Bus Voltage Energy Storage voltage is low. If the charging function is operating (i.e., the DC voltage as indicated on the GDM is increasing) no action is required.
  • Page 101 The SCR short circuit detection (1) Check the SCRs have no Timeout hardware in the Utility Disconnect short circuit. (2) Ensure detected that an SCR did not that the PCS100 UPS-I is open. not mechanically bypassed. (3) Check connections to/from the SCR short circuit detector in the Utility Disconnect.
  • Page 102 System HW The load’s current exceeds the Ensure that the load is Overcurrent rating of PCS100 UPS-I. There suitable for the PCS100 may be short term transient over UPS-I. currents. Note: The limit is set by the hardware.
  • Page 103 Note: The temperature is not too high. calculated using a thermal model. Copper Hot The reactor winding is hot (near Ensure the PCS100 UPS-I is limit). not overloaded and configured too sensitively. Note: The temperature is Ensure that the module calculated using a thermal model.
  • Page 104 Module DSPE (Digital Signal Processor Engine). Inverter AC Voltage The PCS100 UPS-I input voltage is Check the Event Log for below the operation threshold. other faults or warnings reported from the same Note: This is normal when the module.
  • Page 105 PCS100 UPS-I User Manual been activated through mode. parameter: 915 Relay Test Mode Negative Phase Negative phase rotation detected Check the input phases are Rotation wired to the correct input Not Passed Tester This fault occurs when a module Replace the faulty module.
  • Page 106 RMS voltage being out of limits. Info Transfer Back The PCS100 UPS-I is Info only synchronizing with the utility before it connects. Info Online The PCS100 UPS-I is ready to take Info only over the load in the event of a...
  • Page 107 PCS100 UPS-I User Manual utility failure. Info Discharge T/O The maximum autonomy period Info only has been exceeded and the PCS100 UPS-I will transfer back to the Utility. Info Inverter Off Info End Of Discharge The Battery or Ultracapacitor Info only Energy Storage is discharged.
  • Page 108 Energy Storage Enclosures circuit breaker has been tripped. for short circuits to earth or other faults. Note: If the PCS100 UPS-I has additional healthy Energy Storage Enclosures it can still operate but at reduced capacity. The DC circuit breaker cannot be tripped by the PCS100 UPS-I software.
  • Page 109 PCS100 UPS-I User Manual have faults. modules. Unbalanced dcbus The DC bus voltage from mid-bus Check for ground fault on to ground is outside the DC bus / Energy Storage. threshold of 40V. There may be a ground fault on the DC.
  • Page 110 LED 7 on the SCR firing board will be off (not illuminated) . The FSB will close while this Warning is present even if the PCS100 UPS-I is ON LINE. This warning is masked for the first 6 seconds it is active to allow time for the FSB spring to charge.
  • Page 111 PCS100 UPS-I User Manual (2) disconnected the load from the utility. Info Emergency power Emergency power off switch Info only activated FSB On Timeout The Fail-Safe Bypass (FSB) has For a 2200 or 4200 A FSB not opened within the required...
  • Page 112 PCS100 UPS-I User Manual Code Origin Event GDM Description Event Description Recommended Action Type SCM Comms lost The Auxiliary Master Module has (1) Check the Event Log for failed to receive a response to a SCM errors. status request from the SCM.
  • Page 113 IGBT being switched. the fault is not resolved Desaturation is a failsafe fault, so contact your ABB Service this indicates a fault in the IGBT Agent to have relevant driving components. module replaced. Table 11-2: PCS100 UPS-I Event Descriptions...

  • Page 114: Remote Monitoring

    GDM is available on any networked PC connected to the PCS100 UPS-I. In addition, downloading event and service information is possible from the integrated web server. Modbus TCP. For connection to plant wide SCADA or monitoring systems the PCS100 UPS-I has a list –...

  • Page 115: Cybersecurity

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 116: Connecting The Network Connection

    Connecting a GDM directly to a computer using an Ethernet cable. Figure 12-4: GDM Ethernet connection You can connect one or more PCS100 UPS-I GDMs to a network using a Ethernet switch or hub and ethernet cables. Figure 12-5: Multiple GDM connections...

