Ups
Short Description
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AC UPS Training Manual
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BIO-QUR-O42 REV.B D T D 2 1 . 0 4 . 2 0 0 8 DESCRIZIONE PROGETTO - PROJECT DESCRIPTION :
CONSTRUCTION OF QURAYYAH OPEN CYCLE GAS TURBINE POWER PLANT BATTERIES, BATTERY CHARGERS & UPS SYSTEMS IMPIANTO - SITE :
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TITOLO - TITLE :
AC UPS TRAINING MANUAL MATRICOLA - PART NUMBER :
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114-115-121-122-123-124-125-127-128 / 08
JGE411930
Il presente documento è di esclusiva della BORRI S.r.l. che tutelerà i propri diritti a termine di legge This document remains the exlusive property of BORRI S.r.l. and we reserve all rights according to copyright laws Rev.
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Description
First Issue
Date 24.06.2009
Checked
Released
V.Lomonico Approved
P.Conti
Date
Type of doc.
Pag. N°
A4
1
Pag. Tot.
24.06.2009 Date
24.06.2009 Cod. JGE411930
218
AC UPS Training Manual
AC UPS TRAINING MANUAL
Index of sections
Code
1 – AC UPS TECH DATA
JUD410382
2 – AC UPS INSTALLATION, OPERATING AND MAINETNANCE MANUAL
JGE410503
3 – AC UPS OPERATING DESCRIPTION
JUD411298
4 – AC UPS TEST PROCEDURE
JUD411618
5 – AC UPS TROUBLESHOOTING PROCEDURES
JUD411299
6 – RTB_E MAINTENANCE
JUD411546
7 – ITB_E / IMB_E MAINTENANCE
JUD411547
8 – RTB.E CONFIGURATION
JUD411353
9 – UPS TEST SOFTWARE
JUD411293
10 – APPENDIX
Rev.
-
JUD411495
UPS dielectric strength test
JUD411350
Setting of FMC board
JUD411351
Operating instr. for thermal probe mounting on RTB.e
JRE409515
Operating instr. for N_FS3011 board mounting
JRE409517
Operating instr. for battery recharge LEM use
JRE409518
Description
First Issue
Date 24.06.2009
Checked
Released
V.Lomonico Approved
P.Conti
Date
Type of doc.
Pag. N°
A4
2
Pag. Tot.
24.06.2009 Date
24.06.2009 Cod. JGE411930
218
AC UPS E2001.e GENERAL TECHNICAL DATA
UPS General data
INDUSTRIAL UPS – GENERAL TECHNICAL DATA Index 1 INTRODUCTION .............................. 3
3 OPERATING MODES ......................7
2
GENERAL DESCRIPTION.............. 3
3.1 NORMAL OPERATION ............................. 7
2.1 RECTIFIER BATTERY CHARGER ............3
3.2 BATTERY OPERATION ............................ 8
2.1.1 Automatic recharge of the battery.........3
3.3 BYPASS OPERATION .............................. 8
2.1.1.1
Recharge IU according to the DIN 41773 standard ....................................4
3.4 MANUAL BYPASS .................................... 8
2.1.1.2
I1 I2 U recharge ...................................4
2.1.1.3
U1 U2 I recharge..................................4
4 TECHNICAL CHARACTERISTICS..9
2.1.2 Timed boost charge ................................5
5 PROGRAMMING AND PARAMETER SETTING ..........................................9
2.1.3 Manual recharge......................................5
6 ALARMS, STATUS AND SIGNALS 9
2.2 INVERTER ..................................................5
7 FRONT PANEL ..............................10
2.2.1 Operation with non-linear load ..............5 2.2.2 Overload management ...........................6
8 PARALLEL REDUNDANT OPERATION ..................................10
2.2.2.1
Overload with Bypass available ...........6
2.2.2.2
Overload with Bypass NOT available ..6
9 DESIGN STANDARDS ..................11
2.2.3 Short circuit operation............................6
10 MECHANICAL LAYOUT ................11
2.2.4 IGBT bridge protection ...........................7
11 DATASHEETS ...............................12
2.3 STATIC SWITCH ........................................7
11.1 UPS 110VDC / 115VAC........................... 12
2.3.1 Inverter Æ Emergency Line transfer .....7
11.2 UPS 110VDC / 230VAC........................... 15
2.3.2 Emergency Line Æ Inverter transfer .....7
11.3 UPS 220VDC / 115VAC........................... 18
2.4 MANUAL BY-PASS....................................7
11.4 UPS 220VDC / 230VAC........................... 21
Rev.
/ A
Descrizione Description
First Issue Changed mech. dimension
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
Lingua Language
Pagina Page
di Pag. of Pag.
19/03/08 23/12/08
P. Conti P. Conti
E. Simoni E. Simoni
E. Simoni E. Simoni
E
1
23
Codice / Code
JUD410382
UPS General data
Index of pictures Picture 1 – UPS block diagram ................................... 3 Picture 2 – Rectifier ..................................................... 3 Picture 3 – IU recharge ............................................... 4 Picture 4 – I1 I2 U recharge ........................................ 4 Picture 5 – U1 U2 I recharge....................................... 5 Picture 6 – Timed recharge ......................................... 5 Picture 7 – Inverter...................................................... 5 Picture 8 – Diagram of the power................................ 5 Picture 9 – Operation with non-linear load .................. 6 Picture 10 – Thermal image characteristic .................. 6 Picture 11 – Overload with bypass available............... 6 Picture 12 – Overload with bypass not available......... 6 Picture 13 – Short circuit characteristic (By-pass not available)..................................................................... 7 Picture 14 – IGBT bridge protection ............................ 7
2 of 23
Picture 15 – Static switch and Manual by-pass........... 7 Picture 16 – Normal Operation ................................... 8 Picture 17 – Battery operation .................................... 8 Picture 18 – Bypass operation (manual change-over) 8 Picture 19 – Bypass operation (automatic changeover) ........................................................................... 8 Picture 20 – Manual Bypass for functional tests ......... 8 Picture 21 – Manual Bypass for repair or maintenance works .......................................................................... 9 Picture 22 – Front panel ........................................... 10 Picture 23 – Parallel redundant configuration (double battery) ..................................................................... 10 Picture 24 – Parallel redundant configuration (single battery) ..................................................................... 11
JUD410382
Rev.A 23/12/08
UPS General data
1
INTRODUCTION
The UPS is the type “ON LINE DOUBLE CONVERSION” and is connected between main power and user loads (see picture 1). As far as architecture and layout is concerned, this project is optimised with particular care in order to make it suitable for applications where reliability and high performances are fundamental for critical loads. The UPS operation is optimised by microprocessor digital control and the IGBT inverter is based on a high frequency PWM waveform. The UPS operation is controlled by two DSP 16-bit microprocessors, one for the rectifier and one for the inverter. The control logics are interfaced to a microprocessor-based LCD panel, which can be easily programmed by means of a control software to modify the LED signalisations and the alarms available on the relay cards. Procedures for power-on, power-off, switching to and from bypass are described step by step on LCD display, in order to help the users to easily operate the UPS. Results of electrical measurement, alarm, work condition, event log and battery status are displayed real time on the LCD front panel.
Picture 1 – UPS block diagram
With this configuration UPS guarantees high quality output, needed by loads requiring a stable and clean source of power. The main features are: • Protection for black-out, in the limits of battery autonomy • Complete filtering of main power noise • High quality output power, provided under any condition of input power and loads • Stable output frequency, independent from input frequency • Full compatibility with every type of load • Configurable with any neutral wire configuration (under request) • Automatic control of battery, during both charging and discharging phases • Easy to interface with user devices • Auto-diagnostic feature and troubleshooting support • Flexibility of complete bypass configuration • Full access from the front and from the roof for maintenance Rev. A 23/12/08
JUD410382
The block diagram shows the UPS subsystem that will be analysed in the following chapters: • Rectifier/Battery Charger (R) • Inverter (I) • Battery (B) • Static switch: Static inverter switch (SSI) and Static Bypass switch (SB) • Manual Bypass (MB)
2
GENERAL DESCRIPTION
2.1
RECTIFIER BATTERY CHARGER
The rectifier converts the alternate voltage at the input, with frequency and amplitude variable according to the Technical Specification (ST), into a continuous output voltage that is stabilized in voltage and controlled in current, by means of a three-phase SCR rectifier bridge (6 pulses version) or a couple of bridges connected in parallel (12 pulses version). The galvanic isolation of the input mains (when required by the ST) is carried out by means of a transformer. Additional protection against power surges, under and over voltage are included as a standard. Optionally a grounded screen between the primary and secondary windings and semiconductor fast transient protection devices (varistors) can be provided. A programmable soft-start, reducing the inrush current of the rectifier during the start up, is included as a standard. In “Manual Regulation” mode it is possible to set the output rectifier voltage by means of external potentiometers. In this modality a maximum current limitation (to be set) is also active. The transfer command “AUTOMATIC/MANUAL” and vice-versa is activated by means of a selector on the front panel; it is also possible to carry out the same command through the remote PC. The system can be interfaced with similar equipment through a digital link for parallel operation with equal sharing of the load (+/-5% tolerance) and automatic exclusion of the faulty unit.
Picture 2 – Rectifier
2.1.1 Automatic recharge of the battery When selected the rectifier recharges the battery automatically, according to the predefined 3 of 23
UPS General data modalities. The recharging cycle begins consequently according to one of the following events (which are programmable): - Mains failure for a period longer than the programmed value - Intervention of the current threshold. - Intervention of the voltage threshold. - Timed boost charge The predefined cycles can be programmed in the Menu Parameters. 2.1.1.1
Recharge IU according to the DIN 41773 standard The recharge is divided in two different phases: - Phase 1: the current is constant and the voltage increases. - Phase 2: the current decreases and the voltage is constant. When the recharging current goes below a certain value the battery is assumed fully recharged and the cycle ends. Consequently the output voltage is set at the floating level. During the floating the battery voltage is controlled as minimum value in order to avoid undesirable discharges, and as maximum value in order to avoid excessive heating of the electrolyte. The “thermal compensation” of the floating voltage in function of the battery temperature can be added as an option.
Picture 3 – IU recharge
2.1.1.2 I1 I2 U recharge This recharge is used mainly for Ni-Cd batteries. During the recharge a boost charge of approx. 125% is provided, to compensate the losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows: If the mains fails for a time longer than the programmable threshold, when the mains returns the output voltage of the rectifier switches to a level higher than the floating, called boost charge and a safety timer is activated. If the recharging current exceeds the programmed threshold, normally a certain percent of C10, the voltage is maintained and a first phase of boost charge 4 of 23
starts, where the current is constant and the voltage is increasing. After a certain time the current starts to decrease and the voltage remains constant at the boost charge level. This is the second phase of the boost charge. Finally, when the current go down below the programmed level for the return in floating, the output voltage of the rectifier is taken back to floating. If this does not happen within the max. programmed time, the safety timer blocks the charge and the voltage is forced to floating. This event generates an alarm.
Picture 4 – I1 I2 U recharge
2.1.1.3 U1 U2 I recharge This recharge is used mainly for Ni-Cd batteries. During the recharge a boost charge of approx. 125% is provided, to compensate the losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows: If the mains fails for a time which is longer than the programmable threshold, when the mains returns the output voltage of the rectifier switches to a level higher than the floating, called boost charge and a safety timer is activated. If the recharging voltage doesn’t exceed the programmed crossing threshold, normally a certain percent of the floating, the voltage is maintained and a first phase of boost charge starts, where the current is constant and the voltage is increasing. After a certain time the recharging voltage reaches the programmed level for the second phase of boost charge; a timer is started and the battery is kept under boost charge conditions for the time programmed. After this time has elapsed the output voltage of the rectifier is switched back to the floating value. If this does not happen within the maximum programmed time, the safety timer block the charge and the voltage is forced to floating. This event generates an alarm.
JUD410382
Rev. A 23/12/08
UPS General data 2.2
Picture 5 – U1 U2 I recharge
2.1.2 Timed boost charge This recharge is used mainly for Ni-Cd batteries. During the recharge a boost charge of approx. 125% is provided, to compensate the losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows: If the mains fails for a time longer than the programmable threshold, when the mains returns the output voltage of the rectifier switches to a level higher than the floating, called boost charge for a pre-programmed time. The boost charge command can also be associated to an external command.
Picture 6 – Timed recharge
2.1.3 Manual recharge The manual recharge of the battery, called also of forming or of equalizing is a function offered by the RCN that allows the operator to carry out a recharge under his own manual control. This modality of recharge can be used to form the battery after that it has been stocked for a long period, or after that the electrolyte has been filled up, in the case of batteries having been shipped dry, or in order to equalize the voltage of the battery cells after having been used for a certain period. The manual recharge procedure is described in detail in the relevant menu of the FRONT PANEL chapter of the Operating Manual. Generally, when manual recharge is selected it is possible to change manually the output voltage by means of a potentiometer to vary the recharging battery current. Such current is however always limited to a pre-selectable maximum value.
Rev. A 23/12/08
JUD410382
INVERTER
The DC voltage is converted by the IGBT bridge, that uses four switches, controlled using PWM (Pulse Width Modulation) technology at high commutation frequency. The PWM generation as well as the control of the operating variables is completely managed by the microprocessor. The DC current transducer CT provides for the monitoring of the inverter input current. Its feedback signal is managed by the microprocessor to activate the output short circuit current limitation (see 2.2.3) and the IGBT protection (see 2.2.4).
Picture 7 – Inverter
The output transformer provides the galvanic insulation between DC and AC side, as well as voltage adaptation. Its integrated inductance forms, together with the AC capacitors, a lowpass filter that provides to eliminate the high frequency ripple and keeps the total harmonic distortion of the inverter waveform (THD) lower than 2% (with linear load). The inverter, thanks to its manufacturing technology and to the microprocessor control, is able to supply indifferently inductive or capacitive loads. The maximum apparent power varies slightly in case the load is highly capacitive (p.f. < 0,9) and a de-rating factor, according to the picture 5, must be applied. The data “100% kW” indicates the maximum active power that the UPS can supply to a resistive load (ex: for a 20kVA UPS Pmax=16kW).
Picture 8 – Diagram of the power
2.2.1 Operation with non-linear load A non-linear load is characterized by a high peak current versus its RMS value, that in normal condition would introduce a distortion on the output waveform. The inverter is provided with an instantaneous voltage correction facility, completely managed 5 of 23
UPS General data by the microprocessor, that provides to vary the PWM generation according to the actual output waveform, in order to keep the THD within 5% even with loads having crest factor equal to 3.
2.2.2.1
Overload with Bypass available
Picture 11 – Overload with bypass available Picture 9 – Operation with non-linear load
2.2.2 Overload management Inverter can provide continuously 100% of nominal load and can tolerate overload conditions up to 125% for 10 minutes or 150% for 1 minute. Peak conditions such as take-off of engines or magnetic parts are managed limiting the output current to 200% for 5 cycles, than reducing to 125%. Any times output power grows above 100% the inverter keeps feeding the loads, while the microprocessor activates the “thermal image” algorithm (technical figure) to calculate thermal image based on output current and duration of the overload in function of the time. User loads are powered by inverter output up to the end of maximum allowed time, and then the static bypass switches to emergency line without interruption of output power.
As soon as an overload is detected the algorithm starts to calculate the increment of the energy. When the limit is reached the load is transferred to bypass. To allow a safe cooling of the inverter power components (IGBT’s, transformer) the inverter is switched off for 30 minutes. When this time has elapsed the inverter is switched on again and the load transferred back to the primary supply. 2.2.2.2
Overload with Bypass NOT available
Picture 12 – Overload with bypass not available
Picture 10 – Thermal image characteristic
As soon as an overload is detected the algorithm starts to calculate the increment of the energy. When the limit is reached the inverter is switched off to avoid severe damages to the power components. As soon as the bypass is available again the load is supplied by the bypass static switch. After 30 minutes the inverter is switched on again and the load re-supplied. WARNING: this operation causes the loss of the supply to the load 2.2.3 Short circuit operation As soon as an output short circuit is detected (alarm A25) the load is transferred immediately to the emergency line that provides to eliminate the fault thanks to its higher short circuit current.
6 of 23
JUD410382
Rev. A 23/12/08
UPS General data In case the bypass is not available the inverter reduces its output voltage and limits its output current to 200% for 100ms, and then to 125% for 5 seconds, after that it’s switched off (according to EN 62040-3 / EN 50091-3).
The thyristor connected to the main power is protected by a fast-acting fuse.
Picture 15 – Static switch and Manual by-pass
Thanks to the transfer logic integrated in the control, the load is supplied by the bypass static switch even in case of microprocessor failure. Overload capability:
Picture 13 – Short circuit characteristic (By-pass not available)
2.2.4 IGBT bridge protection The inverter current is monitored by the DC current transducer connected upstream the inverter bridge. Therefore the control logic is able to distinguish an output short circuit from an IGBT short circuit. The behaviour of the inverter in case of short circuit on the load has been described at 2.2.3; the output current is limited and the IGBT bridge current doesn’t reach the protection threshold. In case of short circuit in the inverter bridge the DC input current increases immediately and there’s no possibility of limitation but stopping the PWM. In this case the alarm A24 – Current stop is activated and must be reset manually after having verified the status of the semiconductors.
150% continuously 200% for 1 minute 2000% for 1 cycle
2.3.1 Inverter Æ Emergency Line transfer The transfer (in less than ¼ cycle) is activated only if emergency line is in tolerance, for the following reasons: • Output short circuit • Fault of the inverter • DC over-voltage or under-voltage (inverter OFF) • Over-temperature • Thermal image shutdown • Forced commutation by “BYPASS SWITCH” 2.3.2 Emergency Line Æ Inverter transfer As soon as inverter is correctly working and synchronized, the unit automatically switches to inverter in less than 1 msec. If the system switches back and forth more than 6 times in two minutes, an alarm is generated to inform the user, and the load is blocked to emergency line until a manual reset will clear the faulty condition. 2.4
MANUAL BY-PASS
In order to allow safe maintenance and repair of the unit, the inverter is provided with a manual bypass switch. In bypass mode all the repair and test activities to verify the efficiency of the whole unit can be carried out safely. Manual by-pass can be inserted by following the relevant instructions. During manual by-pass operation there’s no interruption of the supply to the load.
Picture 14 – IGBT bridge protection
2.3
STATIC SWITCH
Static switch is based on power semiconductor (thyristors), rated to work continuously at 150% of nominal output power. Rev. A 23/12/08
JUD410382
3
OPERATING MODES
3.1
NORMAL OPERATION
During normal operation all the circuit breakers/switches are closed except MBCB (maintenance bypass). The three-phase input AC voltage feeds the rectifier via the isolation transformer; the rectifier supplies the inverter and compensate mains voltage fluctuations as well as load variation, 7 of 23
UPS General data maintaining the DC voltage constant. At the same time it provides to keep the battery in stand-by (floating charge or boost charge depending on the type of battery). The inverter converts the DC voltage into an AC sine-wave, stabilized in voltage and frequency, and provides to supply the load through its static switch SSI.
the load is transferred back to inverter without interruption.
Picture 18 – Bypass operation (manual change-over)
The automatic change-over occurs for the reasons explained in the UPS technical description (see paragraph 2.4.1); basically when the power supply to the load within the specified tolerance cannot be assured by the inverter. Picture 16 – Normal Operation
3.2
BATTERY OPERATION
In the event of mains failure, or rectifier failure, the inverter is no longer supplied by the rectifier, so the battery, that is connected to the DC intermediate circuit, is called up immediately and without interruption to supply the load. The battery voltage drops as a function of the magnitude of the discharge current. The voltage drops has no effect on the inverter output voltage since it is kept constant by varying the PWM modulation. As the battery approaches the discharge limit an alarm is activated. In case the power is restored (even using a diesel generator) before the limit is reached the system switches automatically back to normal operation, if not, the inverter shuts down and the load is transferred to the bypass (bypass operation). If the bypass mains is not available or outside the tolerance range the complete system shuts down as soon as the lowest battery level is reached. As soon as the power is restored the rectifier charges the battery, and, depending on the depth of the discharge, the charging current is limited by means of the battery current limitation.
Picture 19 – Bypass operation (automatic changeover)
3.4
MANUAL BYPASS
The manual bypass operation is necessary every time the functionality of the UPS needs to be checked or during maintenance or repair works. The manual bypass procedure is described in the UPS operating manual and must be followed carefully in order to avoid damages to the UPS. During the functional check of the UPS, all the breakers can be closed, except for the output breaker OCB, and the full functionality can be tested.
Picture 20 – Manual Bypass for functional tests Picture 17 – Battery operation
3.3
BYPASS OPERATION
Bypass operation may occur for both manual or automatic change-over. The manual transfer is due to the BYPASS SWITCH, that forces the load to bypass. In the event of a bypass failure 8 of 23
During the manual bypass operation for repair or maintenance, the UPS is completely switched off and the load is supplied directly by the bypass mains.
JUD410382
Rev. A 23/12/08
UPS General data
List of the alarms
Picture 21 – Manual Bypass for repair or maintenance works
4
TECHNICAL CHARACTERISTICS
For technical characteristics see the attached data sheets (chapter 11).
5
PROGRAMMING AND PARAMETER SETTING
The “setting” menu on the front panel allows to adjust the most important operating parameters for the rectifier, inverter and static bypass. In alternative the programming can be carried out by a PC connected to the serial port RS232 of the front panel, using the dedicated interface software. At the end of the setting the modified parameters must be memorized in the nonvolatile memory (EEPROM). Another software suite, specifically designed for the front panel, allows the programming of the signalization LED’s and alarm relays.
6
ALARMS, STATUS AND SIGNALS
The alphanumeric display offers a complete diagnostic of the system. Each alarm and status is associated to a code; the alarm codes are stored in the events history. The display management for the alarms and status, including the history log, is described in the chapter FRONT PANEL of the Operating Manual. List of the status Code
Description
S1 S2 S2-1 S2-2 S2-3 S3 S4 S5 S6 S7
Rectifier OK Battery on charge Floating charge Boost charge Manual charge Battery OK Inverter OK Bypass OK Inverter synchronised Inverter feeds load
Rev. A 23/12/08
Code
Description
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28..A39 A40 A41 A42..A49 A50..A59 A61 A62 A63 A64
Mains fault Rectifier fuses blown Rectifier high temperature Rectifier Overload Maximum DC voltage Minimum DC voltage Charging fault Rect. Input CB open Battery CB open Battery discharging Battery low Battery in test Battery fault Inverter VDC fault Inverter high temperature Inverter out tolerance Max. current stop Inverter not synchronised Inverter overload Bypass not available Bypass feed load Bypass switch activated Retransfer blocked Fans failure Inverter output CB open Manual bypass CB closed EPO activated Not available DC earth fault Rectifier output CB open Not Available Programmable Communication fault Rectifier common alarm Inverter common alarm Common alarm
The alarms and status can be remotely transferred by means of SPDT (Single Pole Double Throw) voltage-free relay contacts (OPTION).
ARC #1
JUD410382
RELAY
MEANING
RL1 RL2 RL3 RL4 RL5 RL6
Mains fault Rectifier OK Floating charge Boost charge Battery CB open Charging fault
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UPS General data
ARC #2 RELAY
MEANING
RL1 RL2 RL3 RL4 RL5 RL6
Battery low voltage DC earth fault High temperature Inverter OK Inverter synchronized Inverter feeds load
8
ARC #3
7
RELAY
MEANING
RL1 RL2 RL3 RL4 RL5 RL6
Bypass OK Bypass feeds load Overload Retransfer blocked Fans failure Common alarm
FRONT PANEL
The front panel of the UPS, consisting of a four-row alphanumeric display plus 15 function keys, allows the complete monitoring of the UPS status. The power flow diagram helps to understand the operating status of the UPS.
PARALLEL REDUNDANT OPERATION
The parallel system consists of “n” (up to 4) units, which are equipped like standard units. Only the manual bypass can be external and unique for all the units (on request). On each inverter one extra PCB (RPIBUSCAN), that provides the parallel redundant functions, is installed. In addition to the standard functions as uninterruptible power supply, total power control and protection of the load from mains distortion, the parallel redundant system guarantees an uninterrupted power supply even in case of an internal failure in one of the inverters. This is possible because all units are constantly in operation and feed the load in parallel at “total load / n”, where “n” is the number of the UPS. The AC automatic current sharing control equalizes the currents of the “n” inverters and reduces the total unbalance to less than 10%, under all load conditions. The load is supplied by the inverters in parallel for an instantaneous overload up to “n x 200%” of the nominal load of a single unit. In case of failure in one unit, the other units supply the load. The load is supplied by the static bypass only when the redundancy logic, that can be set by a dedicated software program, is no longer satisfied.
Picture 22 – Front panel
The front panel main functions are: - Show all the relevant input and output current, voltage and frequency measures - Show all the alarms and status of the UPS - Show the events history The following remote connections are also available: 1. Through an RS232 protocol 2. Through a ModBus RS485 protocol The relay cards and the signalisations by LED’s can be programmed by a dedicated software interface. The front panel can also be set in “transparent” mode to connect a PC to the rectifier or inverter microprocessors in order to check and/or adjust all the operating variables. 10 of 23
Picture 23 – Parallel redundant configuration (double battery)
In case of parallel redundant system with single battery bank (common DC bus) the rectifiers can be equipped with an additional parallel board that controls the current sharing on the DC bus. In this case the rectifiers are connected by means of a communication cable, through which all the information necessary for the current sharing and the alarms management are exchanged.
JUD410382
Rev. A 23/12/08
UPS General data During the floating charge each rectifier supplies the 50% of the total load (Active Current Sharing), therefore in case of failure of one unit the load is supplied by the remaining rectifier without affecting the DC bus-bar. During a mains failure the batteries supply the necessary energy. The battery charging cycle is automatically started upon the mains return; during the current limitation phase (operation as current generator) the current is completely supplied by the rectifier #1, whereas the rectifier #2 follows the DC busbar voltage without supplying any current. In case of failure of the rectifier #1 the load is supplied by the rectifier #2, still operative, without affecting the DC bus-bar. At the end of the current limitation phase the Active Current Sharing control is restored. In case two batteries are connected to the DC bus-bar the recharge is carried out limiting the battery that absorbs the highest current.
Cables
:
Safety
:
Protection degree Mechanical
: :
Semiconductors Protection devices Contactors Lamps
: : : :
10
CEI 60947-2 CEI 20-38 CEI 20-22 CEI 20-14 EN 50178 EN 62040-1-2 IEC 60529 EN 60439-1 EN 62040-1 EN 60146 EN 60127 EN 60947-4 EN 60945-5
MECHANICAL LAYOUT
The following drawings are given as examples of mechanical layout for the inverter series IMN. Width and depth varies according to the voltage and current ratings; further details are given in the datasheet. Version 1 : IP20
Version 2 : IP31 Picture 24 – Parallel redundant configuration (single battery)
9
DESIGN STANDARDS
Quality / Environment
:
Inverter basic standard EMC standard
: :
Performances Power transformers Low voltage switchgear
: : :
Rev. A 23/12/08
ISO 9001:2000 EN 14001 EN 62040 EN 61000-6-2 EN 61000-6-4 EN 62040-3 IEC 60076 IEC 60439
JUD410382
11 of 23
UPS General data
11
DATASHEETS
11.1 UPS 110VDC / 115VAC UPS 110Vdc/115Vac - SIZE (kVA)
5
10
15
20
30
40
50
ELECTRICAL DATA – GENERAL 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz)
50-60 (selectable) +/- 10%
Output voltage (Vac)
110 – 115 – 120 (selectable) +/- 1% 50-60 (selectable) +/- 4% (programmable)
Output frequency (Hz) Output power @ p.f. 0,8 (kVA)
5
10
15
20
30
40
50
Output power @ p.f. 1 (kW)
4
8
12
16
24
32
40
≥ 54 ≥ 61 ≥ 67 ≥ 75
≥ 54 ≥ 62 ≥ 68 ≥ 76
≥ 55 ≥ 62 ≥ 68 ≥ 76
≥ 59 ≥ 72 ≥ 75 ≥ 80
≥ 58 ≥ 71 ≥ 74 ≥ 80
≥ 58 ≥ 74 ≥ 76 ≥ 82
≥ 59 ≥ 74 ≥ 78 ≥ 82
2,77
4,15
4,35
6,53
7,78
9,72
Efficiency at nominal load
25% 50% 75% 100%
Heat dissipation @ nominal load - Kw
1,45
Active load sharing (CAN-BUS connection) Up to 4 units
Parallel redundant configuration
ELECTRICAL DATA – RECTIFIER 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz) Input short circuit current (kA rms) (@ 400Vac, IEC standard) Max. Input power (kVA) (@ 100% load, nominal input) Input current distortion (THD) (@ 100% load, nominal input)
50-60 (selectable) +/- 10% ≤ 16 (other on request) 8,3
16,4
24,7
32,2
48,3
63,7
≤ 27% with 6 pulses bridge (standard) ≤ 12% with 12 pulses bridge (on request) ≤ 6% with 12 pulses plus input THD filter (on request)
Input power factor (@ 100% load, nominal input) Output voltage (Vdc)
≥ 0,75 (No manual charge provided) 110
- Nominal - Floating charge
2,2÷2,3 V/cell for Lead acid battery (Adjustable) 1,4÷1,5 V/cell for NiCd battery (Adjustable)
- Boost charge
2,4÷2,45 V/cell for Lead acid battery (Adjustable) 1,5÷1,65 V/cell for NiCd battery (Adjustable)
- Manual (equalizing) charge
up to 2,7 V/cell for Lead acid battery up to 1,7 V/cell for NiCd battery Forced boost push button (on request) Thermal compensation for lead acid battery (on request) ≤ 2 (other on request)
Output ripple (% rms) Rated output current (A)
12 of 23
79,7
50
100
150
JUD410382
200
300
400
500
Rev. A 23/12/08
UPS General data
UPS 110Vdc/115Vac - SIZE (kVA)
5
10
15
20
30
40
50
ELECTRICAL DATA – INVERTER 90 ÷ 160
Input voltage range (Vdc)
110 – 115 – 120 (selectable) +/- 1%
Output voltage (Vac)
50-60 (selectable)
Output frequency (Hz) Output frequency stability (Hz)
+/- 0,001 +/- 2 (programmable)
- Free running quartz oscillator - Inv. Synchronized with mains Output current @ 115Vac (A) 34 43
- p.f. 1 - p.f. 0,8
68 86
104 130
138 173
208 260
277 347
347 434
Output harmonic distortion (THD) < 2% < 5%
- Linear load - Not linear load (75% Pn, CF=3:1)
125% Pn for 10’, 150% Pn for 1’, 200% In for 100ms
Overload capability (p.f. 0,8) 68
Short circuit current (A) Short circuit protection Output voltage static stability Output voltage dynamic stability
0 - 50% 0% - 100%
136 208 276 416 554 694 200% In for 100ms, then 125% In Inverter stop after 5 seconds (according to EN62040-3) +/- 1% +/- 5% With recovery at +/- 1% within 40ms +/- 8% With recovery at +/- 2% within 40ms
ELECTRICAL DATA – STATIC BYPASS Electronic thyristor switch
Automatic static bypass Nominal input voltage (Vac) Input frequency (Hz) Overload capability (p.f. 0,8)
110 – 115 – 120 (selectable) +/- 20% 50-60 (selectable) +/- 4% (programmable) 150% Pn continuous, 200% Pn for 10’, 2000% In for 1 cycle Fast acting fuse
Static bypass protection Transfer INV Æ BYPASS
< ¼ cycle < 1ms
- Sensing and transfer time - Commutation time Retransfer INV Æ BYPASS - Sensing and transfer time Manual bypass
Rev. A 23/12/08
0 seconds (controlled) Block on mains after 6 commutation in 2 minutes With electric security and without interruption (Make Before Break type)
JUD410382
13 of 23
UPS General data
UPS 110Vdc/115Vac - SIZE (kVA)
5
10
15
20
30
40
50
ENVIRONMENTAL DATA Acoustic noise level (according EN 50091) - dB EMI Operating Temperature (°C) Storage Temperature (°C) Relative Humidity (non condens.) Ventilation Altitude (mt. above see level)
< 67
< 70
< 72
EN 61000-6-2 /EN 61000-6-4 -10 .. +40 -20 .. +70 < 95% (with tropicalization on request) Forced (redundant fans on request) < 2000 ( de-rating According EN62040-3) MECHANICAL DATA
Protection degree (IEC60529)
IP 20 (other on request)
Painting colour and type Dimensions (mm) W D H Weights (Kg) Input/output cable connection
RAL 7035, ≥ 60μm (others on request)
Transport Transport mechanical stress Installation Accessibility
14 of 23
800 1400 1800 800 800 800 2100 2100 2100 450 500 600 650 820 900 1000 Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front (rear for fans access)
JUD410382
Rev. A 23/12/08
UPS General data 11.2 UPS 110VDC / 230VAC UPS 110Vdc/230Vac - SIZE (kVA)
5
10
15
20
30
40
50
ELECTRICAL DATA – GENERAL 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz)
50-60 (selectable) +/- 10%
Output voltage (Vac)
220 – 230 – 240 (selectable) +/- 1% 50-60 (selectable) +/- 4% (programmable)
Output frequency (Hz) Output power @ p.f. 0,8 (kVA)
5
10
15
20
30
40
50
Output power @ p.f. 1 (kW)
4
8
12
16
24
32
40
≥ 54 ≥ 61 ≥ 67 ≥ 75
≥ 54 ≥ 62 ≥ 68 ≥ 76
≥ 55 ≥ 62 ≥ 68 ≥ 76
≥ 59 ≥ 72 ≥ 75 ≥ 80
≥ 58 ≥ 71 ≥ 74 ≥ 80
≥ 58 ≥ 74 ≥ 76 ≥ 82
≥ 59 ≥ 74 ≥ 78 ≥ 82
2,77
4,15
4,35
6,53
7,78
9,72
Efficiency at nominal load
25% 50% 75% 100%
Heat dissipation @ nominal load - Kw
1,45
Active load sharing (CAN-BUS connection) Up to 4 units
Parallel redundant configuration
ELECTRICAL DATA – RECTIFIER 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz) Input short circuit current (kA rms) (@ 400Vac, IEC standard) Max. Input power (kVA) (@ 100% load, nominal input) Input current distortion (THD) (@ 100% load, nominal input)
50-60 (selectable) +/- 10% ≤ 16 (other on request) 8,3
16,4
24,7
32,2
48,3
63,7
79,7
≤ 27% with 6 pulses bridge (standard) ≤ 12% with 12 pulses bridge (on request) ≤ 6% with 12 pulses plus input THD filter (on request)
Input power factor (@ 100% load, nominal input) Output voltage (Vdc)
≥ 0,75 (No manual charge provided) 110
- Nominal - Floating charge
2,2÷2,3 V/cell for Lead acid battery (Adjustable) 1,4÷1,5 V/cell for NiCd battery (Adjustable)
- Boost charge
2,4÷2,45 V/cell for Lead acid battery (Adjustable) 1,5÷1,65 V/cell for NiCd battery (Adjustable)
- Manual (equalizing) charge
up to 2,7 V/cell for Lead acid battery up to 1,7 V/cell for NiCd battery Forced boost push button (on request) Thermal compensation for lead acid battery (on request) ≤ 2 (other on request)
Output ripple (% rms) Rated output current (A)
Rev. A 23/12/08
50
100
JUD410382
150
200
300
400
500
15 of 23
UPS General data
UPS 110Vdc/230Vac - SIZE (kVA)
5
10
15
20
30
40
50
ELECTRICAL DATA – INVERTER 90 ÷ 160
Input voltage range (Vdc)
220 – 230 – 240 (selectable) +/- 1%
Output voltage (Vac)
50-60 (selectable)
Output frequency (Hz) Output frequency stability (Hz)
+/- 0,001 +/- 2 (programmable)
- Free running quartz oscillator - Inv. Synchronized with mains Output current @ 230Vac (A) 17 21
- p.f. 1 - p.f. 0,8
34 43
52 65
69 87
104 130
139 174
174 217
Output harmonic distortion (THD) < 2% < 5%
- Linear load - Not linear load (75% Pn, CF=3:1)
125% Pn for 10’, 150% Pn for 1’, 200% In for 100ms
Overload capability (p.f. 0,8) 34
Short circuit current (A) Short circuit protection Output voltage static stability Output voltage dynamic stability
0 - 50% 0% - 100%
68
104 138 208 278 348 200% In for 100ms, then 125% In Inverter stop after 5 seconds (according to EN62040-3) +/- 1% +/- 5% With recovery at +/- 1% within 40ms +/- 8% With recovery at +/- 2% within 40ms
ELECTRICAL DATA – STATIC BYPASS Automatic static bypass Nominal input voltage (Vac) Input frequency (Hz) Overload capability (p.f. 0,8)
Electronic thyristor switch 220 – 230 – 240 (selectable) +/- 20% 50-60 (selectable) +/- 4% (programmable) 150% Pn continuous, 200% Pn for 10’, 2000% In for 1 cycle Fast acting fuse
Static bypass protection Transfer INV Æ BYPASS
< ¼ cycle < 1ms
- Sensing and transfer time - Commutation time Retransfer INV Æ BYPASS - Sensing and transfer time Manual bypass
16 of 23
0 seconds (controlled) Block on mains after 6 commutation in 2 minutes With electric security and without interruption (Make Before Break type)
JUD410382
Rev. A 23/12/08
UPS General data
UPS 110Vdc/230Vac - SIZE (kVA)
5
10
15
20
30
40
50
ENVIRONMENTAL DATA Acoustic noise level (according EN 50091) - dB EMI Operating Temperature (°C) Storage Temperature (°C) Relative Humidity (non condens.) Ventilation Altitude (mt. above see level)
< 67
< 70
< 72
EN 61000-6-2 /EN 61000-6-4 -10 .. +40 -20 .. +70 < 95% (with tropicalization on request) Forced (redundant fans on request) < 2000 ( de-rating According EN62040-3) MECHANICAL DATA
Protection degree (IEC60529)
IP 20 (other on request)
Painting colour and type Dimensions (mm) W D H Weights (Kg) Input/output cable connection
RAL 7035, ≥ 60μm (others on request)
Transport Transport mechanical stress Installation Accessibility
Rev. A 23/12/08
800 1400 1800 800 800 800 2100 2100 2100 450 500 600 650 820 900 1000 Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front (rear for fans access)
JUD410382
17 of 23
UPS General data 11.3 UPS 220VDC / 115VAC UPS 220Vdc/115Vac - SIZE (kVA)
5
10
15
20
30
40
50
60
80
100
80
100
ELECTRICAL DATA – GENERAL 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz)
50-60 (selectable) +/- 10%
Output voltage (Vac)
110 – 115 – 120 (selectable) +/- 1% 50-60 (selectable) +/- 4% (programmable)
Output frequency (Hz) 5
Output power @ p.f. 0,8 (kVA) Output power @ p.f. 1 (kW) Efficiency at nominal load
25% 50% 75% 100%
Heat dissipation @ nominal load - Kw
10
15
20
30
40
50
60
4
8
12
16
24
32
40
48
64
80
≥ 54 ≥ 62 ≥ 68 ≥ 77
≥ 56 ≥ 64 ≥ 70 ≥ 79
≥ 56 ≥ 63 ≥ 70 ≥ 79
≥ 58 ≥ 65 ≥ 72 ≥ 81
≥ 58 ≥ 66 ≥ 72 ≥ 81
≥ 58 ≥ 72 ≥ 75 ≥ 81
≥ 58 ≥ 72 ≥ 75 ≥ 82
≥ 58 ≥ 73 ≥ 76 ≥ 82
≥ 59 ≥ 73 ≥ 77 ≥ 84
≥ 60 ≥ 74 ≥ 79 ≥ 85
1,29
2,34
3,52
4,22
6,33
8,44
10,1
12,1
14,2
16,5
Active load sharing (CAN-BUS connection) Up to 4 units
Parallel redundant configuration
ELECTRICAL DATA – RECTIFIER 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz) Input short circuit current (kA rms) (@ 400Vac, IEC standard) Max. Input power (kVA) (@ 100% load, nominal input)
50-60 (selectable) +/- 10% ≤ 16 (other on request) 8,3
16,4
24,7
32,6
48,8
65,1
81,4
97,7
128,9
≤ 27% with 6 pulses bridge (standard) ≤ 12% with 12 pulses bridge (on request) ≤ 6% with 12 pulses plus input THD filter (on request)
Input current distortion (THD) (@ 100% load, nominal input) Input power factor (@ 100% load, nominal input) Output voltage (Vdc)
≥ 0,75 (No manual charge provided) 220
- Nominal - Floating charge
2,2÷2,3 V/cell for Lead acid battery (Adjustable) 1,4÷1,5 V/cell for NiCd battery (Adjustable)
- Boost charge
2,4÷2,45 V/cell for Lead acid battery (Adjustable) 1,5÷1,65 V/cell for NiCd battery (Adjustable)
- Manual (equalizing) charge
up to 2,7 V/cell for Lead acid battery up to 1,7 V/cell for NiCd battery Forced boost push button (on request) Thermal compensation for lead acid battery (on request) ≤ 2 (other on request)
Output ripple (% rms) Rated output current (A)
18 of 23
159,4
25
50
75
100
JUD410382
150
200
250
300
400
500
Rev. A 23/12/08
UPS General data
UPS 220Vdc/115Vac - SIZE (kVA)
5
10
15
20
30
40
50
60
80
100
556 695
695 869
ELECTRICAL DATA – INVERTER 180 ÷ 300
Input voltage range (Vdc)
110 – 115 – 120 (selectable) +/- 1%
Output voltage (Vac)
50-60 (selectable)
Output frequency (Hz) Output frequency stability (Hz)
+/- 0,001 +/- 2 (programmable)
- Free running quartz oscillator - Inv. Synchronized with mains Output current @ 115Vac (A) 34 43
- p.f. 1 - p.f. 0,8
68 86
104 130
138 173
208 260
277 347
347 434
417 521
Output harmonic distortion (THD) < 2% < 5%
- Linear load - Not linear load (75% Pn, CF=3:1)
125% Pn for 10’, 150% Pn for 1’, 200% In for 100ms
Overload capability (p.f. 0,8) 68
Short circuit current (A) Short circuit protection Output voltage static stability Output voltage dynamic stability
0 - 50% 0% - 100%
136
208 276 416 554 694 834 1112 1390 200% In for 100ms, then 125% In Inverter stop after 5 seconds (according to EN62040-3) +/- 1% +/- 5% With recovery at +/- 1% within 40ms +/- 8% With recovery at +/- 2% within 40ms
ELECTRICAL DATA – STATIC BYPASS Electronic thyristor switch
Automatic static bypass Nominal input voltage (Vac) Input frequency (Hz) Overload capability (p.f. 0,8)
110 – 115 – 120 (selectable) +/- 20% 50-60 (selectable) +/- 4% (programmable) 150% Pn continuous, 200% Pn for 10’, 2000% In for 1 cycle Fast acting fuse
Static bypass protection Transfer INV Æ BYPASS
< ¼ cycle < 1ms
- Sensing and transfer time - Commutation time Retransfer INV Æ BYPASS - Sensing and transfer time Manual bypass
Rev. A 23/12/08
0 seconds (controlled) Block on mains after 6 commutation in 2 minutes With electric security and without interruption (Make Before Break type)
JUD410382
19 of 23
UPS General data
UPS 220Vdc/115Vac - SIZE (kVA)
5
10
15
20
30
40
50
60
80
100
ENVIRONMENTAL DATA Acoustic noise level (according EN 50091) - dB EMI Operating Temperature (°C) Storage Temperature (°C) Relative Humidity (non condens.) Ventilation
< 67
< 70
< 72
EN 61000-6-2 /EN 61000-6-4 -10 .. +40 -20 .. +70 < 95% (with tropicalization on request) Forced (redundant fans on request) < 2000 ( de-rating According EN62040-3)
Altitude (mt. above see level)
MECHANICAL DATA Protection degree (IEC60529)
IP 20 (other on request)
Painting colour and type Dimensions (mm) W D H Weights (Kg) Input/output cable connection
RAL 7035, ≥ 60μm (others on request)
Transport Transport mechanical stress Installation Accessibility
20 of 23
450
800 800 2100 500
600
1200 800 2100 650
1400 800 2100 750 830
1600 1800 2400 800 800 800 2100 2100 2100 920 1050 1190 1350
Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front (rear for fans access)
JUD410382
Rev. A 23/12/08
UPS General data 11.4 UPS 220VDC / 230VAC UPS 220Vdc/230Vac - SIZE (kVA)
5
10
15
20
30
40
50
60
80
100
ELECTRICAL DATA – GENERAL 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz)
50-60 (selectable) +/- 10%
Output voltage (Vac)
220 – 230 – 240 (selectable) +/- 1% 50-60 (selectable) +/- 4% (programmable)
Output frequency (Hz) Output power @ p.f. 0,8 (kVA)
5
10
15
20
30
40
50
60
80
100
Output power @ p.f. 1 (kW)
4
8
12
16
24
32
40
48
64
80
≥ 54 ≥ 62 ≥ 68 ≥ 77
≥ 56 ≥ 64 ≥ 70 ≥ 79
≥ 56 ≥ 63 ≥ 70 ≥ 79
≥ 58 ≥ 65 ≥ 72 ≥ 81
≥ 58 ≥ 66 ≥ 72 ≥ 81
≥ 58 ≥ 72 ≥ 75 ≥ 81
≥ 58 ≥ 72 ≥ 75 ≥ 82
≥ 58 ≥ 73 ≥ 76 ≥ 82
≥ 59 ≥ 73 ≥ 77 ≥ 84
≥ 60 ≥ 74 ≥ 79 ≥ 85
1,29
2,34
3,52
4,22
6,33
8,44
10,1
12,1
14,2
16,5
Efficiency at nominal load
25% 50% 75% 100%
Heat dissipation @ nominal load - Kw
Active load sharing (CAN-BUS connection) Up to 4 units
Parallel redundant configuration
ELECTRICAL DATA – RECTIFIER 380 – 400 – 415 (selectable) +/- 10%
Nominal input voltage (Vac) Input frequency (Hz) Input short circuit current (kA rms) (@ 400Vac, IEC standard) Max. Input power (kVA) (@ 100% load, nominal input)
50-60 (selectable) +/- 10% ≤ 16 (other on request) 8,3
16,4
24,7
32,6
48,8
65,1
81,4
97,7
128,9
≤ 27% with 6 pulses bridge (standard) ≤ 12% with 12 pulses bridge (on request) ≤ 6% with 12 pulses plus input THD filter (on request)
Input current distortion (THD) (@ 100% load, nominal input) Input power factor (@ 100% load, nominal input) Output voltage (Vdc)
≥ 0,75 (No manual charge provided) 220
- Nominal - Floating charge
2,2÷2,3 V/cell for Lead acid battery (Adjustable) 1,4÷1,5 V/cell for NiCd battery (Adjustable)
- Boost charge
2,4÷2,45 V/cell for Lead acid battery (Adjustable) 1,5÷1,65 V/cell for NiCd battery (Adjustable)
- Manual (equalizing) charge
up to 2,7 V/cell for Lead acid battery up to 1,7 V/cell for NiCd battery Forced boost push button (on request) Thermal compensation for lead acid battery (on request) ≤ 2 (other on request)
Output ripple (% rms) Rated output current (A)
Rev. A 23/12/08
159,4
25
50
JUD410382
75
100
150
200
250
300
400
500
21 of 23
UPS General data
UPS 220Vdc/230Vac - SIZE (kVA)
5
10
15
20
30
40
50
60
80
100
278 348
348 435
ELECTRICAL DATA – INVERTER 180 ÷ 300
Input voltage range (Vdc)
220 – 230 – 240 (selectable) +/- 1%
Output voltage (Vac)
50-60 (selectable)
Output frequency (Hz) Output frequency stability (Hz)
+/- 0,001 +/- 2 (programmable)
- Free running quartz oscillator - Inv. Synchronized with mains Output current @ 230Vac (A) 17 21
- p.f. 1 - p.f. 0,8
34 43
52 65
69 87
104 130
139 174
174 217
209 261
Output harmonic distortion (THD) < 2% < 5%
- Linear load - Not linear load (75% Pn, CF=3:1)
125% Pn for 10’, 150% Pn for 1’, 200% In for 100ms
Overload capability (p.f. 0,8) 34
Short circuit current (A) Short circuit protection Output voltage static stability Output voltage dynamic stability
0 - 50% 0% - 100%
68
104 138 208 278 308 418 556 696 200% In for 100ms, then 125% In Inverter stop after 5 seconds (according to EN62040-3) +/- 1% +/- 5% With recovery at +/- 1% within 40ms +/- 8% With recovery at +/- 2% within 40ms
ELECTRICAL DATA – STATIC BYPASS Automatic static bypass Nominal input voltage (Vac) Input frequency (Hz) Overload capability (p.f. 0,8)
Electronic thyristor switch 220 – 230 – 240 (selectable) +/- 20% 50-60 (selectable) +/- 4% (programmable) 150% Pn continuous, 200% Pn for 10’, 2000% In for 1 cycle Fast acting fuse
Static bypass protection Transfer INV Æ BYPASS
< ¼ cycle < 1ms
- Sensing and transfer time - Commutation time Retransfer INV Æ BYPASS - Sensing and transfer time Manual bypass
22 of 23
0 seconds (controlled) Block on mains after 6 commutation in 2 minutes With electric security and without interruption (Make Before Break type)
JUD410382
Rev. A 23/12/08
UPS General data
UPS 220Vdc/230Vac - SIZE (kVA)
5
10
15
20
30
40
50
60
80
100
ENVIRONMENTAL DATA Acoustic noise level (according EN 50091) - dB EMI Operating Temperature (°C) Storage Temperature (°C) Relative Humidity (non condens.) Ventilation
< 67
< 70
< 72
EN 61000-6-2 /EN 61000-6-4 -10 .. +40 -20 .. +70 < 95% (with tropicalization on request) Forced (redundant fans on request) < 2000 ( de-rating According EN62040-3)
Altitude (mt. above see level)
MECHANICAL DATA Protection degree (IEC60529)
IP 20 (other on request)
Painting colour and type Dimensions (mm) W D H Weights (Kg) Input/output cable connection
RAL 7035, ≥ 60μm (others on request)
Transport Transport mechanical stress Installation Accessibility
Rev. A 23/12/08
800 800 2100 450
500
1200 800 2100 600
650
750
1400 800 2100 830
920
1600 800 2100
1800 800 2100
1050 1140 1300
Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front (rear for fans access)
JUD410382
23 of 23
AC UPS Installation, Operating and Maintenance Manual
COMMESSA - JOB :
CLIENTE - CUSTOMER :
080A1696 ORDINE N° - ORDER N°
BIO-QUR-O42 REV.B D T D 2 1 . 0 4 . 2 0 0 8 DESCRIZIONE PROGETTO - PROJECT DESCRIPTION :
CONSTRUCTION OF QURAYYAH OPEN CYCLE GAS TURBINE POWER PLANT BATTERIES, BATTERY CHARGERS & UPS SYSTEMS IMPIANTO - SITE :
QURAYYAH SAUDI ARABIA
TITOLO - TITLE :
AC UPS INSTALLATION, OPERATING AND MAINTENANCE MANUAL MATRICOLA - PART NUMBER :
CODICE DOC. - DOCUMENT NUMBER :
114-115-121-122-123-124-125-127-128 / 08
JGE410503
Il presente documento è di esclusiva della BORRI S.r.l. che tutelerà i propri diritti a termine di legge This document remains the exlusive property of BORRI S.r.l. and we reserve all rights according to copyright laws Rev.