  • Page 117: Configuring The Network Connection

    Configuring the Network Connection. The Ethernet network is configured using parameters B11 to B15. See section 10.3.12. For a full description on how to configure the network connection see ABB document No. 2UCD20000E001 How to View the GDM Remote Web Pages.

  • Page 118: Service Page

    Information useful for the ABB service department such as parameter settings and the event log can be downloaded. The information is contained within a zip file which can be sent to the ABB factory to assist in analyzing problems with the product. To download this information: Click Service Information Download.

  • Page 119: Modbus Tcp

    12.3.4 Modbus TCP User Parameters The following table lists the user parameters available from the PCS100 UPS-I. The address listed is the offset (raw) address. For 4xxxx address add 40001 to the offset address. Each address refers to a 16 bit register.
  • Page 120 PCS100 UPS-I User Manual Address Name Access Type Raw Value & Scaling Product Status Read Only 16-bit, 0 – FAULT Enum 1 – STOP 2 – STARTING 3 – RUN 4 – STOPPING 5 - BYPASS Warning Indication Read Only 16-bit, 0 –...
  • Page 121 Address Name Access Type Raw Value & Scaling 1001- Cached registers 1- Read Only As for Same as for registers 1-23 1023 23 (see section registers Error! Reference 1-23 source not found.) Table 12-3: PCS100 UPS-I Modbus TCP cached user parameters...

  • Page 122: Modbus Tcp Error Codes

    The MODBUS server is unable to process this command at present. Retry this Slave device Busy command again later. GDM VCAN server is busy, unavailable or has returned an error GDM VCAN cable has been unplugged from the GDM Table 12-4: PCS100 UPS-I Modbus TCP error codes...

  • Page 123: Wiring

    The PCS100 UPS-I systems with a 900 A Utility Disconnect have the main input and output The PCS100 UPS-I systems with a 2200 A and 4200 A connections on the left side. Utility Disconnect have the main input and output terminals on right side of the Utility Disconnect Enclosure.

  • Page 124: Control Connections

    PCS100 UPS-I User Manual 13.2 Control Connections The PCS100 UPS-I includes control connections for the need of local control or monitoring of the system. Control connection terminals are located on Auxiliary Master Module at the bottom of the Master Inverter Enclosure.

  • Page 125: Emergency Power Off (Epo)

    (Looped from input 15). Inputs 13 to 15 are configured as a 3-wire start/stop which is modified as required according to parameter 541 Start Command. The following control connections are available for wired remote control or monitoring of the PCS100 UPS-I. 3 wire 4 wire Stop/...

  • Page 126: Maintenance

    More detailed maintenance information can be found in the product manuals and detailed maintenance instructions. The design lifetime of the PCS100 UPS-I product (excluding energy storage) is 15 years with operation in specified operational and environmental conditions, and maintenance performed according to the recommended schedule.
  • Page 127 PCS100 UPS-I User Manual Energy Storage Test discharge 1 year Battery balance check 6 months Ultracapacitor MK1 energy storage balance check 1 year Ultracapacitor MK2 energy storage balance check 5 years Ultracapacitor MK2 energy storage enclosure LEDs 1 year Float charger LEDs...

  • Page 128: Repairs

    All repairs must be performed by ABB Service or an authorized service agent. When contacting ABB Service please provide the serial number of the PCS100 UPS-I and a copy of the Event Log which can be downloaded via the Remote Web Pages as described in section 12.2.4.

  • Page 129: Dimensions And Layouts

    PCS100 UPS-I User Manual — 15 DIMENSIONS AND LAYOUTS 15.1 Dimensions and Weights The following tables show the dimensions and weights of different types of enclosures. Enclosure Dimensions Enclosure Type Weight Size H x W x D Shared Enclosures 2154 x 1209 x 804 Inverters, Utility...