-
Description
First Issue
Date 10.12.2008
Checked
Released
V.Lomonico Approved
P.Conti
Date
Type of doc.
Pag. N°
Pag. Tot.
A4
1
77
10.12.2008 Date
10.12.2008 Cod. JGE410503
AC UPS Installation, Operating and Maintenance Manual
INDEX 1.
UPS GENERAL DESCRIPTION AND INSTALLATION…………………….
3
2.
AC UPS FRONT PANEL ……………………………………………………….
15
3.
START-UP, SHUT DOWN AND MANUAL BY-PASS PROCEDURE…….
70
Rev.
-
Description
First Issue
Date 10.12.2008
Checked
Released
V.Lomonico Approved
P.Conti
Date
Type of doc.
Pag. N°
Pag. Tot.
A4
2
77
10.12.2008 Date
10.12.2008 Cod. JGE410503
Ups general description & installation
UPS GENERAL DESCRIPTION AND INSTALLATION
Index 1. INTRODUCTION.................................................................................. 3 1.1 ENVIRONMENT ................................................................................................ 3 1.1.1
UPS treatment at the end of service life ................................................. 3
1.1.2
Packing ..................................................................................................... 3
1.1.3
Lead battery .............................................................................................. 3
1.2 SAFETY RULES ............................................................................................... 3
2.
1.2.1
Safety of persons ..................................................................................... 3
1.2.2
Product safety .......................................................................................... 3
1.2.3
Special precautions ................................................................................. 4
UPS GENERAL DESCRIPTION......................................................... 4 2.1
TYPOLOGY ...................................................................................................... 4
2.2
SYSTEM DESCRIPTION .................................................................................. 6
2.2.1
Rectifier ..................................................................................................... 6
2.2.2
Inverter ...................................................................................................... 6
2.2.3
Battery charger......................................................................................... 6
2.2.4
Static bypass ............................................................................................ 6
2.2.5
Manual bypass ......................................................................................... 6
2.2.6
Front panel................................................................................................ 6
2.3
3.
2.3.1
Normal operation ..................................................................................... 7
2.3.2
Load supplied by bypass due to inverter fault ...................................... 7
2.3.3
Rectifier failure or mains failure ............................................................. 8
2.3.4
Manual bypass ......................................................................................... 8
INSTALLATION .................................................................................. 9 3.1
Rev.
/
OPERATING STATUS ...................................................................................... 7
RECEIPT OF THE UPS .................................................................................... 9
Descrizione Description
First issue
Data Date
Emesso Issued
10.12.2008 V.Lomonico
Controllato Checked
Approvato Approved
P.Conti
E.Simoni
Lingua Language
Pagina Page
di Pag. of Pag.
E
1
11
Codice / Code
JGE410503
Ups general description & installation 3.2
HANDLING OF THE UPS ................................................................................ 9
3.3
POSITIONING AND INSTALLATION ............................................................ 11
3.4
ELECTRICAL CONNECTION ........................................................................ 11
3.5
BATTERY INSTALLATION ........................................................................... 11
Index of pictures Picture 1 - Block diagram ............................................................................................................................. 5 Picture 2 - Normal operation ......................................................................................................................... 7 Picture 3 - Load supplied by bypass............................................................................................................. 7 Picture 4 - Rectifier failure or mains failure................................................................................................... 8 Picture 5 - Manual bypass ............................................................................................................................ 8 Picture 6 - Handling of UPS ........................................................................................................................ 10
2 of 11
JGE410503
10.12.2008
Ups general description & installation
1.
INTRODUCTION
1.1 ENVIRONMENT 1.1.1 UPS treatment at the end of service life The UPS manufacturer undertakes to recycle, by certified companies and in compliance with all applicable regulations, all UPS products recovered at the end of their service life (contact your branch office). 1.1.2 Packing UPS packing materials must be recycled in compliance with all applicable regulations. 1.1.3 Lead battery This product contains lead-acid batteries. Lead is a dangerous substance for the environment if it is not correctly recycled by specialised companies. 1.2 SAFETY RULES 1.2.1 Safety of persons The UPS must be installed in a room with restricted access (qualified personnel only, according to standard EN50091-1-2). UPS power outlets may be energised even if the UPS is disconnected from the ACpower source (because the UPS is connected to a battery). Dangerous voltage levels are present within the UPS. It should be opened exclusively by qualified service personnel. Warning, after the UPS shut-down, a dangerous voltage will be present on the battery circuit breaker BCB. The UPS must be properly earthed. The battery supplied with the UPS contains small amounts of toxic materials. To avoid accidents, the directives listed below must be observed. ω Never operate the UPS if the ambient temperature and relative humidity are higher than the levels specified in the documentation. Never burn the battery (risk of explosion). ω Do not attempt to open the battery (the electrolyte is dangerous for the eyes and skin). ω Comply with all applicable regulations for the disposal of the battery. 1.2.2 Product safety A protection circuit breaker must be installed upstream and be easily accessible. Never install the UPS near liquids or in an excessively damp environment. Never let a liquid or foreign body penetrate inside the UPS. Never block the ventilation grates of the UPS. Never expose the UPS to direct sunlight or a source of heat. 10.12.2008
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Ups general description & installation 1.2.3 Special precautions ω The UPS connection instructions contained in this manual must be followed in the indicated order. ω Check that the indications on the rating plate correspond to your AC-power system and to the actual electrical consumption of all the equipment to be connected to the UPS. ω If the UPS must be stored prior to installation, storage must be in a dry place. ω The admissible storage temperature range is -10° C to +70° C. ω If the UPS remains de-energised for a long period, we recommend that you energise the UPS for a period of 24 hours, at least once every month. This charges the battery, thus avoiding possible irreversible damage. ω The UPS is designed for normal climatic and environmental operating conditions as defined in the data sheets. ω Using the UPS within the given limits guarantees its operation, but may affect the service life of certain components, particularly that of the battery and its autonomy. The maximum storage time of the UPS is limited due to the need to recharge its integrated battery. ω Unusual operating conditions may justify special design or protection measures: harmful smoke, dust, abrasive dust, humidity, vapor, salt air, bad weather or dripping, explosive dust and gas mixture, extreme temperature variations, bad ventilation, conductive or radiant heat from other sources, strong electromagnetic fields, radioactive levels higher than those of the natural environment, fungus, insects, vermin, etc., battery operating conditions.
The UPS must always be installed in compliance with: -
the requirements of HD 384.4.42 S1/A2 - Chapter 42: thermal effects.
-
standard IEC 60364-4-482 - Chapter 482: Fire protection.
Protection from
The manufacturer declines all responsibility for damages to people or equipment deriving from non-fulfilment of the above.
2.
UPS GENERAL DESCRIPTION
2.1 TYPOLOGY The UPS covered by this manual are on-line, double conversion; the inverter supplies always energy to the load, whether mains is available or not (according to the battery autonomy time).
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Ups general description & installation WARNING The UPS output is energized even during mains failure, therefore in compliance with the prescriptions of EN 50091-1, the installer will have to identify the line or the plugs supplied by the UPS making the User aware of this fact. This configuration guarantees the best service to the User, as it supplies clean continuously regulated power and guarantees the voltage and frequency will be stabilised at nominal value independently from mains status. Thanks to the double conversion, it makes the load completely immune from micro-interruptions due to excessive mains variation, and prevents damage to the critical load (Computer Instrumentation - Scientific equipment etc.).
Picture 1 - Block diagram
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Ups general description & installation 2.2 SYSTEM DESCRIPTION 2.2.1 Rectifier It converts the three phase voltage of the mains into continuous DC voltage. It’s designed to supply the inverter at full load and the battery at the maximum recharge current. The system offers very low ripple content during the charging cycle. 2.2.2 Inverter It converts the continuous voltage coming from the rectifier or from the battery into alternating voltage stabilized in amplitude and frequency. The inverter uses IGBT technology with a frequency commutation of approximately 10 KHz. The control electronics is completely digital and uses a 16 Bit μP, that, thanks to its processing capability, generates an excellent output sine-wave, which has a very low distortion even in presence of loads having high crest factor currents. 2.2.3 Battery charger The battery charger control logic is completely integrated inside the total-controlled rectifier control board; the battery is charged, according to the DIN 41773 Standard, every time it has been partially or completely discharged and it is kept floating, even when it’s charged, to compensate for any autodischarge. 2.2.4 Static bypass It’s designed to transfer the load between INVERTER and MAINS, and vice-versa, without break, and uses SCR’s as power commutation elements. 2.2.5 Manual bypass It‘s used to by-pass the UPS, supplying the load directly to the mains in case of maintenance or serious failure. WARNING The sequence of bypass switching must be carried out with respect to the procedure indicated on the UPS and in the chapter “Start-up, shut-down and manual bypass”. The manufacturer cannot accept responsibility for damages arising from incorrect operation. 2.2.6 Front panel The front panel of the UPS, consisting of a four row alphanumeric displays plus a keyboard, allows the complete monitoring of the UPS status and the setting of the parameters. The mimic diagram helps to understand the operating status of the UPS. For more information see the chapter “FP-AC-UPS FRONT PANEL OPERATING MANUAL”.
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Ups general description & installation 2.3 OPERATING STATUS The following paragraphs show all the possible operating status of the UPS. 2.3.1 Normal operation The inverter is supplied by the rectifier; the load, through the static switch, is supplied directly by the inverter output.
Picture 2 - Normal operation
2.3.2 Load supplied by bypass due to inverter fault The load is transferred to bypass through the static switch; the transfer is carried out without interruption.
Picture 3 - Load supplied by bypass
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2.3.3 Rectifier failure or mains failure The inverter is supplied by the battery for the required autonomy time; the load, through the static switch, is supplied directly by the inverter output.
Picture 4 - Rectifier failure or mains failure
2.3.4 Manual bypass The load is supplied by the mains through the manual bypass; the operator can work in safety on the UPS to carry out maintenance or repairing operations.
Picture 5 - Manual bypass
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3.
INSTALLATION
3.1 RECEIPT OF THE UPS When the UPS is received, please attend immediately to its unpacking and carry-out an accurate visual check to be sure that the equipment has not been damaged during transport. IMPORTANT In case of objections relating to damage incurred during transport these must be immediately notified to the transportation company after receipt of the equipment. When the UPS is not installed immediately it must be stored carefully in vertical position, as indicated on the packing and conserved in a dry and sheltered room in its box so that it is protected from dust. 3.2 HANDLING OF THE UPS Before positioning the UPS, in order to avoid risks of turnover, it’s recommended to move the system on the wood pallet on which the UPS is fixed. Before the positioning in the final location, remove the UPS from the pallet. The UPS can be lifted and handled using a pallet truck or a forklift after having takenoff (manually), the lower frontal panel, so that a pallet truck or a forklift can be inserted (see picture 6). The UPS technical data are shown on a label fixed on the internal side of the front door.
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Remove
Forklift
Picture 6 - Handling of UPS
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Ups general description & installation 3.3 POSITIONING AND INSTALLATION The UPS must be installed in a clean and dry room, preferably not dusty. The User must ensure that there is enough air exchange in the room so that the equipment can be adequately cooled; if this is not guaranteed, the room must be adequately aired. 3.4 ELECTRICAL CONNECTION The electrical connection is part of the work which is normally provided by the supplier that carries out the electrical installation and not by the UPS manufacturer. For this reason, the following recommendations are only an indication, as the UPS manufacturer is not responsible for the electrical installation. In any case we recommend to carry-out the installation and the electrical connections of the input and output in compliance with the local standards. During the electrical installation take particular care to check the phase rotation with a suitable instrument. The terminal boards are positioned at the front of the UPS, under the breakers. To access the terminals remove the protection, extracting the fixing bolts. WARNING The connection to the mains must be carried out with protection fuses between the mains and the UPS. The use of residual current devices in the line supplying the UPS is unadvisable. The leakage current due to the RFI filters is rather high and it can cause spurious tripping of the protection device. According to the EN50091-1 standard, in order to take into account the UPS’ leakage current, residual current devices having adjustable threshold can be used.
3.5 BATTERY INSTALLATION IMPORTANT For battery installation please respect the prescriptions of the EN50091-1 standard, paragraph 4.5. To obtain the battery life indicated by the battery manufacturer, the operating temperature must remain between 0 and 25 °C. However, although the battery can operate up to 40 °C , there will be a significant reduction of the battery life. To avoid the formation of any kind of potentially explosive hydrogen and oxygen mixture, suitable ventilation must be provided where the battery are installed (see EN50091-1 annex N). It is recommended to install the batteries when the UPS is capable of charging them. Please remember that, if the battery is not charged for periods over 2-3 months they can be subject to irreparable damage.
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AC-UPS FRONT PANEL
Index 1
PCB OPERATION ................................................................................. 4 1.1
TROUBLESHOOTING ........................................................................................ 4
1.2
MIMIC DESCRIPTION......................................................................................... 8
1.3
NAVIGATION .................................................................................................... 11
1.3.1
Default Menu ............................................................................................. 11
1.3.2
Main Menu ................................................................................................. 11
1.3.3
Measures Menu......................................................................................... 12
1.3.3.1 1.3.3.2 1.3.3.3 1.3.3.4 1.3.3.5 1.3.4
Menu Input .............................................................................................. 13 Menu Output ........................................................................................... 14 Bypass .................................................................................................... 15 AC/DC ..................................................................................................... 16 Battery .................................................................................................... 16
Alarms – Status ........................................................................................ 17
1.3.4.1 UPS Status ............................................................................................. 18 1.3.4.2 History ..................................................................................................... 18 1.3.4.3 The alarms and status list ....................................................................... 19 1.3.5
Special ....................................................................................................... 20
1.3.5.1 Reset UPS .............................................................................................. 21 1.3.5.2 Battery operation..................................................................................... 21 1.3.5.2.1 Boost charge .................................................................................... 22 Deep battery test ............................................................................................... 23 1.3.5.2.2 Quick battery test.............................................................................. 23 1.3.5.3 UPS settings ........................................................................................... 24 1.3.5.3.1 Clock setting ..................................................................................... 25 1.3.5.3.2 Rectifier Settings .............................................................................. 25 1.3.5.3.2.1 Boost charge parameters setting ............................................... 27 1.3.5.3.2.1.1 Mains fault delay modification ......................................... 28 1.3.5.3.2.1.2 Safety time modification ................................................... 28 1.3.5.3.2.1.3 Boost charge voltage modification .................................. 28 1.3.5.3.2.1.4 Float-boost current modification ..................................... 29 1.3.5.3.2.1.5 Boost-float current modification ...................................... 29 Rev.
/
Descrizione Description
First Issue
Data Date
Emesso Issued
10.12.2008 V.Lomonico
Controllato Checked
Approvato Approved
P. Conti
E. Simoni
Lingua Language
Pagina Page
I
1
di Pag. of Pag.
56
Codice / Code
JGE410503
AC-UPS FRONT PANEL 1.3.5.3.2.2 Float charge parameters ............................................................ 29 1.3.5.3.2.2.1 Floating voltage modification........................................... 30 1.3.5.3.2.2.2 Recharge max current modification ................................ 30 1.3.5.3.2.2.3 Thermal compensation per cell modification ................. 31 1.3.5.3.2.3 Input parameters ........................................................................ 31 1.3.5.3.2.3.1 Input voltage modification ................................................ 32 1.3.5.3.2.3.2 High input voltage modification ....................................... 33 1.3.5.3.2.3.3 Low input voltage modification ........................................ 33 1.3.5.3.2.3.4 Input frequency modification ........................................... 33 1.3.5.3.2.3.5 High input frequency modification .................................. 34 1.3.5.3.2.3.6 Low input frequency modification ................................... 34 1.3.5.3.2.4 Output parameters ..................................................................... 34 1.3.5.3.2.4.1 Max output voltage modification ..................................... 35 1.3.5.3.2.4.2 Max Vout delay modification ............................................ 35 1.3.5.3.2.4.3 Min output voltage modification ...................................... 36 1.3.5.3.2.4.4 Diesel mode voltage modification ................................... 36 1.3.5.3.3 Inverter Settings ............................................................................... 37 1.3.5.3.3.1 Input parameters ........................................................................ 37 1.3.5.3.3.1.1 Low DC shutdown modification ....................................... 38 1.3.5.3.3.1.2 High DC shutdown modification ...................................... 38 1.3.5.3.3.1.3 Max input voltage modification ........................................ 39 1.3.5.3.3.2 Output parameters ..................................................................... 39 1.3.5.3.3.2.1 Output nominal voltage modification .............................. 40 1.3.5.3.3.2.2 Output overvoltage modification ..................................... 40 1.3.5.3.3.2.3 Output undervoltage modification ................................... 40 1.3.5.3.4 Bypass Settings ................................................................................ 41 1.3.5.3.4.1 Bypass parameters .................................................................... 41 1.3.5.3.4.1.1 Frequency range modification ......................................... 42 1.3.5.3.4.1.2 Bypass high voltage modification ................................... 42 1.3.5.3.4.1.3 Bypass low voltage modification ..................................... 43 1.3.5.3.5 Battery Settings ................................................................................ 43 1.3.5.3.5.1 Battery information ..................................................................... 44 1.3.5.3.5.1.1 Battery size modification .................................................. 44 1.3.5.3.5.2 Discharge parameters ................................................................ 44 1.3.5.3.5.2.1 Discharge level 1 modification ......................................... 45 1.3.5.3.5.2.2 Discharge level 2 modification ......................................... 46 1.3.5.3.5.2.3 Discharge level 3 modification ......................................... 46 1.3.5.4 History reset ............................................................................................ 46 1.3.6
Info ............................................................................................................. 46
1.3.6.1 Firmware version .................................................................................... 48 1.3.6.2 Serial number.......................................................................................... 48 1.3.6.3 Statistics ................................................................................................. 49 1.4
TRANSPARENT MODE .................................................................................... 50
1.5
MODBUS COMMUNICATION .......................................................................... 50
1.6
PCB PROGRAMMING ...................................................................................... 53
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APPENDIX A. LIST OF COMANDS ........................................................ 54
Index of pictures Picture 1: Front Panel …………………………………………………………………………………….…………8 Picture 2: Mimic Diagram ……………………………………………………………………………………………8 Picture 3: Front Panel Alarm List
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1 PCB OPERATION 1.1
TROUBLESHOOTING
The alphanumeric display offers a complete diagnostic of the system through visualisation of alarms and UPS operating modes. Each parameter is associated to a code in order to be stored in the events history. However certain alarms are associated to a code which identifies the cause of the alarm. The table below reports the detailed list of the possibile alarms: =
A1 MAINS FAULT
Rectifier input mains failure
Possible causes: 1) Plant Black-out 2) Problems in the distribution upstream of the UPS 3) RICB breaker open or input fuses blown Code:
A2 RECT BLOWN FUSES
1 0
= Wrong phase rotation = Black Out
=
Input fuses blown
Possible causes: 1) Rectifier bridge failure Code:
A3 RECT HIGH TEMP
1 2
Problem with the rectifier 1 bridge Problem with the rectifier 2 bridge
=
Rectifier bridge overtemperature
Possible causes: 1) Excessive load 2) Cooling system failure or malfunctioning 3) Wrong position of the UPS unit (minimum clearances, such as distance from the walls, not respected) Code:
1 2
Problem with the rectifier 1 bridge Problem with the rectifier 2 bridge
A4 RECT OVERLOAD
=
OVERLOAD
A5 MAX DC VOLTAGE
=
Rectifier maximum output voltage
A6 MIN DC VOLTAGE
=
Rectifier minimum output voltage
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A7 CARGING FAULT
=
Battery charging error
A8 RICB OPEN
=
Rectifier input circuit breaker open
A9 BCB OPEN
=
Battery circuit breaker open
A10 BATT DISCHARGING
=
Battery discharging
Possible causes: 1) Rectifier input mains failure (alarms A1 or A2 present) 2) Rectifier failure A11 BATTERY LOW
=
Minimum battery voltage
A12 BATTERY IN TEST
=
Battery test running
A13 BATTERY FAULT
=
Battery test failed
Possibile causes: 1) The test has been carried out with the battery not perfectly charged 2) One or more battery cells are damaged A14 INV DC FAULT
=
Inverter input voltage out of tolerance.
A15 INV HIGH TEMP
=
Inverter bridge overtemperature
Possible causes: 1) Excessive load 2) Cooling system failure or malfunctioning 3) Wrong position of the UPS unit (minimum clearances, such as distance from the walls, not respected) A16 INV OUT OF TOL
=
Inverter output voltage out of tolerance
Possible causes: 1) Short circuit current limitation (current exceeding 200%) 2) Inverter failure 3) Inverter switched off A17 INV CURR STOP
=
Inverter bridge switched off per maximum current
Possible causes: 1) Short circuit for more than 5 sec. at the UPS output 2) Inverter bridge failure A18 INV NO SYNCHR Issued 10.12.2008
=
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A19 OVERLOAD
=
Inverter overload The load exceed the nominal load. Thermal image protection already activated
A20 BYPASS FAULT
=
Emergency line not available
Possible causes: 1) 2) 3) 4) A21 BYP FEED LOAD
=
Emergency line failure Distribution problems upstream of the UPS SBCB circuit breaker open Wrong phase rotation Load fed by static bypass
Possible causes: 1) Inverter overload 2) Thermal image protection activated 3) Forced commutation due to the bypass switch operation (alarm A27) 4) Inverter failure 5) Load blocked on bypass (alarm A26) A22 BYPASS SWITCH
=
Closure of the commutation switch which forces the load to bypass (e.g maintenance purposes)
A23 RETR BLOCKED
=
Load blocked on bypass
Possible causes: 1) Repeated inverter overloads A24 FANS FAILURE
=
Cooling fans failure
A25 UPS OCB OPEN
=
UPS output circuit breaker open
A26 MBCB CLOSED
=
Manual bypass circuit breaker closed
A27 EPO PRESSED
=
Emergency power off pushbutton pressed
A40 DC EARTH FAULT
=
Earth fault on DC circuit (Optional)
A41 ROCB OPEN
=
Rectifier output circuit breaker open (Optional)
A50 CONFIGURABLE
=
User programmable
A51 CONFIGURABLE
=
User programmable
A52 CONFIGURABLE
=
User programmable
A53 CONFIGURABLE
=
User programmable
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AC-UPS FRONT PANEL A54 CONFIGURABLE
=
User programmable
A55 CONFIGURABLE
=
User programmable
A56 CONFIGURABLE
=
User programmable
A57 CONFIGURABLE
=
User programmable
A58 CONFIGURABLE
=
User programmable
A59 CONFIGURABLE
=
User programmable
A61 COMMUNIC FAULT
=
Communication failure
1 2 4 0
= I2C error. = Rectifier communication interrupted = Inverter communication interrupted else
A62 RECT COM ALARM
=
At least one of the rectifier related alarms still active
A63 INV COM ALARM
=
At least one of the inverter related alarms still active
A64 COMMON ALARM
=
At least one of the alarms still active
Code:
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1.2
MIMIC DESCRIPTION
Picture 1: Front Panel
Picture 2: Mimic diagram
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AC-UPS FRONT PANEL Picture shows the mimic diagram with leds present on the front panel. The following chapter describes the meaning of the leds: LED 1
⇒
Lit-up green = Rectifier input mains present. Else off.
LED 2
⇒
Lit-up green = Rectifier running correctly Lit-up red = Rectifier failure
LED 3
⇒
Lit-up green = Battery OK. Lit-up orange = Battery discharging Lit-up red = Battery test failed, BCB open, battery not operating
LED 4
⇒
Lit-up green = Inverter OK. Lit-up red = Inverter failure
LED 5
⇒
Lit-up green = Load fed by inverter OFF = SSI switched off.
LED 6
⇒
Lit-up green = Voltage present on the load. Lit-up orange = OCB circuit breaker open.
LED 7
⇒
Lit-up orange = Load fed by static bypass. Else OFF.
LED 8
⇒
Lit-up green = Emergency line OK. Else OFF.
LED 9
⇒
Lit-up orange = MBCB closed. Else OFF.
LED 10
⇒
Lit-up red = EPO pushbutton pressed. Else OFF.
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1.3
NAVIGATION
1.3.1 Default Menu
xxx kVA
XXX YYY ZZZ V XXX YYY ZZZ A
The default screen appears on the LCD panel when the UPS is in normal operation (with no alarm present); it shows the name of the UPS, the nominal power and the values of the UPS output voltage and current. The main menu, with all the functions and parameters, is accessed pressing the arrow key (chapter 1.3.2) 1.3.2 Main Menu The main menu screen appears as described below:
xxx kVA
Default screen: pressing or other menus are scrolled down.
XXX YYY ZZZ V XXX YYY ZZZ A
xxx kVA
MEASURES
xxx kVA
ALARMS - STATUS
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MEASURES Menu. It is accessed pressing the key (see1.3.3), pressing the keys or other menus are scrolled down key leads Pressing the back to Default Menu.
ALARMS – STATUS Menu. It is accessed pressing the key (see 1.3.4), pressing the keys or other menus are scrolled key down. Pressing the leads back to Default Menu. 11 of 56
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xxx kVA
SPECIAL Menu. It is accessed pressing the key (see 1.3.5), pressing the keys or other menus are scrolled down. Pressing the key leads back to Default Menu.
SPECIAL
xxx kVA
INFO Menu. It is accessed pressing the key (see 1.3.6), pressing the keys or other menus are scrolled down. Pressing the key leads back to Default Menu.
INFO
The menus are scrolled in cycle, therefore the Default screen and INFO Menu are considered consecutive. 1.3.3 Measures Menu The Measures Menu screen is described below: INPUT
OUTPUT
BYPASS
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MEASURES Menu INPUT. It is accessed pressing the key (see 1.3.3.1), pressing the keys or other menus are scrolled down. Pressing the key leads back to MEASURES Menu (§1.3.2).
MEASURES Menu OUTPUT. It is accessed pressing the key (see 1.3.3.2), pressing the keys or other menus are scrolled down. Pressing the RESET key leads back to MEASURES Menu (§1.3.2). MEASURES Menu BYPASS. It is accessed pressing the key (see 1.3.3.3), pressing the keys or other menus are scrolled down. Pressing the key leads back to MEASURES Menu. (§1.3.2).
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AC/DC
BATTERY
EXIT
MEASURES Menu AC/DC. It is accessed pressing the key (see 1.3.3.4), pressing the keys or other menus are scrolled down. Pressing the key leads back to MEASURES menu (§1.3.2).
MEASURES Menu BATTERY. It is accessed pressing the key (see 1.3.3.5), pressing the keys or other menus are scrolled down. Pressing the key leads back to MEASURES Menu (§1.3.2).
Pressing the or keys other sub-menus are scrolled down. Pressing the key or key leads back to MEASURES Menu (§1.3.2).
The menus are scrolled in cycle, therefore Menu INPUT and Menu EXIT are considered consecutive.
1.3.3.1 Menu Input XXX YYY ZZZ V
XXX YYY ZZZ A
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Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures INPUT (§1.3.3). Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures INPUT (§1.3.3).
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XX.X
Hz
XXX
kVA
EXIT
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures INPUT (§1.3.3).
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures INPUT (§1.3.3).
Pressing the key or key you go back to Menu Measures INPUT (§1.3.3), pressing the keys or input measures are shown.
1.3.3.2 Menu Output
XXX YYY ZZZ V
XXX YYY ZZZ A
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Pressing the key the following parameter is shown, while the key leads to the previous screen. key leads Pressing the back to Menu Measures OUTPUT (§1.3.3).
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures OUTPUT (§1.3.3).
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XX.X
Hz
XXX
kVA
EXIT
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures OUTPUT (§1.3.3).
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures OUTPUT (§1.3.3).
Pressing the key or key you go back to Menu Measures OUTPUT (§1.3.3), pressing the keys or output measures are shown.
1.3.3.3 Bypass
XXX YYY ZZZ VLL
xx.x
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Hz
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Pressing the key the following parameter is shown, while the key leads to the previous screen. key leads Pressing the back to Menu Measures BYPASS (§1.3.3).
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures BYPASS (§1.3.3).
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EXIT
Pressing the key or key you go back to Menu Measures BYPASS (§1.3.3), pressing the keys or the bypass measures are shown.
1.3.3.4 AC/DC XXX V XXX A
EXIT
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures AC/DC (§1.3.3).
Pressing the key or key you go back to Menu Measures AC/DC (§1.3.3), or the pressing the keys AC/DC measures are shown.
1.3.3.5 Battery
XXX V XXX A
XXX min
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Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures Battery (§1.3.3). Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures Battery (§1.3.3).
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XX °C
XX Ah
EXIT
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures Battery (§1.3.3).
Pressing the key the following parameter is shown, while the key leads to the previous screen. Pressing the key leads back to Menu Measures Battery (§1.3.3).
Pressing the key or key you go back to Menu Measures BATTERY (§1.3.3), pressing the keys or the battery measures are shown.
1.3.4 Alarms – Status The Alarms-Status screen is described below: UPS STATUS
HISTORY
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JGE410503
Menu Alarms-Status of the UPS STATUS. It is accessed pressing the key (§1.3.4.1), pressing the keys or other sub-menus are scrolled down. Pressing the key leads back to Menu ALARMS-STATUS (§1.3.2). Alarms-Status HISTORY. It is accessed pressing the key (§1.3.4.2), pressing the keys or other sub-menus are scrolled down. Pressing the key leads back to Menu ALARMSSTATUS (§1.3.2). 17 of 56
AC-UPS FRONT PANEL
EXIT
Pressing the keys or other sub-menus are scrolled down. Pressing the key or key leads back to Menu ALARMS-STATUS (§1.3.2).
The menus are scrolled in cycle, therefore Menu UPS STATUS and Menu EXIT are considered consecutive. 1.3.4.1 UPS Status
XX: XXXXXXXXXX CODE N: XX
Pressing the keys or the status and/or the alarm list of the UPS is scrolled down. Pressing the key leads back to Menu Alarms-Status UPS STATUS (§1.3.4).
This screen permits the visualisation of all alarms and/or UPS status active. The third row shows the description of the UPS status and/or alarm (chapter 1.3.4.3), and the fourth row shows the code number. 1.3.4.2 History
COR/TOT ID XX:XX:XX XX/XX/XX
Pressing the keys or the alarms list can be scrolled down. Pressing the key leads back to Menu Alarms-Status HISTORY (§1.3.4).
This screen shows all the events memorised in the HISTORY list. The list contains all the alarms that were activated and also all the alarms that got cleared up in the meantime. The third row shows: index of the current alarm reported with the respect to the total number of all alarms (COR/TOT) alarm identification code (ID, e.g. A1) if the alarms was cleared up in the meantime, next to identification code ID will be shown asterisk sign. The forth row shows the time and the date relating the event. 18 of 56
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL
1.3.4.3 The alarms and status list Alarms list
Status list
A1 A2 A3 A4 A5 A6 A7
MAINS FAULT RECT BLOWN FUSES RECT HIGH TEMP RECT OVERLOAD MAX DC VOLTAGE MIN DC VOLTAGE CHARGING FAULT
S1
A8 A9 A10 A11 A12 A13
RICB OPEN BCB OPEN BATT DISCHARGING BATTERY LOW BATTERY IN TEST BATTERY FAULT
S2
A14 A15 A16 A17 A18 A19
RECTIFIER OK
S2-1 S2-2 S2-3
BATT ON CHARGE Floating Charge Boost Charge Manual Charge
S3
BATTERY OK
INV DC FAULT INV HIGH TEMP INV OUT OF TOL INV CURR STOP INV NO SYNCHR OVERLOAD
S4
INVERTER OK
A20 A21 A22 A23 A24 A25 A26 A27
BYPASS FAULT BYP FEED LOAD BYPASS SWITCH RETR BLOCKED FANS FAILURE OCB OPEN MBCB CLOSED EPO PRESSED
S5 S6
BYPASS OK INV SYNCHRONIZED
S7
INV FEED LOAD
A40 A41
DC GROUND FAULT ROCB OPEN
A50-A59 CONFIGURABILI A61 A62 A63 A64
COMMUNIC FAULT RECT COM ALARM INV COM ALARM UPS COMMON ALARM
The status shown in this list is always displayed in ascending order when the UPS STATUS menu is entered, the alarms are shown when they are present and can be Issued 10.12.2008
JGE410503
19 of 56
AC-UPS FRONT PANEL silenced with the buzzer. The alarms remain displayed whilst they are present and they are automatically stored in the event history memory with date and time. 1.3.5 Special IMPORTANT When entering the SPECIAL menu a password is required, as the operations which are allowed need to be carried out by competent personnel.
Insert the password *** and press ENTER
Password is inserted using the numeric board or pressing the keys or . Press key to confirm. If the password inserted is correct, the menu can be accessed, on the contrary the menu SPECIAL is shown again (§1.3.2).
Menu special RESET UPS. it is accessed pressing the key (§1.3.5.1), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu SPECIAL (§1.3.2).
RESET UPS
BATTERY OPERATION
UPS SETTINGS
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Menu special BATTERY OPERATION. It is accessed pressing the key (§1.3.5.2), or other pressing the keys sub-menus can be scrolled down Pressing the key leads back to menu SPECIAL (§1.3.2).
Menu special UPS SETTINGS. It is accessed pressing the key (§1.3.2), pressing the keys other sub-menus can be or scrolled down Pressing the key leads back to menu SPECIAL (§1.3.2). JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL
HISTORY RESET
EXIT
Menu special HISTORY RESET. It is accessed pressing the key (§1.3.5.4), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu SPECIAL (§1.3.2).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu SPECIAL (§1.3.2).
1.3.5.1 Reset UPS This menu provides the complete reset of the UPS system. Press ENTER to start Press RESET to exit
Pressing the key starts the reset procedure. The Default screen will be shown as soon as the reset procedure has been completed (§1.3.1). Pressing the key the procedure can be interrupted and the menu goes back to Menu special RESET UPS (§1.3.5).
1.3.5.2 Battery operation the battery operation menu enables to perform two different tests for the battery and in addition can perform the boost charge of the battery. BOOST CHARGE
Issued 10.12.2008
JGE410503
Menu battery operation BOOST CHARGE. It can be accessed (§1.3.5.2.1), pressing the key pressing the keys or other
21 of 56
AC-UPS FRONT PANEL sub-menus can be scrolled down. Pressing the key leads back to menu Special BATTERY OPERATION (§1.3.5). $ DEEP BATTERY TEST
QUICK BATTERY TEST
EXIT
Menu battery operation DEEP TEST. It can be accessed pressing the key (§0), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Special BATTERY OPERATION (§1.3.5).
Menu battery operation QUICK TEST. It can be accessed pressing the key (§1.3.5.2.2), or other pressing the keys sub-menus can be scrolled down. Pressing the key leads back to menu Special BATTERY OPERATION (§1.3.5).
Pressing the keys or other sub-menus can be scrolled down. key or Pressing the key leads back to menu Special BATTERY OPERATION (§1.3.5).
1.3.5.2.1 Boost charge
Press ENTER to start Press RESET to exit
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Pressing the key the battery boost charge gets performed. After its conclusion, the menu measures BATTERY will be shown Î VOLT/CURR (§1.3.3.5). Pressing the key leads back to battery operation BOOST CHARGE (§1.3.5.2). JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL Deep battery test
Press ENTER to start Press RESET to exit
Test in progress... XXX V XXX sec RESET to abort
TEST FAILD/PASSED Press RESET to exit
Pressing the key and enter, the deep test gets performed. Pressing the key leads back to menu battery operation DEEP TEST (§1.3.5.2).
Pressing the key the test can be interrupted and this action leads back to default screen (§1.3.1). Else, once the test is terminated, the following screen is shown.
The third row shows the test results (failed or passed). Pressing the key leads back to default screen(§1.3.1).
1.3.5.2.2 Quick battery test
Press ENTER to start Press RESET to exit
Test in progress... XXX V XXX A RESET to abort
Issued 10.12.2008
JGE410503
Pressing the key and enter will start the quick battery test in the following screen. Pressing the key leads back to menu battery operation quick battery test (§1.3.5.2).
Pressing the key the test can be interrupted and this action leads back to default screen (§1.3.1). Else, once the test is terminated, the following screen is shown.
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AC-UPS FRONT PANEL
TEST FAILD/PASSED Press RESET to exit
The third row shows the test results (failed or passed). key leads Pressing the back to default screen (§1.3.1).
1.3.5.3 UPS settings
CLOCK SETTING
RECTIFIER SETTINGS
INVERTER SETTINGS
BYPASS SETTINGS
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Menu UPS settings CLOCK. It can be accessed pressing the key (§1.3.5.3.1), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Special UPS SETTINGS (§1.3.5). Menu UPS settings RECTIFIER. It can be accessed pressing the (§1.3.5.3.2), pressing the key keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Special UPS SETTINGS (§1.3.5). Menu UPS settings INVERTER. It can be accessed pressing the (§1.3.5.3.3), pressing the key or other sub-menus keys can be scrolled down. Pressing the key leads back to menu Special UPS SETTINGS (§1.3.5). Menu UPS settings BYPASS. It can be accessed pressing the key (§1.3.5.3.4), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu Special UPS SETTINGS (§1.3.5).
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL
BATTERY SETTINGS
EXIT
Menu UPS settings BATTERY. It can be accessed pressing the (§1.3.5.3.5), pressing the key keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Special UPS SETTINGS (§1.3.5).
Pressing the keys or other sub-menus can be scrolled down key or Pressing the key leads back to menu special UPS SETTINGS (§1.3.5).
1.3.5.3.1 Clock setting
XX-XX-XX
XX:XX
The date and the time can be set using either numerical keyboard or . or pressing the keys Press the key to confirm. key to go back. Press the
This menu enables the modification of the date and the time. The new data are shown in the third row in the following order: Day Month Year Hour Minutes If the date is not inserted correctly (for e.g. 31-02-07) an error message will be shown and the screen will automatically go back to menu UPS setting CLOCK without saving any data.
1.3.5.3.2 Rectifier Settings In this menu is possible to set some rectifier parameters.
Issued 10.12.2008
JGE410503
25 of 56
AC-UPS FRONT PANEL
BOOST CH PARAMETERS
FLOAT CH PARAMETERS
INPUT PARAMETERS
OUTPUT PARAMETERS
EXIT
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Menu Rectifier settings BOOST. It can be accessed pressing the (§1.3.5.3.2.1), pressing key the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings RECTIFIER (§1.3.5.3).
Menu Rectifier settings FLOAT. It can be accessed pressing the key (§1.3.5.3.2.2), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings RECTIFIER (§1.3.5.3).
Menu Rectifier settings INPUT. It can be accessed pressing the (§1.3.5.3.2.3), pressing key the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings RECTIFIER (§1.3.5.3).
Menu Rectifier settings OUTPUT. It can be accessed pressing the (§1.3.5.3.2.4), pressing key the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings RECTIFIER (§1.3.5.3).
Pressing the keys or other sub-menus can be scrolled down. key or Pressing the key leads back to menu UPS settings RECTIFIER (§1.3.5.3).