  • Page 130: Individual Enclosures - Plan View

    PCS100 UPS-I User Manual 15.2 Individual Enclosures – Plan View The following plan views show the dimensions and required clearances of the enclosures. 200 mm min Clearance Recommended 1209 1209 1209 1500 mm min Clearance Recommended 15.3 Individual Enclosures – Elevations The following front elevations show the height of the enclosures and clearance required above each enclosure.

  • Page 131: Clearances

    The doors must open 120° to allow normal cabinet to access the PCS100 UPS-I module replacement. 15.5 Layout Plans For layout plans and dimension information refer to the PCS100 UPS-I Technical Catalogue, Document number 2UCD120000E002, and installation documents / drawings.

  • Page 132: Protection Requirements

    16.2 Short Circuit Protection The power system fault current (kA) must not exceed the fault capacity of the PCS100 UPS-I. A circuit breaker that is set to clear a short circuit failure (within the PCS100 UPS-I’s withstand period) is required. For PCS100 UPS-I fault capacities and withstand periods refer to the model tables earlier in this catalogue.

  • Page 133: Arc Fault Protection Recommendation

    Mechanical air circuit breakers (ACBs) do not provide any sub-cyclic current limitation in short circuits and are usually slower than MCCBs. The ABB Emax series is specified to clear in 70 ms, but EMax2 is specified to clear in only 40 ms. Other ACBs may be slower than this and protection relays may add to the time. ACBs are applied to systems from about 1500 A and above, where MCCBs are less commonly available.

  • Page 134: Installation Requirements

    ABB requires the input and output breakers of a maintenance bypass to be lockable for an ABB service personnel to carry out any work on the PCS100 UPS-I. Please note that ABB LV breakers do not provide this as standard but as an option.

  • Page 135: Load Imbalance

    PCS100 UPS-I discharging mode. As fast charging of batteries through PCS100 UPS-I Inverters can be up to 30 minutes additional load on supply transformer should be taken in consideration.

  • Page 136: Service And Technical Support

    ABB product lifetime 18.3 Life Cycle Management ABB’s life cycle management model maximizes the value of the equipment and maintenance investment by maintaining high availability, eliminating unplanned repair costs and extending the lifetime of the drive. Life cycle...
  • Page 137 Other life cycle engineering and technical support is available by phone, email, or on-site visits, or as – agreed in an ABB services contract Redundant inverter design increase reliability and availability and is part of a proven family of global –...

  • Page 138: Appendices

    DC capacitors need selective treatment according to IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

  • Page 139: Open-Source Software

    PCS100 UPS-I User Manual System Configuration Module. A small circuit board located inside the master module. When the PCS100 product powers up the SCM checks the SW revisions and the hardware configuration (i.e., the number of inverter and rectifier modules).

  • Page 140: Detailed Single-Line Diagram

    PCS100 UPS-I User Manual 19.6 Detailed Single-Line Diagram Figure 19-1: PCS100 UPS-I Single line diagram...

  • Page 141: Torque Settings And Bolt Order

    PCS100 UPS-I User Manual 19.7 Torque settings and Bolt order Following table shows torque settings recommended for the power cable connections. Tightening Torque for Standard Bolts and Nuts Bolt Diameter Pitch Torque Nm (lb ft) (mm) (mm) Use only high tensile bolts Flat Washer 4.5 (3.6)

  • Page 142: Appendices

    PCS100 UPS-I Transfer Performance 2UCD200000E041 PCS100 Open-Source Software Information. 2UCD120000E406 PCS100 UPS-I Spares List – PCS100 UPS-I (2200 A & 4200 A UD) 2UCD120000E407 PCS100 UPS-I Spares List – Battery Energy Storage 2UCD120000E408 PCS100 UPS-I Spares List – Ultra Capacitor Energy Storage...
  • Page 143 PCS100 UPS-I User Manual...
  • Page 144 — ABB Ltd. 111 Main North Road 4110, Napier New Zealnd abb.com/ups © Copyright 2020 ABB. All rights reserved. Specifications subject to change without notice.

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