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL 1.3.5.3.2.1 Boost charge parameters setting
Cur value: XXX min ENTER to modify
Cur value: XXX min ENTER to modify
Cur value: XXX V ENTER to modify
Cur value: XXX A ENTER to modify
Cur value: XXX A ENTER to modify
Issued 10.12.2008
JGE410503
It can be accessed pressing the key (§1.3.5.3.2.1.1), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu Rectifier settings BOOST (§1.3.5.3.2).
It can be accessed pressing the key (§1.3.5.3.2.1.2), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings BOOST (§1.3.5.3.2).
It can be accessed pressing the key (§1.3.5.3.2.1.3), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu Rectifier settings BOOST (§1.3.5.3.2).
It can be accessed pressing the (§1.3.5.3.2.1.4), pressing key the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu Rectifier settings BOOST (§1.3.5.3.2).
It can be accessed pressing the (§1.3.5.3.2.1.5), pressing key the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings BOOST (§1.3.5.3.2). 27 of 56
AC-UPS FRONT PANEL EXIT
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Rectifier settings BOOST (§1.3.5.3.2).
The first row shows the name of the parameter to be modified, the third row shows the current value. 1.3.5.3.2.1.1 Mains fault delay modification Cur value: XXX min xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
On the second row is shown the current value of the parameter, on the third row is possible to set the new value. 1.3.5.3.2.1.2 Safety time modification Cur value: XXX min xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
On the second row is shown the current value of the parameter, on the third row is possible to set the new value. 1.3.5.3.2.1.3 Boost charge voltage modification Cur value: XXX V xxx ENTER to confirm
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The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving. JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL On the second row is shown the current value of the parameter, on the third row is possible to set the new value. 1.3.5.3.2.1.4 Float-boost current modification Cur value: XXX A xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
On the second row is shown the current value of the parameter, on the third row is possible to set the new value. 1.3.5.3.2.1.5 Boost-float current modification Cur value: XXX A xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
On the second row is shown the current value of the parameter, on the third row is possible to set the new value. 1.3.5.3.2.2 Float charge parameters Cur value: XXX V ENTER to modify
Cur value: XXX A ENTER to modify
Issued 10.12.2008
JGE410503
It can be accessed pressing the key (§1.3.5.3.2.2.1), pressing or other sub-menus the keys can be scrolled down. Pressing the key leads back to menu Rectifier settings FLOAT (§1.3.5.3.2).
It can be accessed pressing the key (§1.3.5.3.2.2.2), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings FLOAT (§1.3.5.3.2).
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AC-UPS FRONT PANEL
Cur value: X.X mV/°C ENTER to modify
EXIT
It can be accessed pressing the key (§1.3.5.3.2.2.3), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings FLOAT (§1.3.5.3.2).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Rectifier settings FLOAT (§1.3.5.3.2).
On the first row is shown the name of the parameter to be modified, on the third one the current value is shown. 1.3.5.3.2.2.1 Floating voltage modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
On the second row is shown the current value of the parameter, on the third row is possible to set the new value.
1.3.5.3.2.2.2 Recharge max current modification
Cur value: XXX A xxx ENTER to confirm
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The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.2.3 Thermal compensation per cell modification
Cur value: X.X mV/°C x.x ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.3 Input parameters
Cur value: XXX V ENTER to modify
Cur value: XXXV+XX% ENTER to modify
Cur value: XXXV-XX% ENTER to modify
Issued 10.12.2008
JGE410503
It can be accessed pressing the key (§1.3.5.3.2.3.1), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu Rectifier settings INPUT (§1.3.5.3.2).
It can be accessed pressing the (§1.3.5.3.2.3.2), pressing key the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings INPUT (§1.3.5.3.2).
It can be accessed pressing the key (§1.3.5.3.2.3.3), pressing or other sub-menus the keys can be scrolled down. Pressing the key leads back to menu Rectifier settings INPUT (§1.3.5.3.2).
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AC-UPS FRONT PANEL Cur value: XX Hz ENTER to modify
Cur value: XXHZ+X% A ENTER to modify
Cur value: XXHZ-X% A ENTER to modify
EXIT
It can be accessed pressing the key (§1.3.5.3.2.3.4), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings INPUT (§1.3.5.3.2).
It can be accessed pressing the key (§1.3.5.3.2.3.5), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings INPUT (§1.3.5.3.2).
It can be accessed pressing the key (§1.3.5.3.2.3.6), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu Rectifier settings INPUT (§1.3.5.3.2).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Rectifier settings INPUT (§1.3.5.3.2).
The name of the parameter to be modified is shown on the first row, on the third one the current value is shown. 1.3.5.3.2.3.1 Input voltage modification
Cur value: XXX V Xxx ENTER to confirm
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The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.3.2 High input voltage modification
Cur value: XXXV+XX% xx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.3.3 Low input voltage modification
Cur value: XXXV-XX% xx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value.
1.3.5.3.2.3.4 Input frequency modification
Cur value: XX Hz xx ENTER to confirm
Press the keys or in order to select the frequency. Press the to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. Issued 10.12.2008
JGE410503
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AC-UPS FRONT PANEL 1.3.5.3.2.3.5 High input frequency modification Cur value: XXHZ+X% A x ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.3.6 Low input frequency modification Cur value: XXHZ-X% A x ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.4 Output parameters Cur value: XXX V ENTER to modify
Cur value: XXX sec ENTER to modify
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It can be accessed pressing the key (§1.3.5.3.2.4.1), pressing or other sub-menus the keys can be scrolled down. Pressing the key leads back to menu Rectifier settings OUTPUT (§1.3.5.3.2).
It can be accessed pressing the key (see 1.3.5.3.2.4.2), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings OUTPUT (§1.3.5.3.2).
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL Cur value: XXX V ENTER to modify
Cur value: XXX V ENTER to modify
EXIT
It can be accessed pressing the key (§1.3.5.3.2.4.3), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings OUTPUT (§1.3.5.3.2). It can be accessed pressing the key (§1.3.5.3.2.4.4), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Rectifier settings OUTPUT (§1.3.5.3.2). Pressing the keys or other sub-menus can be scrolled down. key or Pressing the key leads back to menu Rectifier settings OUTPUT (§1.3.5.3.2).
The name of the parameter to be modified is shown on the first row, on the third one the current value is shown. 1.3.5.3.2.4.1 Max output voltage modification Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.4.2 Max Vout delay modification Cur value: XXX sec xxx ENTER to confirm
Issued 10.12.2008
JGE410503
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving. 35 of 56
AC-UPS FRONT PANEL The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.2.4.3 Min output voltage modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. . 1.3.5.3.2.4.4 Diesel mode voltage modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value.
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JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL
1.3.5.3.3 Inverter Settings This menu enables the configuration of inverter parameters. INPUT PARAMETERS
OUTPUT PARAMETERS
EXIT
Menu Inverter settings INPUT. It can be accessed pressing the key , pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings INVERTER (§1.3.5.3). Menu Inverter settings OUTPUT. It can be accessed pressing the , pressing the keys or key other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings INVERTER (§1.3.5.3).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu UPS settings INVERTER (§1.3.5.3).
1.3.5.3.3.1 Input parameters Cur value: XXX V ENTER to modify
Cur value: XXX V ENTER to modify
Issued 10.12.2008
JGE410503
It can be accessed pressing the key (§1.3.5.3.3.1.1), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Inverter settings INPUT (§1.3.5.3.3). It can be accessed pressing the (§1.3.5.3.3.1.2), pressing key the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Inverter settings INPUT (§1.3.5.3.3). 37 of 56
AC-UPS FRONT PANEL
Cur value: XXX V ENTER to modify
EXIT
It can be accessed pressing the key (§1.3.5.3.3.1.3), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Inverter settings INPUT (§1.3.5.3.3).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Inverter settings INPUT (§1.3.5.3.3).
The name of the parameter to be modified is shown on the first row, on the third one the current value is shown. 1.3.5.3.3.1.1 Low DC shutdown modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.3.1.2 High DC shutdown modification
Cur value: XXX V xxx ENTER to confirm
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The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.3.1.3 Max input voltage modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.3.2 Output parameters
Cur value: XXX V ENTER to modify
Cur value: XXX V ENTER to modify
Cur value: XXX V ENTER to modify
Issued 10.12.2008
JGE410503
It can be accessed pressing the key (§1.3.5.3.3.2.1), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Inverter settings OUTPUT (§1.3.5.3.3).
It can be accessed pressing the (§1.3.5.3.3.2.2), pressing key or other sub-menus the keys can be scrolled down. Pressing the key leads back to menu Inverter settings OUTPUT (§1.3.5.3.3).
It can be accessed pressing the key (§1.3.5.3.3.2.3), pressing the keys or other sub-menus can be scrolled down. key leads Pressing the back to menu Inverter settings OUTPUT (§1.3.5.3.3).
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AC-UPS FRONT PANEL EXIT
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Inverter settings OUTPUT (§1.3.5.3.3).
The name of the parameter to be modified is shown on the first row, on the third one the current value is shown. 1.3.5.3.3.2.1 Output nominal voltage modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.3.2.2 Output overvoltage modification Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.3.2.3 Output undervoltage modification Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 40 of 56
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL
1.3.5.3.4 Bypass Settings This menu enables the configuration of bypass parameters.
BYPASS PARAMETERS
EXIT
Menu Bypass settings PARAMETERS. It can be accessed pressing the key (§1.3.5.3.4.1), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings BYPASS (§1.3.5.3).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu UPS settings BYPASS (§1.3.5.3).
1.3.5.3.4.1 Bypass parameters
Cur value: x.x % ENTER to modify
Cur value: XXX V ENTER to modify
Issued 10.12.2008
JGE410503
It can be accessed pressing the key (§1.3.5.3.4.1.1), pressing or other sub-menus the keys can be scrolled down. Pressing key leads back to the menu Bypass settings PARAMETERS (§1.3.5.3.4).
It can be accessed pressing the key (§1.3.5.3.4.1.2), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Bypass settings PARAMETERS (§1.3.5.3.4).
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AC-UPS FRONT PANEL Cur value: XXX V ENTER to modify
EXIT
It can be accessed pressing the key (§1.3.5.3.4.1.3), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Bypass settings PARAMETERS (§1.3.5.3.4).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Bypass settings PARAMETERS (§1.3.5.3.4).
The name of the parameter to be modified is shown on the first row, on the third one the current value is shown. 1.3.5.3.4.1.1 Frequency range modification
Cur value: x.x % x.x ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.4.1.2 Bypass high voltage modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 42 of 56
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AC-UPS FRONT PANEL 1.3.5.3.4.1.3 Bypass low voltage modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value.
1.3.5.3.5 Battery Settings This menu enables the configuration of battery parameters. BATTERY INFO
DISCHARGE PARAMETERS
EXIT
Issued 10.12.2008
JGE410503
Menu Battery settings INFO. It can be accessed pressing the key (§1.3.5.3.5), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu UPS settings BATTERY (§1.3.5.3).
Menu Battery settings DISCHARGE. It can be accessed pressing the key (§1.3.5.3.5.2), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu UPS settings BATTERY (§1.3.5.3).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu UPS settings BATTERY (§1.3.5.3).
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AC-UPS FRONT PANEL 1.3.5.3.5.1 Battery information Cur value: XXXX Ah ENTER to modify
EXIT
It can be accessed pressing the key (§1.3.5.3.5.1.1), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Battery settings INFO (§1.3.5.3.5).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Battery settings INFO (§1.3.5.3.5).
The name of the parameter to be modified is shown on the first row, on the third one the current value is shown. 1.3.5.3.5.1.1 Battery size modification
Cur value: XXXX Ah xxxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. The fourth number is fixed to zero and can not be modified. 1.3.5.3.5.2 Discharge parameters
Cur value: XXX V ENTER to modify
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It can be accessed pressing the key (§1.3.5.3.5.2.1), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu Battery settings DISCHARGE (§1.3.5.3.5). JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL Cur value: XXX V ENTER to modify
Cur value: XXX V ENTER to modify
EXIT
It can be accessed pressing the key (§1.3.5.3.5.2.2), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Battery settings DISCHARGE (§1.3.5.3.5).
It can be accessed pressing the key (§1.3.5.3.5.2.3), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu Battery settings DISCHARGE (§1.3.5.3.5).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Battery settings DISCHARGE (§1.3.5.3.5).
The name of the parameter to be modified is shown on the first row, on the third one the current value is shown. 1.3.5.3.5.2.1 Discharge level 1 modification
Cur value: XXX V Xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value.
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AC-UPS FRONT PANEL 1.3.5.3.5.2.2 Discharge level 2 modification
Cur value: XXX V Xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press key to confirm. Press the key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value. 1.3.5.3.5.2.3 Discharge level 3 modification
Cur value: XXX V xxx ENTER to confirm
The new value can be set using the numerical keyboard. Press to confirm. Press the key key one time to reset the value, twice to go back to the previous screen without saving.
The current value of the parameter is shown on the second row, on the third row is possible to set the new value.
1.3.5.4 History reset This menu enables the reset of the events history. Press ENTER to start Press RESET to exit
Pressing the key will start the reset of the events history, and once completed the screen will go back to default menu. Pressing the key interrupts the operation and you go back to menu special HISTORY RESET.
1.3.6 Info The INFO screen is described as follows:
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AC-UPS FRONT PANEL FIRMWARE VERSION
SERIAL NUMBER
Info VERSION. It can be accessed pressing the key (§1.3.6.1), pressing the keys or other sub-menus can be scrolled down. Pressing the key leads back to menu INFO (§1.3.2).
Info SERIAL NUMBER. It can be accessed pressing the key (§1.3.6.2), pressing the keys or other sub-menus can be scrolled down. Pressing key leads back to the menu INFO (§1.3.2).
Info STATISTICS. It can be accessed pressing the key or (§1.3.6.3), pressing the keys other sub-menus can be scrolled down. Pressing the key leads back to menu INFO (§1.3.2).
STATISTICS
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu INFO (§1.3.2).
EXIT
Note that the menus are disposed in cicle, therefore the menu INPUT and menu OUTPUT can be considered consecutive.
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AC-UPS FRONT PANEL
1.3.6.1 Firmware version
RCN: INV:
X.X.X X.X
PANEL1: XX.XX.XX.XX PANEL1: XX.XX.XX.XX
EXIT
Pressing the key the following parameter is shown, pressing the key will lead to previous screen. Pressing the key leads back to menu Info VERSION (§1.3.6). Pressing the key the following parameter is shown, pressing the key will lead to previous screen. Pressing the key leads back to menu Info VERSION (§1.3.6).
Pressing the keys or other sub-menus can be scrolled down. key or Pressing the key leads back to menu Info VERSION (§1.3.6).
1.3.6.2 Serial number XXXXXXXXX
EXIT
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Pressing the key the following parameter is shown, pressing the will lead to previous key screen. Pressing the key leads back to menu Info SERIAL NUMBER (§1.3.6).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Info SERIAL NUMBER (§1.3.6).
JGE410410
Issued 10.12.2008
AC-UPS FRONT PANEL 1.3.6.3 Statistics
PART TOT MIN: XXX XXX MAX: XXX XXX
Pressing the key the following parameter is shown, pressing the key will lead to previous screen. Pressing the key leads back to menu Info STATISTICS (§1.3.6).
Pressing the key the following parameter is shown, pressing the key will lead to previous screen. Pressing the key leads back to menu Info STATISTICS (§1.3.6).
PARTIAL: TOTALS:
XXX XXX
NORMAL: XXX BATTERY: XXX BYPASS: XXX
Pressing the key the following parameter is shown, pressing the will lead to previous key screen. Pressing the key leads back to menu Info STATISTICS (§1.3.6).
Pressing the keys or other sub-menus can be scrolled down. Pressing the key or key leads back to menu Info STATISTICS (§1.3.6).
EXIT
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AC-UPS FRONT PANEL
1.4
TRANSPARENT MODE
In this mode the panel behaves as if the user itself is connected directly to the unit. (rectifier or inverter depending of the selectors disposition). This enables direct communication with the unit. It is possible to receive the data as well as send commands. 1.5
MODBUS COMMUNICATION
MODBUS is an application layer messaging protocol, positioned at level 7 of the OSI model, that defines the modes of communication between a "master" and one or more "slaves". It is possible to connect one master to up to 247 slave units, using one common bus. The MODBUS protocol defines: how master and slave establish and interrupt the communication, how to identify receiving and transmitting, how to exchange the messages, and the techniques of error identifying. Only unit identified as master can start the transmitting, which can be "question/answer" based type (with one single slave), or based on a "broadcast" type in which the message is sent to all slave units, but slave units do not send any answer back. The transmission is set up in RTU mode (Remote Terminal Unit) and the end of the message of request towards one of the devices is identified by 100ms interval, in which no answers are sent back. The question and answers have the following structure: Slave Address
Function
Data
1 byte
1 byte
N byte
CRC (Cyclical Redundancy Check) 2 byte
MODBUS function codes are elements of MODBUS request/reply PDUs (Protocol Data Units). Communication parameters are the following:
two stop bit parità: none BAUD rate Î 9600 bit/s RTU format data Î 8 bit
In order to configure the address (from 1 to 247) the following coman is to be used, sending it through the serial interface: SET MODBUS ADDRESS. There is also a comand which enquires about the address that was already set: GET MODBUS ADDRESS. Please refer to Apendix "A" in this chapter in order to find futher information about comands. The software is using the function coded as 03 of the PDU (Holding Register). When receives this instruction, the panel responds by sending the data table described below:
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AC-UPS FRONT PANEL
BYTE 1 2 3 4 5 6 7 8
BYTE 10
DESCRIPTION Input voltage phase R Input voltage phase S Input voltage phase T Input current phase R Input current phase S Input current phase T Mains nominal frequency Mains nominal frequency
DESCRIPTION Watchdog counter
RECTIFIER RANGE
NOTE
Expressed in period1 Expressed in Hz WATCHDOG RANGE
NOTE
BYPASS BYTE 20 21 22 23 24
BYTE 40 41 42 43 44 45
BYTE 100 101 102 103 104
DESCRIPTION Bypass voltage phase R Bypass voltage phase S Bypass voltage phase T Bypass nominal frequency Bypass nominal frequency
RANGE
Expressed in period1 Expressed in Hz BATTERY RANGE
NOTE
INVERTER RANGE
NOTE
DESCRIPTION Battery voltage Battery current Battery capacity Not defined Battery autonomy(Minutes) Not defined
DESCRIPTION Inverter voltage phase R Inverter voltage phase S Inverter voltage phase T Inverter frequency Inverter frequency
NOTE
Expressed in period1 Expressed in Hz OUTPUT
BYTE 120 121 122 123 124 125
DESCRIPTION Output voltage phase R Output voltage phase S Output voltage phase T Output current phase R Output current phase S Output current phase T
Issued 10.12.2008
RANGE
JGE410503
NOTE
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AC-UPS FRONT PANEL 126 127 128 129 130
BYTE 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177-188 189 190 191 –198 199 200 201 202 203 204 205 206 207 52 of 56
Expressed in period1
Output frequency OUTPUT_LOAD_PERC_R OUTPUT_LOAD_PERC_S OUTPUT_LOAD_PERC_T Output frequency
Expressed in Hz
PANEL ALARMS DESCRIPTION RANGE A1 – Mains fault A2 – Rect. blown fuses A3 – Rect. high temperature A4 – Rect. overload A5 – Max DC Voltage A6 – Min DC Voltage A7 – Charging fault A8 – RICB open A9 – BCB Open A10 – Battery discharging A11 – Battery low A12 – Battery in test A13 – Battery fault A14 – Inverter DC fault A15 – Inverter high temperature A16 – Inverter out of tolerance A17 – Inverter current stop A18 – Inverter no synchronized A19 – Overload A20 – Bypass fault A21 – Bypass feed load A22 – Bypass switch A23 – Retransfer blocked A24 – Fans failure A25 – OCB open A26 - MBCB closed A27 – EPO pressed A28 – A39 not defined A40 – DC earth fault A41 – RICB open A31 – A49 not defined A50 – Programmable A51 – Programmable A52 – Programmable A53 – Programmable A54 – Programmable A55 – Programmable A56 – Programmable A57 – Programmable A58 – Programmable JGE410410
NOTE
Issued 10.12.2008
AC-UPS FRONT PANEL 208 209 210 211 212 213
A59 – Programmable A60 not defined A61 – Comunication fault A62 . Rectifier common alarm A63 – Inverter common alarm A64 – Common alarm
BYTE IDENTIFICATION The alarms are identified as described: BIT 15 Æ if set the alarm is masked. BIT 14 Æ if set the alarms is present (active) BIT 13 – BIT 8 Æ Not used BIT 7 – BIT0 Æ Code
PANEL STATUS RANGE
BYTE DESCRIPTION NOTE 214 S1 – Rectifier OK 215 S2 – Battery on charge 216 S3 – Battery OK 217 S4 – Inverter OK 218 S5 – Bypass OK 219 S6 – Inverter synchronized 220 S7 – Inverter feed load 221 – 245 S8 – S32 not defined BYTE IDENTIFICATION The alarms are identified as described: BIT 15 Æ if set the alarm is masked. BIT 14 Æ if set the alarms is present (active) BIT 13 – BIT 8 Æ Not used BIT 7 – BIT0 Æ Code
1.6
PCB PROGRAMMING
The panel has 20 led that are programmable. It is possible to associate the activation ro alarms, status or certain parameters of the UPS. The same operation can be performed for 18 relays and 10 alarms, though configuration software “FC_ACUPS_Toolkit” (please, refer to the appropriate chapter of the manual). Regarding the leds, it is also possible to set the colour for on status.
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AC-UPS FRONT PANEL
APPENDIX A. LIST OF COMANDS SET NAME
Set the name of the unit Use: Comand to send is: SET NAME Example: SET NAME Name Reply: “... OK” Æ operation terminated successfuly “... INVALID VALUE” Æ The sent value is not valid no reply Æ comand not recognised
SET SIZE
Set the size. Use: Comand to send is: SET SIZE Example: SET SIZE 10 Reply: “... OK” Æ operation terminated successfuly “... INVALID VALUE” Æ The sent value is not valid no reply Æ comand not recognised
SET SN or Set the serial number SET SERIALNUMBER Use: Comand to send is: SET SN Or: SET SERIALNUMBER Example: SET SN E8RTG5GG3 Reply: “... OK” Æ operation terminated successfuly “... INVALID VALUE” Æ The sent value is not valid no reply Æ comand not recognised SET MODBUS ADDRESS Set MODBUS address Use: Comand to send is: SET MODBUS ADDRESS Example: SET MODBUS ADDRESS 100 Reply: “... OK” Æ operation terminated successfuly “... INVALID VALUE” Æ The sent value is not valid no reply Æ comand not recognised GET NAME
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Sends the name of the unit Use: Comand to send is: GET NAME Reply: “GET NAME ” Æ sends back the name preceded by comand itself no reply Æ comand not recognised
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AC-UPS FRONT PANEL GET SIZE
Sends back size. Use: Comand to send is: GET SIZE Reply: “GET SIZE ” Æ sends back the size preceded by comand itself no reply Æ comand not recognised
GET SN or Sends back the serial number. GET SERIALNUMBER Use: Comand to send is: GET SN Or: GET SERIALNUMBER Reply: “GET SERIALNUMBER ” Æ sends back the serial number preceded by comand itself no reply Æ comand not recognised GET MODBUS ADDRESS Sends back the MODBUS address Use: Comand to send is: GET MODBUS ADDRSS Reply: “GET MODBUS ADDRSS ” Æ sends back the MODBUS address preceded by comand itself no reply Æ comand not recognised Store in EEPROM the unit parameters (name, size...) Use: Comand to send is: STORE PARAMETER Reply: “... OK” Æ operation terminated successfuly “... ERROR” Æ an error occured during the process no reply Æ comand not recognised
STORE PARAMETER
Forces loading the unit parameters stored in EEPROM (name, size...). Use: Comand to send is: LOAD PARAMETER Reply: “... OK” Æ operation terminated successfuly “... ERROR” Æ an error occured during the process no reply Æ comand not recognised
LOAD PARAMETER
LOAD CUSTOM
Issued 10.12.2008
Forces loading the alarms, leds and relays configuration stored in EEPROM. Use: Comand to send is: LOAD CUSTOM Reply: “... OK” Æ operation terminated successfuly “... ERROR” Æ an error occured during the process no reply Æ comand not recognised
JGE410503
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AC-UPS FRONT PANEL Erases all unit parameters stored in EEPROM (name, size…). Use: Comand to send is: ERASE PARAMETER Reply: “... OK” Æ operation terminated successfuly “... ERROR” Æ an error occured during the process no reply Æ comand not recognised
ERASE PARAMETER
ERASE CUSTOM
Erases alarms, led and relays configuration stored in EEPROM . Use: Comand to send is: ERASE CUSTOM Reply: “... OK” Æ operation terminated successfuly “... ERROR” Æ an error occured during the process no reply Æ comand not recognised
Erases history information. ERASE HISTORY INFO Use: Comand to send is: ERASE HISTORY INFO Reply: “... OK” Æ operation terminated successfuly “... ERROR” Æ an error occured during the process no reply Æ comand not recognised ERASE HISTORY EVENT Erases events history. Use: Comand to send is: ERASE HISTORY EVENT Reply: “... OK” Æ operation terminated successfuly “... ERROR” Æ an error occured during the process no reply Æ comand not recognised Erases statistics regarding the current session of data acquisition of the front panel. Use: Comand to send is: ERASE STATISTICS Reply: “... OK” Æ operation terminated successfuly no reply Æ comand not recognised
ERASE STATISTICS
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Start-up, shut-down & manual bypass
START-UP, SHUTDOWN & MANUAL BYPASS
Index 1. INTRODUCTION.................................................................................. 2 2. START-UP PROCEDURE ................................................................... 2 3. SHUT-DOWN PROCEDURE (LOAD NOT SUPPLIED ) ..................... 3 4. EMERGENCY SHUT-DOWN PROCEDURE – ESD ........................... 3 5. START-UP FROM EMERGENCY SHUT-DOWN – ESD..................... 3 6. MANUAL BY-PASS PROCEDURE..................................................... 5 7. START-UP FROM MANUAL BY-PASS .............................................. 5
Rev.
/
Descrizione Description
First Issue
Data Date
Emesso Issued
10.12.2008 V.Lomonico
Controllato Checked
Approvato Approved
P.Conti
E. Simoni
Lingua Language
Pagina Page
di Pag. of Pag.
E
1
6
Codice / Code
JGE410503
Start-up, shut-down & manual bypass
1.
INTRODUCTION
Before carrying out whatever procedure described in this chapter, read carefully the instructions, in order to avoid possible damages to persons or thing due to wrong manoeuvre.
2.
START-UP PROCEDURE For the UPS start-up, proceed as follows.
WARNING Before switching on the UPS, make sure: 1) the emergency power off “EPO” push-button (if present), placed near the front panel, is in the release position; if not, press it and proceed with the start-up procedure; 2) the input and output phase rotation is correct. 1) 2) 3)
Close QIRA. Close RCB and wait until display is supplied. Move “Normal-Bypass” switch SW1 on “Normal” position.
WARNING If you close BCB breaker before it is required (by the front panel) you can damage the inverter capacitor bank and the battery. 4) 5)
2 of 6
Follow the instructions shown on the display to close the circuit breakers/isolator switches. If the start-up procedure has been carried out correctly, the display will show: START UP END.
JGE410503
First Issue 10.12.2008
Start-up, shut-down & manual bypass
3. Nr.
SHUT-DOWN PROCEDURE (LOAD NOT SUPPLIED ) ACTION
LCD DISPLAYING
UPS OPERATION
1
Open OCB
A64 COMMON ALARM The supply to the load is interrupted. LED #6 lit orange.
2
Open BCB
A64 COMMON ALARM The battery is disconnected rectifier. LED #3 lit red.
3
Open SBCB
A64 COMMON ALARM The by-pass line is disconnected. LED #8 off.
4
Open QIRA
A64 COMMON ALARM The By-pass section is disconnected.
5
Push the Inverter OFF push button
A64 COMMON ALARM The inverter is switched off.
6
Open RICB
A64 COMMON ALARM The rectifier and inverter are switched off.
7
4.
BLANK
from
the
Shut-down procedure end.
EMERGENCY SHUT-DOWN PROCEDURE – ESD (LOAD SUPPLIED BY BYPASS LINE )
Push the ESD push button on the front panel. All breakers/isolators will automatically open and the load will be supplied by the By-pass line.
5. Nr.
START-UP FROM EMERGENCY SHUT-DOWN – ESD ACTION
LCD DISPLAYING
UPS OPERATION
1
Re-load all the circuit breaker in position “0”
BLANK
The UPS is OFF. The load is supplied by By-pass line.
2
Move the “NORMALBYPASS” switch on BYPASS
BLANK
The UPS is OFF. The load is supplied by By-pass line.
3
Close MBCB
BLANK
The UPS is OFF. The load is supplied by By-pass line.
4
Press ESD push button to reset the ESD function
BLANK
The UPS is OFF. The load is supplied by By-pass line.
5
Close RICB
BLANK
The UPS is OFF. The load is supplied by By-pass line.
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JGE410411
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Start-up, shut-down & manual bypass UPS START UP WAIT PLEASE
6
7
Close SBCB
8
BYPASS START UP CLOSE SBCB BYPASS START UP WAIT PLEASE
9
Close BCB
CLOSE BCB WAIT PLEASE
10
Close OCB
CLOSE OCB WAIT PLEASE
11
Keep pressed PRESD push button while opening MBCB Press the Inverter ON push button
OPEN MBCB WAIT PLEASE
12
13
Move the “NORMALBYPASS” switch on NORMAL
The microprocessor checks that all the bypass parameters (voltage, phase sequence, frequency) are within the tolerance limits. LED #8 is lit green. The by-pass static switch is closed, LED #7 is lit orange. The microprocessor checks all the conditions for the following step are ok. LED #3 is lit green. The load is supplied by the by-pass static switch. The breaker MBCB is still closed. LED #6 is lit green. The load is now supplied by the by-pass static switch only and the inverter can be started-up. LED #9 off.
INVERTER START UP The inverter IGBT bridge starts to modulate and the inverter output voltage reaches the WAIT PLEASE nominal value. The microprocessor checks the synchronisation with the by-pass line. MOVE BYP SWITCH The load is transferred to the inverter static switch. LED #5 is lit green. WAIT PLEASE
14
START UP END WAIT PLEASE
15
UPS MODEL OUTPUT VOLTAGE
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The rectifier is supplied and the DC voltage increases up to the nominal value. All LED’s in the front panel are lit. The microprocessor checks all the start-up conditions are ok. LED’s #1, #2 and #6 are lit green. LED #9 is lit orange.
JGE410503
The microprocessor checks that all the output parameters (voltage, phase sequence, frequency) are within the tolerance limits.
First Issue 10.12.2008
Start-up, shut-down & manual bypass
6.
MANUAL BY-PASS PROCEDURE
WARNING During manual bypass operation the load is supplied directly by the mains, therefore continuous supply is not guaranteed. Nr.
ACTION
LCD DISPLAYING
UPS OPERATION
1
Move the “NORMALBYPASS” switch on BYPASS
A64 COMMON ALARM The load is transferred to the by-pass static switch. LED #5 off, LED #7 lit orange.
2
Close MBCB
A64 COMMON ALARM The load is supplied by the mains through the manual by-pass circuit breaker. The bypass static switch is still closed.
Push the Inverter OFF push button
A64 COMMON ALARM The inverter is switched off.
3
Open RICB
A64 COMMON ALARM The rectifier is switched off; the inverter is still on supplied by the batteries. LED #1 off, LED #3 lit up orange.
4
Open BCB
A64 COMMON ALARM The batteries are disconnected and the inverter is switched off. The load is still supplied by the by-pass static switch. LED #3 lit up red.
5
Open SBCB
BLANK
The by-pass line is disconnected.
6
Open OCB
BLANK
The load is now supplied directly by the mains through the manual by-pass circuit breaker. The UPS is isolated.
7.
START-UP FROM MANUAL BY-PASS
Before the start-up from manual by-pass (after a maintenance or repairing) check that the “NORMAL-BYPASS” switch is in BYPASS position. Nr.
LCD DISPLAYING
1 2
BLANK UPS START UP WAIT PLEASE
3
BYPASS START UP CLOSE SBCB
First Issue 10.12.2008
ACTION
UPS OPERATION
Close RCB The rectifier is supplied and the DC voltage increases up to the nominal value. All LED’s in the front panel are lit. The microprocessor checks all the startup conditions are ok. LED’s #1, #2 and #6 are lit green. LED #9 is lit orange. Close SBCB
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Start-up, shut-down & manual bypass 4
5
6
7
8
9
10
11
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BYPASS START UP WAIT PLEASE
The microprocessor checks that all the by-pass parameters (voltage, phase sequence, frequency) are within the tolerance limits. LED #8 is lit green. The by-pass static switch is closed, LED #7 is lit orange. CLOSE BCB The microprocessor checks all the Close BCB conditions for the following step are ok. WAIT PLEASE LED #3 is lit green. CLOSE OCB The load is supplied by the by-pass Close OCB static switch. The breaker MBCB is still WAIT PLEASE closed. LED #6 is lit green. OPEN MBCB Keep pressed PRESD The load is now supplied by the by-pass push button while static switch only and the inverter can be WAIT PLEASE opening MBCB started-up. LED #9 off. INVERTER START UP The inverter IGBT bridge starts to modulate and the inverter output voltage WAIT PLEASE reaches the nominal value. The microprocessor checks the synchronisation with the by-pass line. MOVE BYP SWITCH Move the “NORMAL- The load is transferred to the inverter BYPASS” switch on static switch. LED #5 is lit green. WAIT PLEASE NORMAL START UP END The microprocessor checks that all the output parameters (voltage, phase WAIT PLEASE sequence, frequency) are within the tolerance limits. UPS MODEL OUTPUT VOLTAGE
JGE410503
First Issue 10.12.2008
AC UPS operating description
AC UPS OPERATING DESCRIPTION Index 1.
GENERAL ........................................................................................... 4 1.1
2.
OPERATING STATUS......................................................................................4
RECTIFIER .......................................................................................... 6 2.1
BASIC STRUCTURE ........................................................................................6
2.2
6-PULSE RECTIFIER (STANDARD)................................................................7
2.3
12-PULSE RECTIFIER (OPTIONAL) ...............................................................7
3.
INVERTER ........................................................................................... 8
4.
STATIC SWITCH ................................................................................. 8
5.
RECTIFIER PCB’S .............................................................................. 9
6.
5.1
BP-DR16 –(BACK PANEL) ..............................................................................9
5.2
PS-DR16 – (POWER SUPPLY) ......................................................................11
5.3
DR16 – (μPROCESSOR CONTROL) .............................................................12
5.3.1
Direct analog readings on AD ...............................................................12
5.3.2
Direct analog readings on AD ...............................................................13
5.3.3
Digital inputs ..........................................................................................14
5.3.4
Communication via RS232 ....................................................................15
5.3.5
SCR firing................................................................................................16
INVERTER AND STATIC SWITCH PCB’S ....................................... 17 6.1
ID / DR-SAT – (IGBT DRIVER).......................................................................17
6.2
PS-LV / PS-MV / PS-SAT – (POWER SUPPLY) ............................................19
6.3
PWM-SAT – (IGBT DRIVERS INTERFACE) ..................................................23
6.4
INV-AV-1F – (INVERTER VOLTAGE FEEDBACK) .......................................23
6.5
VOLT-REF-1F – (BYP / OUT VOLTAGE FEEDBACK)..................................23
6.6
SCRSF-1F / 2SCR-FIR – (THYRISTORS FIRING).........................................23
6.7
I/S-CL (MICROPROCESSOR CONTROL LOGIC).........................................23
6.7.1 Rev.
/
Descrizione Description
First Issue
Introduction ............................................................................................23 Data Date
Emesso Issued
Controllato Checked
Approvato Approved
28.01.09
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
di Pag. of Pag.
E
1
31
Codice / Code
JUD411298
AC UPS operating description 6.7.2
Digital Inputs.......................................................................................... 24
6.7.3
Dip Switches .......................................................................................... 24
6.7.4
Fast Analog Inputs ................................................................................ 25
6.7.5
Watchdog and Reset ............................................................................. 25
6.7.6
RAM, EPROM’s and EEPROM .............................................................. 25
6.7.7
Digital Power Supply............................................................................. 25
6.7.8
RCB board.............................................................................................. 25
6.7.9
SCB board and Thyristor drivers ......................................................... 25
6.7.10
Current Limitation and Max Current Stop........................................ 25
6.7.11
VCB board .......................................................................................... 26
6.7.12
PWM generator .................................................................................. 26
6.7.13
External A/D Converter...................................................................... 27
6.7.14
Card SCB ............................................................................................ 30
6.7.15
Card VCB ............................................................................................ 30
6.8
FCI (FREE CONTACT INTERFACE)............................................................. 31
6.9
FP-ACUPS – (FRONT PANEL) ..................................................................... 31
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JUD411298
First Issue 28/01/09
AC UPS operating description
Index of pictures Picture 1 – UPS block diagram .................................................................................................................... 4 Picture 2 – Normal operation........................................................................................................................ 4 Picture 3 – Load supplied by by-pass .......................................................................................................... 5 Picture 4 – Rectifier failure or mains failure.................................................................................................. 5 Picture 5 – Manual by-pass .......................................................................................................................... 5 Picture 6 – Rectifier block diagram............................................................................................................... 7 Picture 7 – Card BP-DR16 ........................................................................................................................... 9 Picture 8 – Card PS-DR16 ......................................................................................................................... 11 Picture 9 – Card DR16: Input circuit of Type 1........................................................................................... 12 Picture 10 – Card DR16: Input circuit of Type 2......................................................................................... 13 Picture 11 – Card DR16: Input circuit of Type 3......................................................................................... 13 Picture 12 – Card DR16: Input circuit of Type 4......................................................................................... 14 Picture 13 – Card DR16: Input circuit of Type 5......................................................................................... 14 Picture 14 – Card DR16: Digital input circuit .............................................................................................. 15 Picture 15 – Card DR16: Interface RS232 ................................................................................................. 15 Picture 16 – Card DR16: SCR firing........................................................................................................... 16 Picture 17 – ID (IGBT DRIVER) board ....................................................................................................... 17 Picture 18 – Card DR-SAT ......................................................................................................................... 18 Picture 19 – POWER SUPPLY board block diagram................................................................................. 20 Picture 20 – POWER SUPPLY board PS-LV / PS-MV .............................................................................. 21 Picture 21 – POWER SUPPLY board PS-SAT .......................................................................................... 22 Table 1 – DSW 1 ........................................................................................................................................ 24 Table 2 – DSW 2 ........................................................................................................................................ 24 Picture 22 – Card I/S-CL block diagram..................................................................................................... 28 Picture 23 – Card I/S-CL ............................................................................................................................ 29 Picture 24 – Card SCB ............................................................................................................................... 30 Picture 25 – Card VCB ............................................................................................................................... 30
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AC UPS operating description
1.
GENERAL
The UPS of the “E2001.e” industrial series are on-line, double conversion; the inverter supplies always energy to the load, whether the mains is available or not (according to the battery autonomy time). WARNING The UPS output is energized even during mains failure, therefore in compliance with the prescriptions of EN 50091-1, the installer will have to identify the line or the plugs supplied by the inverter making the User aware of this fact. This configuration guarantees the best service to the User, as it supplies clean continuously regulated power and guarantees the voltage and frequency will be stabilised at nominal value independently from mains status. Thanks to the double conversion, it makes the load completely immune from micro-interruptions due to excessive mains variation, and prevents damage to the critical load (Computer - Instrumentation - Scientific equipment etc.).
Picture 1 – UPS block diagram The UPS is composed by three main sections: rectifier (R), inverter (I), static switch (SS). These sections will be described in the following chapters. The final chapter includes the description of the various electronic boards installed inside the UPS as well as their block diagrams and programming instructions.
1.1 OPERATING STATUS Final task of a UPS system is to protect the load from micro-interruptions, black-outs and various disturbances on the network, and guarantee a reliable supply also when internal faults occur. During normal operation the rectifier keeps the batteries in floating charge and provide energy for the inverter to supply the load through the static switch.
Picture 2 – Normal operation 4 of 31
JUD411298
First Issue 28/01/09
AC UPS operating description In case of an inverter failure or an overload the load is automatically transferred, without interruption, to the by-pass static switch.
Picture 3 – Load supplied by by-pass The inverter is the primary supply source, so when its voltage and frequency are in tolerance it synchronises with the by-pass line and the load is transferred again through the static switch. In case of mains failure (or rectifier failure) the inverter draws energy from the battery for the specified autonomy time, after which the inverter is turned off.
Picture 4 – Rectifier failure or mains failure For maintenance operations it’s possible to supply the load through the manual by-pass circuit breaker MBCB, connecting directly the by-pass line to the UPS output. During the manual by-pass procedure the load remains supplied, without any interruptions.
Picture 5 – Manual by-pass
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AC UPS operating description
2.
RECTIFIER
The rectifier converts the alternate input voltage having a variable amplitude and frequency into a constant-voltage and current-controlled direct output power source. Its function is to control the output values via a three-phase fully controlled SCR rectifier bridge (6-pulse version) or via two of these paralleled bridges (12-pulse version). Galvanic insulation from the input mains (when provided for by the technical specification is achieved via a transformer.
2.1 BASIC STRUCTURE The basic structure of the rectifier is the following: •
The input mains crosses the EMI filter for high frequency emissions and gets into the primary winding of input transformer T1, via isolator RICB.
The synchronism signals are taken from the primary winding for the control of the SCR firing angle, the input currents for the measurement and the supply voltage for the control logic (battery redounded) •
The secondary winding is connected to the SCR bridge via protection fuses.
•
In the 12-pulse version, the input transformer has got 2 secondary windings and 2 SCR bridges.
•
The control logic, housed in the rack named DR16, consists of the following cards: BP-DR16 PS-DR16 DR16 -COMP CAN-LINK
Id. no. N_FS3004 Id. no. N_FS3005 Id. no. N_FS3006 Id. no. N_FS3011
Interconnection panel ower supply Control card (CPU) Connection card CAN_BUS (optional for parallel redundant configuration)
•
The firing of the SCR’s is controlled by card DR16-COMP, and is performed via card: RTF Id. no. N_FS3002 SCR firing card
•
The rectified and controlled voltage is filtered by an L (series inductance) and C (paralleled capacitors) unit, calculated in accordance with the maximum ripple voltage provided for by the Technical Specification.
•
On the output of said unit, a feedback voltage is taken for the voltage control and measurements are made regarding the total output current (for the total limitation), as well as the charging and discharging current and voltage of the battery, if this function is provided.
•
The the rectifier output is connected to the loads via isolator ROCB.
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JUD411298
First Issue 28/01/09
AC UPS operating description
Picture 6 – Rectifier block diagram
2.2 6-PULSE RECTIFIER (STANDARD) The type of standard bridge configuration used by the rectifier is three-phase, fully controlled, with SCR’s and 6 pulses. It is so sized as to supply direct current loads and to recharge the battery to the maximum charging current provided for by the Technical Specification. The nominal standard value of the current harmonic distortion (THD) reintroduced into the mains by a 6-pulse rectifier is < 27%.
2.3 12-PULSE RECTIFIER (OPTIONAL) The 12-pulse configuration is used to reduce the current harmonic distortion (THD) reintroduced into the mains, to a value < 12%. This prevents affecting the supply line while respecting the other loads, and avoids the overheating of cables due to the circulation of harmonics.
It consists of two rectifier bridges which, thanks to a phase-shift transformer, operate with 30° difference, eliminating the harmonics typical of 6-pulse bridges, namely the 5th and the 7th harmonic. As a consequence, the harmonics left are the highest ones, namely the 11th, the 13th and multiple ones.
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AC UPS operating description
3.
INVERTER
The inverter is composed by two power blocks, controlled by the IGBT driver boards ID1 and ID2. The inverter bridge is connected to the transformer T1, which provides the galvanic insulation between the DC bus and the AC output. The transformer is provided with a leakage inductance that forms a low-pass filter with the output capacitor Cr; the filter provides to eliminate the high frequency harmonics from the output waveform in order to reduce the distortion of the sine-wave. The inverter supplies the load through the inverter static switch thyristor, which is connected to the output switch OCB. The current transformer TA2 provides the signal for the output current measure. When the inverter is started up the microprocessor control logic I/S-CL generates the IGBT’s control signals (PWM – Pulse Width Modulation) and send them to the driver boards ID1-ID2; the bridge starts to modulate and the output voltage increases. The voltage feedback provided by the INV-AV-1F board is used to control the output voltage value, according to the value set on the VCB board (mounted on the I/S-CL). The inverter current protection (Max Current Stop) and the short circuit current limitation are also managed by the I/S-CL, using the feedback signal provided by the hall-effect current transducer TA1, which is mounted on the inverter bridge input.
4.
STATIC SWITCH
The single-phase emergency line is connected to the input terminals 2-L1, 2-N. The filter RF2 provides to reduce the radio frequency disturbances according to the limits given by the EN50091-2 standard. The by-pass line is energized by closing the input switch SBCB; the fuse protects the static switch thyristor in case of short-circuit at the UPS output. The static by-pass switch is controlled by the SCB board, installed on the microprocessor control logic I/S-CL; the control signals for the thyristors are generated by the I/S-CL and sent to the firing board SCRSF-1F or 2SCR-FIR, connected directly to the gate of the thyristors. The VOLT-REF-1F board provides the feedback signals for the by-pass and output voltage measures. The UPS automatically transfers the load to the by-pass line in case of an inverter failure or overload. The manual by-pass circuit switch MBCB connects directly the emergency line input to the load in case of UPS maintenance.
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AC UPS operating description
5.
RECTIFIER PCB’S
5.1 BP-DR16 –(BACK PANEL) This card includes all the connections coming from the power side and from the signals to the control electronics and the power supply.
Picture 7 – Card BP-DR16
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AC UPS operating description Terminal board M1 M2 M5 M6 M7
Pin
Name
1-3-5 1-2 1-2-3 1-2-3 1-2-3 1-2 3-4 1-2-3 1-2 1-2 1-2 1-2-3 1-2-3 1-4 1-4 1-2 3-4 5-6 7-8 9-10 11-12 13-14 15-16 17-18 19-20 21-22 23-24
R-S-T +24V - Massa Pos-Misura-Neg Pos-Misura-Neg Pos-Misura-Neg C_INR-Massa C_INS-Massa Pos-Misura-Massa Ingresso digitale: Ing0 Ingresso digitale: Ing1 Ingresso digitale: Ing2 Pos-Misura-Massa Pos-Misura-Massa Neg-Pos Neg-Pos Caux_RICB-Massa Caux_BCB-Massa Caux_ROCB-Massa THSW_BR2-Massa FUSE_BR2-Massa THSW_BR1-Massa FUSE_BR1-Massa Sign_FANS-Massa Caux_CONG.-Massa COMM-ON/OFF-Massa Sign_EARTH_F-Massa PULS-ON/OFF-Massa
Connector
Pin No.
Connected to
CN3 CN4 CN5 CN6 CN7 CN8 CN9 CN10 CN11
20 10 10 10 10 10 10 10 10
CN1-SCP CN1-RTF Ponte 2 CN1-RTF Ponte 1 CN1-LED-DR16 CN1-ARC #1 CN1-ARC #2 CN1-ARC #3
CAN
DB 9
M8 M9 M10 M11 M12 M13 M14 M15 M16
M18
M19 M20
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Description
Supplies on transf. secondary side 24Vdc auxiliary supply Hall effect of total current Hall Effect of 12p balancing current Hall Effect of battery current Input current phase R Input current phase S Manual charge potentiometer POT1 Imposition of LEVEL4 (Emergency) Spare personalization input Spare personalization input Spare for 0-20 mA measurement Temperature meas. from BTP probe Rectifier output feedback Battery voltage measurement Auxiliary contact RICB Auxiliary contact BCB Auxiliary contact ROCB Thermal sensor of Bridge 2 heat sink Auxiliary contact of Bridge 2 fuses Thermal sensor of Bridge 1 heat sink Auxiliary contact of Bridge 1 fuses Fan fault signal from FMC Auxiliary contact of parallel bus tie ON/ OFF changeover switch Pole-to-earth signal from ground relay RTB.e RESET button To be used for compatibility with standard UPS control logic Synchronism and measurement on transf. U_IN-V_IN-W_IN 1-3-5 primary side Description
Mimic panel control Bridge 2 control Bridge 1 control Front Led Panel Control ARC #1 Card Control ARC #2 Card Control ARC #3 Card Control To be used for compatibility with standard UPS control logic CN1-SER_CAN Communication via RS232 and RS485 Communication on CAN for parallel Another RCN connection
JUD411298
First Issue 28/01/09
AC UPS operating description 5.2 PS-DR16 – (POWER SUPPLY) This card creates all the power supplies required by the rectifier by taking energy from the secondary voltage of the transformer and from the battery respectively. It also contains the three transformers for the synchronism and the measurement of the input voltage of RCN. J1-A J2-A
3 Syncr. and Measure Transformers
U_IN V_IN W_IN
R S T NEG-BATT NEG-BATT POS-BATT POS-BATT
V_MA_U V_MA_V V_MA_W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
+8V
J2-C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
U_IN V_IN
Graetz Bridge
W_IN
Multiple Outputs
GND_MICRO GND_MICRO +15V -15V
R GND_FIR GND_FIR +24FIR +5FIR
S
Insulated Forward Converter
T NEG-BATT NEG-BATT POS-BATT POS-BATT
GND_SPI +12SPI -12SPI +5SPI +12SER GND_SER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
J1-C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
+8V
GND_MICRO +15V -15V AC1 AC2 GND_FIR GND_FIR +24FIR +5FIR
GND_SPI +12SPI -12SPI +5SPI +12SER +5SER +5SER GND_SER GND_SER
Picture 8 – Card PS-DR16 The multiple output voltages are generated by a switching power supply of forward type, with 2500 Vac insulation, which takes its supply from the transformer’s secondary voltage (R,S,T) and by the redundant battery (POS_BATT, NEG_BATT). The three synchronism and measurement voltages (V_MA_U, V_MA_V, V_MA_W) are generated starting from the three input voltages of RCN (U_IN, V_IN, W_IN).
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AC UPS operating description 5.3
DR16-COMP – (μPROCESSOR CONTROL)
This card controls the whole operation of the rectifier. It is based on a 16-bit microprocessor (Motorola HC16) where all the digital control algorithms are implemented. Its main functions can be subdivided as follows:
5.3.1 Direct analog readings on AD The following readings are performed directly on the channels of the AD converter located within HC16: Value
Input circuit
AD channel no.
Variable
Zero
Input Voltage Phase U
Type 1
AD0
VOLT_ING_R
No
Input Voltage Phase V
Type 1
AD1
VOLT_ING_S
No
Input Voltage Phase W
Type 1
AD2
VOLT_ING_S
No
Battery Current
Type 2
AD3
VOLT_VAL_CBAT
Yes
Input Current Phase U
Type 2
AD4
CORR_ING_R
No
(Total) Output Current
Type 2
AD5
VOLT_VAL_CTOT
Yes
Input Current Phase V
Type 2
AD6
CORR_ING_S
No
12p Balancing Current
Type 2
AD7
VOLT_VAL_CBAL
Yes
Input Current Phase W
Type 2
-(AD4+AD6)
CORR_ING_T
No
CB
470N
R13 VMains_V 3K92
+15V
2 3K32
3
C26 100N 6 U6 OP-07/SO
7 1
D6 BAT41
+
J1-C-4
R15
V_MA_V
-
D5 BAT41
4 8
-15V
-15V
C29 +15V
100N
Picture 9 – Card DR16-COMP: Input circuit of Type 1
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AC UPS operating description C34 1uF R28 154K
4 8
-15V
6
CBAT
OP-07/SO C40
+15V
100N
1
7 1
2
2
3 154K
JP2 JUMPER-2
1
JP1 JUMPER-2
C38 100N
U10
+
2
-
R29 C_BATT
J1-C-7
R31 332R
C41 4N7
R32 332R
R33 332R
C42 4N7
R34 332R
C43 4N7
C44 4N7
Picture 10 – Card DR16-COMP: Input circuit of Type 2
5.3.2 Direct analog readings on AD The following readings are performed on the channels of the external (serial) AD converter U24-TLC1542: Value
Input circuit
AD input no.
Variable
Zero
Battery Temperature
Type 3
IN0
TEMPERATURA
No
Manual Charge Pot. Used as (digital) Input 0
Type 4
IN1
POT1
No
Type 4
IN2
ING0
No
Used as (digital) Input 1
Type 4
IN3
ING1
No
Used as (digital) Input 2
Type 4
IN4
ING2
No
0-20 mA analog input
Type 3
IN5
SPI_SPARE
No
Rectifier Feedback Voltage
Type 5
IN6
VRECT
No
Battery Voltage
Type 5
IN7
VBATT
No
R123
R124
10K
47K5
+12SPI
-12SPI
4 8
D68
J2-A-2
R128
TEMPERATURE
3
D70 BAT41
C111 100N
R271
OP-07/SO
562R
U36 6
SPI_TEMP
10K 7 1
100K
+
2 R127
-
BAT41
C114
R130 33R
C115 1uF
100N +12SPI
GND_SPI
Picture 11 – DR16-COMP: Input circuit of Type 3
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AC UPS operating description R133
R134
10K
10K
+12SPI
-12SPI
4 8
D72 2 R137
R138 3
D74 BAT41
C117 100N
U37
R272
6
SPI_POT1
OP-07/SO
562R
10K 7 1
100K
+
POT-1
J2-A-3
-
BAT41
C120
R140 C121 1uF
100N
24K9 +12SPI
Picture 12 – DR16-COMP: Input circuit of Type 4 R141
C122
10K
470N R142
R143 10K 100K C123
R144
-12SPI -12SPI
V-RECT
J2-C-6
1uF
2
BAT41
2 R147
6 OP-07/SO
3
OP-07/SO 562R
C129 4N7
C128 100N
100N
R152 J2-C-7
R277 SPI_VRECT
6
C130
7 1 R148 2K74
C124 100N
U43
10K 7 1
3
C125 100N
U42
+
BAT41
D76
-
D75
+
C129 4N7
-
R148 2K74
4 8
4 8
100K
V-RECT-RET
+12SPI
+12SPI 100K
R154 100K
C133 1uF
Picture 13 – Card DR16-COMP: Input circuit of Type 5
5.3.3 Digital inputs The following digital inputs are sensed by an opto-coupler and selected via the chip select CS2 that goes to latches U15 and U16 - 74HC244; the Dip Switches of SW1 are sensed in the same way: Connector
J2
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Pin A-14 A-9 C-14 A-12 C-9 C-10 C-11 C-12 A-10 A-11 A-13 C-13
OPTO ISO1 ISO1 ISO2 ISO2 ISO3 ISO3 ISO4 ISO4 ISO5 ISO5 ISO6 ISO6
JUD411298
Origin Auxiliary contact RICB Auxiliary contact BCB Auxiliary contact ROCB ON/ OFF changeover switch Fan fault signal from FMC Auxiliary contact of parallel bus tie Auxiliary contact of Bridge 2 fuses Auxiliary contact of Bridge 1 fuses Thermal probe of Bridge 2 heat sink Thermal probe of Bridge 1 heat sink Pole-to-earth signal from ground relay Rectifier RESET button
First Issue 28/01/09
AC UPS operating description +12SPI +5V C79
+5V D27 20
1N4148 J2-C-11
U15
FUSE_BR2_aux
R90 4K7
D15 D14 D13 D12 D11 D10 D9 D8
R91 4K7
D29 C80 100N
ISO4 1
7
I_FUSE_BR2
2 4
8 6
I_FUSE_BR1
3
5
1N4148
18 16 14 12 9 7 5 3
1Y1 1Y2 1Y3 1Y4 2Y1 2Y2 2Y3 2Y4
10
100N
VCC
R88 1K54
1 19
1G 2G
GND
DIP1 DIP2 DIP3 DIP4 I_RESET_MAX_VOUT I_RICHIAMO_CARICA_RAPIDA I_NORMALE/MANUALE I_FANS
2 4 6 8 11 13 15 17
1A1 1A2 1A3 1A4 2A1 2A2 2A3 2A4
74HC244
CS2
+12SPI +5V C82
U16 J2-C-12
FUSE_BR1_aux
18 16 14 12 9 7 5 3
D7 D6 D5 D4 D3 D2 D1 D0
D33 C83 100N 1N4148
10
1Y1 1Y2 1Y3 1Y4 2Y1 2Y2 2Y3 2Y4
20
D31 1N4148
VCC
R94 1K54
GND
100N 1A1 1A2 1A3 1A4 2A1 2A2 2A3 2A4 1G 2G
2 4 6 8 11 13 15 17
I_THSW_BR2 I_THSW_BR1 I_FUSE_BR1 I_FUSE_BR2 I_RADD_ON/OFF I_ROCB I_BCB I_RICB
1 19
74HC244 CS2
Picture 14 – Card DR16-COMP: Digital input circuit
5.3.4 Communication via RS232 The following section is used to interface the microprocessor with card SER_DR16 for the serial connection, in compliance with standard RS232. +5SER C195 OP8
U53A
HP2601
R225 365R CN1-16
TXD
1
2
2
100N
8
0
R226 365R
7 3
74HC14A
TXD_SER
J2-A-31
5
6
0 +5V C196 OP9 R211
HP2601 100N R227 365R
U53B
8
RXD_SER
2
J2-C-31
7 365R 3
CN1-17
RXD
4
3
6
0 5
74HC14A
Picture 15 – Card DR16-COMP: Interface RS232
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AC UPS operating description 5.3.5 SCR firing The following section allows to transfer the firings digitally generated by the microprocessor, to the SCR’s of Bridge 1 and Bridge 2 (12p configuration).
+5V
R270 10K
FIR_BR1_SCR1 FIR_BR1_SCR2 FIR_BR1_SCR3 FIR_BR1_SCR4 FIR_BR1_SCR5 FIR_BR1_SCR6
J1-A-24 J1-C-24 J1-A-23 J1-C-23 J1-A-22 J1-C-22
CLK CLR
U32 74HC273
10
2 5 6 9 12 15 16 19
Optocouplers
VCC
FIR_BR2_SCR1 FIR_BR2_SCR2 FIR_BR2_SCR3 FIR_BR2_SCR4 FIR_BR2_SCR5 FIR_BR2_SCR6
CLK CLR
C156
U62 74HC273
100N 3 4 7 8 13 14 17 18
1D 2D 3D 4D 5D 6D 7D 8D
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
2 5 6 9 12 15 16 19
J1-A-21 J1-C-21 J1-A-20 J1-C-20 J1-A-19 J1-C-19
CLK CLR
10
GND
11 1
+5FIR
20
+5V
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
GND
11 1
CS5
1D 2D 3D 4D 5D 6D 7D 8D
10
3 4 7 8 13 14 17 18
20
100N D0 D1 D2 D3 D4 D5 D6 D7
2 5 6 9 12 15 16 19
GND
11 1
VCC
C225
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
Driver
BR2_ENABLE (Selects BR2)
1D 2D 3D 4D 5D 6D 7D 8D
Driver
BR1_ENABLE (Selects BR1)
20
100N 3 4 7 8 13 14 17 18
+5FIR
VCC
C156
U33 74HC273
Picture 16 – Card DR16-COMP: SCR firing
Integrated circuits U62, U32, U33 are the firing latches that allow to switch the firing pulses to the two bridges.
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AC UPS operating description
6.
INVERTER AND STATIC SWITCH PCB’S
6.1 ID / DR-SAT – (IGBT DRIVER) The IGBT’s driver cards are used to transfer the turn-on signals created by the microprocessor card I/S-CL to the IGBT. The drivers draw the power from a 40kHz square wave coming from the POWER SUPPLY card; the square wave is properly isolated, rectified and filtered and made controllable by a green LED. The turn-on command for the IGBT’s coming from the card I/S-CL is isolated by an optocoupler and then slightly integrated through a low-pass filter (dead-time). The final amplifying circuit, using MOSFET’s, provides to translate the modulation signal between +15V (ON Level) and -15V (OFF Level). The card ID is designed to control a complete bridge leg (positive and negative IGBT’s), the card DR-SAT can only control a single switch, generally made by two IGBT’s in parallel. In addition, the card DR-SAT is provided with a de-saturation sensor which provide to stop the modulation in case the Collector-Emitter voltage exceed the rated IGBT’s saturation value. CN1
LD3 Power supply on LD4 Power supply on
LD1 Modulation on
R11 IGBT’S gate
LD2 Modulation on
GND IGBT1 M1
GND IGBT2
R30 IGBT’S gate
M4
Picture 17 – ID (IGBT DRIVER) board
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AC UPS operating description
D6 Supply ON
TPG1 Test Point IGBT1
TP5 GROUND J1
TPG2 Test Point IGBT2
CN1 J2
D14 Modulation ON
D17 Led fixed: inverter OK Led blinking: under voltage lock-out
D5 Supply ON
Picture 18 – Card DR-SAT
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AC UPS operating description 6.2 PS-LV / PS-MV / PS-SAT – (POWER SUPPLY) These boards provide the different power supplies to all the sections of the I/S-CL (microprocessor board) and to the front panel. They take the power at the inverter input and their input voltage range is as follows. PS-LV PS-MV PS-SAT_110 PS-SAT_220
Æ Æ Æ Æ
80÷180Vdc 160÷330Vdc 80÷180Vdc 160÷330Vdc
The insulation voltage between output section and the DC input is 2,5kV. The following table summarizes all the different outputs: SECTION Analog measures Free contacts and parallel bus Free contacts Microprocessor and display IGBT’s drivers Power Supply RS-232 and RS-485
LED Test point LD1 TP2-TP4 LD2 TP3-TP4 LD3 TP5-TP4 LD4 LD5 TP8-TP9
Pot.
P2
+12V Analog -12V Analog +24V Analog +12V / Relay & Bus +12V +9V Sq. Wave AC1-AC2 Sq. Wave AC3-AC4
In addition these cards create an insulated voltage proportional to the input DC voltage which is transmitted to the microprocessor as a feed-back signal for the measure of the inverter input voltage. This signal can by adjusted with the potentiometer P1.
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AC1 AC2
A
CN4
CN2
10 9 8 7 6 5 4 3 2 1
+24V
Input Vdc Voltage Measure
40 Khz Square Wave
+12V
Voltage Regulators
+8V
CN1
10 9 8 7 6 5 4 3 2 1
Regulated Vdc Voltage
-12V
LD1 LD2 FU6
FU2
Rectifier Bridge D22-D23-D24-D25
AC3
AC4
+12V / Relay e Bus
D
TP4
+12V / SCR
CN3
1 2 3 4 5 6 7 8 9 10
Input Vdc Voltage (Not Regulated)
P1
LD3
R&B
TP8
TP9
VDC+
Input DC Voltage Measure adjustable by turning P1
TP4
D14 D15
40 Khz Square Wave FU7 FU8
Control IC's Power Supply: provides the power to U2 (12V on DZ2-K) and U3 (12V on DZ5-K).
VDC-
IGBT's Gate voltage adj.
Step Down DC-DC Converter controlled by U2.
P2
TP5 LD4 LD5
D14 D15 D28
R38 R39 R40
Analog Power Supply
Analog Power Supply
Digital Power Supply
Relay & Bus Power Supply
Precharging Thyristor Power Supply
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TP3
SCR
1 2 3 4 5 6 7 8 9 10
1 2 3
AC UPS operating description CNB
FB2
FB1
Fixed duty cycle Switching Modulator controlled by U3
Picture 19 – POWER SUPPLY board block diagram
AC UPS operating description
CN1
CN4 LD5 CN3
CNB
LD4 P1 Vdc μP adjust CW=increase
LD3
FB1 LD2 LD1 TP1
VB+
P2 IGBT’s gate voltage ACW=increase
FB2
CN2 VB-
Picture 20 – POWER SUPPLY board PS-LV / PS-MV
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AC UPS operating description
TP9
P2 IGBT’s gate voltage
CN1
TP8 P1 Vdc μP ad just. CW= Increase
FB2 VB-
CN4
LD5 LD4
VB+
CN3
TP4 GND
FB1
TP2 +12V CN2
Picture 21 – POWER SUPPLY board PS-SAT
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TP3 -12V
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LD2
LD1
TP5 +24V
LD3
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AC UPS operating description 6.3 PWM-SAT – (IGBT DRIVERS INTERFACE) The card PWM-SAT is used only together with the IGBT driver DR-SAT. The turn-on signals for the IGBT’s are available on the connectors CN7 and CN1 of the microprocessor card I/S-CL, respectively for the first and the second bridge leg. The driver card DR-SAT can only control one switch, so two of them are necessary for each bridge leg, and the control signals must be different. The card PWM-SAT is the interface between the I/S-CL and the driver cards DR-SAT that provides to split the turn-on signals and distribute them to the right driver cards.
6.4 INV-AV-1F – (INVERTER VOLTAGE FEEDBACK) The INV-AV-1F provides the inverter voltage feedback for the real-time control loop. The inverter output phase and neutral, taken on the filter capacitor Cr, are connected on CN1 pin 1 and 7 respectively; the voltage value is reduced by the transformer T1 and sent to the microprocessor control logic I/S-CL via the connector W18. The UPS output current transformer T20 is connected to CN3 pin 1 and 2; the current generated by T20 flows through the resistor R4, generating a voltage drop proportional to the UPS output current; this waveform is sent to the I/S-CL measuring section for the output current reading.
6.5 VOLT-REF-1F – (BYP / OUT VOLTAGE FEEDBACK) The VOLT-REF-1F provides the signals for the by-pass line and output voltage measurement. The by-pass is connected on CN1 pin 1 (phase) and 7 (neutral) and supplies the double-secondary transformer T1; a secondary winding, via the single-phase Graetz bridge formed by the diodes D1-D2-D4-D5 and the stabilizer U1, creates a +5V supply that is sent to the I/S-CL board via the connector CN3. This is a redundant supply for the static switch control logic (SCB board) and its presence can be verified by checking the status of the LED DL1. The other secondary winding is used to send the microprocessor, for measuring purposes, a waveform proportional to the by-pass voltage value, via the connector CN4, pin 1 and 4. The UPS output is connected on CN5 pin 1 (phase) and 7 (neutral) and supplies the doublesecondary transformer T2; a secondary winding is connected to the single-phase Graetz bridge formed by the diodes D8-D9-D11-D12, which output is connected in parallel to the stabilizer U1. The other secondary winding is used to send the microprocessor, for measuring purposes, a waveform proportional to the output voltage value, via the connector CN4, pin 5 and 8. The fuses FU1-FU2-FU3 are used for the fans protection.
6.6 SCRSF-1F / 2SCR-FIR – (THYRISTORS FIRING) The SCRSF-1F and the 2SCR-FIR are the thyristors firing boards and are installed directly on the static switch thyristors. The control signals generated by the I/S-CL are connected to the card, isolated by high frequency transformers and sent directly to the thyristors. The green (or red) LED’s show which component is controlled, indicating which line is supplying the load. The card SCRSF-1F is a double firing card, so it can control two pairs of thyristors, that’s to say the whole single-phase static switch. The card 2SCR-Fir can only control one pair of thyristors, so two of them are necessary for a complete single-phase static switch.
6.7 I/S-CL (MICROPROCESSOR CONTROL LOGIC) 6.7.1 Introduction The I/S Control Logic (I/S CL) controls all the inverter functions and signals. It takes the digital inputs (like auxiliary contacts, switches and so on), performs all the analog measures (like voltages, currents and so on) and provides the total control of the UPS. First Issue 28/01/09
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AC UPS operating description 6.7.2 Digital Inputs The digital inputs are connected to the I/S CL via the M3 connector according to the description on the block diagram. All these signals are de-coupled and latched before they are connected to the microprocessor bus.
6.7.3 Dip Switches The dip switches SW1 and SW2 are connected to the microprocessor bus via the latches U67 and U68. The functions of the IMN can be programmed as follows. Dip n. 1 2 3 4 5 4 5 4 5 4 5 6 7 8
Status Off On Off On Off On On On Off On On Off Off Off Off On Off On Off On
Description Single Parallel Frequency 50Hz Frequency 60Hz Single/Parallel Hot Standby Nominal Vout 220V (110V) Nominal Vout 208V (127V) Nominal Vout 230V (115V) Nominal Vout 240V (120V) Test Normal Buzzer disabled Buzzer enabled Three-phase output (not used) Single-phase output
Table 1 – DSW 1 Dip n. 1 3 4 5 6
Status On Off On Off On Off On Off On Off
Description ON/OFF inverter by external switch ON/OFF inverter automatic INT-5 ARC interface Single ARC board Output range: 110-115-120-127 Vac Output range: 208-220-230-240 Vac Rotary switch installed Rotary switch NOT installed “AC-UPS” LCD panel Standard LCD panel
Table 2 – DSW 2 NOTE The setting tables given above refers to the I/S-CL with standard software I180STD or following.
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AC UPS operating description 6.7.4 Fast Analog Inputs The measures of the bypass L1, L2 and L3 phases and output L1, L2 and L3, are directly connected to the microprocessor A/D converter. The measures can be found in the following points (see picture 11): D52 (K) D59 (K)
Output L3 Bypass L3
D57 (K) D64 (K)
Output L2 Bypass L2
D58 (K) D65 (K)
Output L1 Bypass L1
6.7.5 Watchdog and Reset The microprocessor is controlled by a smart watchdog system that provides an automatic reset in case of an error of the microprocessor during the normal operation or a problem in the microprocessor power supply (under-voltage lockout). It is also possible to reset manually the microprocessor by pressing the reset push-button SW3.
6.7.6 RAM, EPROM’s and EEPROM The EEPROM U71 contains the functional parameters of the UPS and the adjustments. The RAM U58 contains the history of the alarms of the UPS. Up to 900 events can be stored in this device and the backup battery allows to preserve the information for three days after the power has been removed. The two EPROM’s contain: U55 Program odd addresses U65 Program even addresses.
6.7.7 Digital Power Supply The digital part of the I/S CL has its own power supply (5 volts). This voltage can be checked on the LED D69 (green) and measured between U75 pin 2 (ground) and pin 3.
6.7.8 RCB board The RCB is an additional card which is fixed on the I/S-CL. It contains the drivers for the digital outputs of the microprocessor. Each output is de-coupled and buffered on this card. The RCB contains also the RS232 and RS485 drivers for the communication.
6.7.9 SCB board and Thyristor drivers The SCB is an additional card which is fixed on the I/S-CL. It contains the decisional logic for both bypass and inverter static switches. It can drive directly the bypass static switch or send the command to the I/S-CL to close the inverter static switch. This card can be programmed through the jumpers J1÷J8 (see picture 12) and it is powered directly by the emergency line at +5V (see par. 4.5.1). This supply can be checked on the LED L1 (green) and measured between U11 pin 10 (ground) and pin 20.
6.7.10 Current Limitation and Max Current Stop The current flowing in the inverter bridge is measured through a hall-effect current transducer on the M1 pin 2. The maximum current level for the inverter stop (desaturation) can be programmed by closing the jumpers J9, J10 and J100. These jumpers must be programmed on each unit according to the indications given in the table below. As the maximum current stop comparator commutates the LED D3 red becomes on, the inverter is stopped and the current stop signal is sent to the microprocessor (alarm A24 - Current Stop). The inverter can be reset by pressing the reset push-button SW4. This protection works in case of a fault or wrong operation on the unit. Normally the inverter output current is controlled by the current limitation block. The current can be checked on the test point TP2 and the limitation level can be adjusted by turning the First Issue 28/01/09
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AC UPS operating description potentiometer P2 on the I/S-CL (see the IMN Test Procedure). As the output current exceeds the limitation value the short circuit detector sends the short circuit signal to the microprocessor (alarm A25 - Short Circuit). JUMPERS
VDCNOM
Resistors on I/S-CL
J9
J10
J100
110
22+47
Closed
Open
Open
220
100+33
Open
Closed
Open
110
33
Open
Closed
Closed
220
22+47
Closed
Open
Open
110
33
Open
Closed
Closed
220
22+33
Open
Closed
Open
110
47
Closed
Open
Closed
220
33
Open
Closed
Closed
110
33
Open
Closed
Closed
220
33
Open
Closed
Closed
110
22
Closed
Closed
Open
220
47
Closed
Open
Closed
110
22
Closed
Closed
Open
220
47
Closed
Open
Closed
60
220
33
Open
Closed
Closed
80
220
22
Closed
Closed
Open
100
220
22
Closed
Closed
Open
UPS [kVA] 5 10 15 20 30 40 50
R18 (J100) = 22R 2W; R39 (J10) = 47R 2W; R40 (J9) = 33R 2W
6.7.11 VCB board The VCB is an additional card which is fixed on the I/S-CL. It contains the sine-wave generator which converts the digital samples of the sine-wave coming from the microprocessor into an analog signal which is transferred to the PWM generator (see below). This card can be programmed by the J1 to work in manual control, (in this case the inverter output voltage can be controlled manually by turning the potentiometer P1 on the I/S-CL) or in closed loop control (in this case the inverter output voltage can be set by turning the potentiometer P1 on the VCB and it is kept the same in all the conditions by the control loop). It is also possible to include or exclude the instantaneous value loop by adding or removing the jumper J2 (see picture 13). This card also sends the measure of the inverter output voltage to the microprocessor via the external A/D Converter (see 4.7.1.13).
6.7.12 PWM generator The I/S control logic can be used to generate both single-phase and three-phase output voltages. This function can be programmed by setting the jumper J1 on the I/S-CL. For singlephase units only one VCB card must be installed, whilst three VCB cards are used for the threephase units. The PWM generator compares the sine-waves coming from the VCB card with a triangular waveform at the switching frequency (U17 pin 6) to generate the PWM modulation to control the inverter power bridge.
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AC UPS operating description 6.7.13 External A/D Converter Several analog measures are sent to the microprocessor via the external A/D converter U22. These measures can be found in the following points: Measure Inverter Output Voltage R Inverter Output Voltage S Inverter Output Voltage T Output Current R Output Current S Output Current T Inverter Input Voltage (DC) Inverter Input Current (DC) Phase Correction for Parallel Redundant Battery Current for Boost Charger
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A/D Channel #0 #1 #2 #3 #4 #5 #6 #7 #8 #9
Test Point D43 (K) D20 (K) D21 (K) D6 (K) D33 (K) D5 (K) D23 (K) D22 (K) D42 (K) D74 (K)
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Ad0 Ad1 Ad2 Ad3 Microprocessor Ad4 Ad5 Reset
EEPROM
U71
Parameters
Odd
EPROM
Even
EPROM
Addresses and Data Bus
RAM
U65
History
U55
U11 pin 10
U11 pin 9
CN6
Relays Output Buffer U11
Optocouplers
Output Buffers U74
P1
J2
Optocouplers
VCB
Sinus Wave Generator U4
Single Phase Feed-back
J1
+12V-SCR
Optocouplers
Rx Tx Gnd Pos
OutOut+ InIn+
RCB
CN4
In9
Battery Curr.
In8 Phase Correct.
In6 Inverter Inp. Volt.
In3 Output Curr. R In4 Output Curr. S In5 Output Curr. T
Optocouplers
Inv. Voltage R In0 Inv. Voltage S In1 Inv. Voltage T In2 DC Current In7
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 20 1
16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6
BYPASS SWITCH
U58 Backup battery
U75 pin 3
U75 pin 2
Addresses and Data Bus
Optocouplers
+12V
MBCB AUX. CONTACT
OCB AUX. CONTACT U61
Digital Power Supply U75
Optocouplers
Single Phase Feed-back
VCB
Sinus Wave Generator U4
U15
BCB AUX. CONTACT
Watch-dog and Undervoltage Lockout
Optocouplers
P1
J2 J1
U14
EPO CONTACT
By-Pass R By-Pass S By-Pass T Output R Output S Output T
Optocouplers
Single Phase Feed-back
VCB
Sinus Wave Generator U4
CN5
SPARE
SPARE
MAINS FAULT
J1 J2 J3 J4
Inverter Feed Load Signal
Optocouplers
CHARGER FAULT SPARE
U11 pin 20
P1
J2 J1
+5V
BT
THERMAL SWITCH
SPARE
+5ST
SCB
Fast Analog to Digital Conversion Channels
Short Circuit Detector
SW3
P1
Analog Power Supply U7
+12V
Static Switch Control Programmable J5 J6 J7 J8 Array Logics Thyristors Driver
Max Current Stop
J1
D11
RS232 Buffer
L1
RS485 Buffer
External A/D Converter U22
Optocouplers
J9 J10 J100
PWM Generator U9-U14
CN4-1 CN4-2 CN4-3 CN4-8 CN4-9 CN4-10
U7 pin 1
M2-9CN3-2 CN4-6 CN8-8 CN8-9 CN8-10
U7 pin 2
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U11 pin 10
Inverter Bridge Current
Switching Frequency Generator U17
CN2
RELAY #2 RELAY #3 RELAY #1 RELAY #4 RELAY #5 RELAY #6 RELAY #7 POS-REL POS-REL POS-REL K1 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
D69
SW1
Current Limitation
CN1
CN14-9 CN14-10 CN14-2 CN14-1
RESET 10 9 8 7 6 5 4 3 2 1
Short Circuit Signal
Optocoupler U39
SW2 CN13-7 CN13-6 CN13-5 CN13-2 CN13-3 CN13-4 CN10
L2 10 9 8 7 6 5 4 3 2 1
+5ST
Input Latches U67-U68 Display Driver Current Stop Signal
Thyristors Driver L1
Input Latches U48-U52-U53 IGBT's Current Selection
P2
CN7
D3 SW4
+24V
GND
M1-2
CN5 CN9 CN11
M2 1 2 3 4 5 6 7 8 9 10
AC UPS operating description
M3
RESET
TP2
M1
2 1
Picture 22 – Card I/S-CL block diagram
AC UPS operating description
CN6
Analog ground J9
R40-100R R39-47R
J10
CN4
CN5
Current Test point D8-short circuit CN3
CN2
J11-MBCB Reset max. Aux. contact curr. NC=1-2 NA=2-3 CN1
M1 Led max corr. J100
M2
CN7
J1 1Ph = 1-2 3Ph = 2-3
R18 22R
Man. Inv. volt. adj. ACW=incr. Modul.
M3 P2 Curr. limit. adjust. ACW=increase curr.
U17 Pin 6=Triangle
D11 Correct +12V analog
CN8 R66 6K8 = 8KHz 13K3 = 4KHz
D23 Vdc measur.
CN11
CN10 Front panel
CNB
CN9
RST–RST Emer. line - Output (D65..D52)
CN14
CN13
J2 Battery connected 1-2 Closed = backup
CN8
CN12 Debug CN7
ODD
Reset
CN15
Normal Debug selection
EVN
Microprocessor ground
Picture 23 – Card I/S-CL
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D69-Correct +8V digital
J7 Open=Watchdog excluded Closed=Watchdog included
JUD411298
SW1
SW2
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AC UPS operating description 6.7.14 Card SCB TP1-2
U12 SAFE_22
U11 OUTGEN
JP7
JP3
JP2 Open = aut. Retransfer Closed = man. retransfer
JP1 Closed = single unit Open = hot stand by – parallel red.
JP4
JP5
JP8
JP6
Picture 24 – Card SCB NOTE For parallel redundant UPS, U11 must be changed to OUTGEN 41 and U22 to SAFE1_23.
6.7.15 Card VCB P1 Close loop inverter voltage adj.
J1 Inv. Voltage reg. 1-2 = closed loop 2-3 = manual
J2 Closed = istant. loop included Open = istant. loop not included
J3 Always open
Picture 25 – Card VCB
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AC UPS operating description 6.8 FCI (FREE CONTACT INTERFACE) The FCI board provides a de-coupling function for all the digital inputs (see point 8.2.1.2) and it’s connected to the microprocessor through the terminal M2. In detail the function of each relay is the following: K1 K2 K3 K4 K5 K6 K7 K8 K9
(terminals 17-18) (terminals 15-16) (terminals 13-14) (terminals 11-12) (terminals 9-10) (terminals 7-8) (terminals 5-6) (terminals 3-4) (terminals 1-2)
used for UPS in parallel configuration Inverter bridge thermal sensors MBCB (manual by-pass breaker) position SW1 (by-pass test switch) position OCB (UPS output breaker) position used with AC-UPS panel EPO (Emergency Power Off) Fans failure contact from card FMC Inverter ON/OFF via external selector
6.9 FP-ACUPS – (FRONT PANEL) The UPS front panel is an active component inside the UPS systems, as it centralize the data coming from the rectifier and inverter CPU’s and, thanks to a pair of twin microprocessors, manages the signals to provide a single graphical interface. The UPSÆUser interface is completely provided by the FP-AC-UPS, including all the signalisations and alarms and the remote connection via relay cards and Modbus adapter. The relay cards as well as some alarms can be programmed using a proper software program. All the details regarding the operation and use of the card are contained inside the document “JUD410410 E2001.e AC-UPS Front Panel”.
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AC UPS Test Procedure
AC UPS TEST PROCEDURE
Index
Code
1 – RTB_E TEST PROCEDURE
JUD411352
2 – IMB_E TEST PROCEDURE
JUD411347
3 – SFP_AC-UPS
JUD411619
Rev.
/
Descrizione Description
First Issue
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
20.03.09
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
E
1
di Pag. of Pag.
1
Codice / Code
JUD411618
AC UPS Troubleshooting procedures
AC UPS TROUBLESHOOTING PROCEDURES Index 1
INTRODUCTION.................................................................................. 5 1.1
2
CONNECTION OF THE TEST SOFTWARE ....................................................5
TROUBLESHOOTING PROCEDURES .............................................. 6 2.1
A1 – MAINS FAULT .........................................................................................6
2.1.1 2.2
Troubleshooting procedure ....................................................................6
A2 – RECT BLOWN FUSES ............................................................................6
2.2.1 2.3
Troubleshooting procedure ....................................................................6
A3 – RECT HIGH TEMPERATURE..................................................................7
2.3.1 2.4
Troubleshooting procedure ....................................................................7
A4 – RECT OVERLOAD / THERMAL IMAGE..................................................7
2.4.1 2.5
Troubleshooting procedure ....................................................................7
A5 – MAX DC VOLTAGE .................................................................................8
2.5.1 2.6
Troubleshooting procedure ....................................................................8
A6 – MIN DC VOLTAGE...................................................................................8
2.6.1 2.7
Troubleshooting procedure ....................................................................8
A7 – CHARGING FAULT .................................................................................9
2.7.1
Troubleshooting procedure (Wrong Floating Low)...............................9
2.7.2
Troubleshooting procedure (Wrong Floating High)..............................9
2.7.3
Troubleshooting procedure (Safety timer).............................................9
2.8
A8 – RICB OPEN..............................................................................................9
2.8.1 2.9
Troubleshooting procedure ....................................................................9
A9 – BCB OPEN.............................................................................................10
2.9.1 2.10
Troubleshooting procedure ..................................................................10 A10 – BATTERY DISCHARGING...............................................................10
2.10.1 2.11
A11 – BATTERY LOW................................................................................10
2.11.1 Rev.
/ A
Troubleshooting procedure...............................................................10 Troubleshooting procedure (Wrong Floating Low) .........................10
Descrizione Description
First Issue Revision JSE411881
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
Lingua Language
Pagina Page
di Pag. of Pag.
28.01.09 08/06/09
P. Conti P. Conti
E. Simoni E. Simoni
E. Simoni E. Simoni
E
1
31
Codice / Code
JUD411299
AC UPS Troubleshooting procedures 2.12
A12 – BATTERY IN TEST.......................................................................... 10
2.13
A13 – BATTERY FAULT............................................................................ 11
2.14
A14 – INV VDC FAULT .............................................................................. 11
2.14.1 2.15
A15 – INV HIGH TEMPERATURE ............................................................. 11
2.15.1 2.16
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Troubleshooting procedure .............................................................. 18
A29 – INVERTER SHORT CIRCUIT .......................................................... 18
2.29.1 2.30
Troubleshooting procedure .............................................................. 18
A28 – THERMAL IMAGE ........................................................................... 18
2.28.1 2.29
Troubleshooting procedure .............................................................. 17
A27 – EPO PRESSED................................................................................ 17
2.27.1 2.28
Troubleshooting procedure .............................................................. 17
A26 – MANUAL BYPASS CLOSED .......................................................... 17
2.26.1 2.27
Troubleshooting procedure .............................................................. 16
A25 – UPS OCB OPEN .............................................................................. 17
2.25.1 2.26
Troubleshooting procedure .............................................................. 16
A24 – FANS FAILURE ............................................................................... 16
2.24.1 2.25
Troubleshooting procedure .............................................................. 16
A23 – RETRANSFER BLOCKED .............................................................. 16
2.23.1 2.24
Troubleshooting procedure .............................................................. 15
A22 – BYPASS SWITCH ........................................................................... 16
2.22.1 2.23
Troubleshooting procedure .............................................................. 15
A21 – BYPASS FEED LOAD ..................................................................... 15
2.21.1 2.22
Troubleshooting procedure .............................................................. 14
A20 – BYPASS FAULT .............................................................................. 14
2.20.1 2.21
Troubleshooting procedure .............................................................. 13
A19 – INV OVERLOAD .............................................................................. 13
2.19.1 2.20
Troubleshooting procedure .............................................................. 13
A18 – INV NO SYNCHR ............................................................................. 13
2.18.1 2.19
Troubleshooting procedure .............................................................. 12
A17 – INV CURRENT STOP ...................................................................... 13
2.17.1 2.18
Troubleshooting procedure .............................................................. 11
A16 – INVERTER OUT OF TOLERANCE ................................................. 12
2.16.1 2.17
Troubleshooting procedure .............................................................. 11
Troubleshooting procedure .............................................................. 18
A40 – DC EARTH FAULT .......................................................................... 19 JUD411299
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A41 – ROCB OPEN ....................................................................................19
2.31.1 2.32
3
Troubleshooting procedure...............................................................19
PROGRAMMABLE ALARMS .....................................................................19
PCB’S AND COMPONENTS SUBSTITUTION ................................. 20 3.1
PCB’S SUBSTITUTION..................................................................................20
3.1.1
PS-DR16 – (RECTIFIER POWER SUPPLY) ...........................................20
3.1.2
DR-16 – (RECTIFIER μPROCESSOR CONTROL) .................................20
3.1.3
PS-LV / PS-MV / PS-SAT – (INVERTER POWER SUPPLY) .................21
3.1.4
I/S-CL – (INVERTER μPROCESSOR CONTROL).................................22
3.1.5
INV-AV-1F – (INVERTER VOLTAGE FEEDBACK) ................................25
3.1.6
VOLT-REF-1F – (BYP/OUT VOLTAGE FEEDBACK) ............................26
3.2
4
Troubleshooting procedure...............................................................19
COMPONENTS SUBSTITUTION ...................................................................26
3.2.1
RECTIFIER BRIDGE THYRISTORS .......................................................26
3.2.2
INVERTER BRIDGE IGBT’S ...................................................................27
3.2.3
STATIC SWITCH THYRISTORS .............................................................27
ON-FIELD TEST PROCEDURES...................................................... 28 4.1
INVERTER ......................................................................................................28
4.1.1
General notes on the TEST mode.........................................................28
4.1.2
EXTERNAL POWER SUPPLY ................................................................28
4.1.3
Blank test of the card I/S-CL .................................................................28
4.1.4
Inverter manual start-up ........................................................................29
4.1.5
Inverter automatic start-up....................................................................30
4.2
STATIC SWITCH ............................................................................................30
4.2.1
Check of the redundant supply.............................................................30
4.2.2
Commutation tests.................................................................................31
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Index of pictures / tables Picture 1 – Configuration dip-switch (software communication) .................................................................. 5 Picture 2 – Signal on cathode of D65 ......................................................................................................... 14 Picture 3 – IGBT turn-on signal .................................................................................................................. 21 Table 1 – DSW 1 ....................................................................................................................................... 22 Table 2 – DSW 2 ....................................................................................................................................... 22 Picture 4 – Current signal on TP2 at 100% of load .................................................................................... 24 Picture 5 – Rectifier input current waveform............................................................................................... 26 Picture 6 – Triangle waveform.................................................................................................................... 29
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1 INTRODUCTION This troubleshooting includes a first level fault description starting from the E2001.E alarms provided by the front panel and suggests how to check the unit to solve the problems. This description assumes that all the connections inside the unit are correct: check them (connectors, power cables, signals and so on) before to start with the procedures. The first level troubleshooting consists of substituting the components of the E2001.E without attempting to repair them. NOTE All the technical descriptions that follow refers to inverter systems installing the software release I180STD or following
1.1 CONNECTION OF THE TEST SOFTWARE The UPS is provided of a interface card with both RS232 and USB port, so the connection between the UPS and the different software programs (test or panel programming) can be performed either using RS232 or USB standard cables. The front panel is provided with a configuration dip-switch S1 (see picture 1) which enables different types of communication interfaces according to the position of the switches. CONFIGURAZIONE Dip 1 Dip 2 OFF OFF OFF ON ON OFF ON ON
Communication mode Programming / Configuration Normal mode / SNMP interface Rectifier CPU Inverter CPU
When the troubleshooting procedure asks to “connect the rectifier test software DR16-Test”, it means that the position of the switches 1-2 of S1 must allow the communication with the rectifier CPU (1-ON, 2-OFF). When the troubleshooting procedure asks to “connect the inverter test software UPSTest”, it means that the position of the switches 1-2 of S1 must allow the communication with the inverter CPU (1-ON, 2-ON).
Picture 1 – Configuration dip-switch (software communication)
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2 TROUBLESHOOTING PROCEDURES 2.1 A1 – MAINS FAULT This alarm normally indicates that there is no power at the input of the UPS. The mains voltage is acquired on the connector M1 of the back panel card BP-DR16 (N_FS3004) through the auxiliary transformer T10.
2.1.1 Troubleshooting procedure 1.
Is the input voltage present and within the tolerance? YES: go to step #2 NO: check the rectifier supply line
2.
Measure the rectifier input voltage and compare the measure with the reading on the DR16-Test screen (or front panel). Are the values shown equal to those measured? YES: go to step #6 NO: go to step #3
3.
Check the fuses F11. Is there any fuse blown? YES: replace the broken fuse(s) NO: go to step #4
4.
Check the auxiliary transformer T10 by measuring the secondary voltages directly on the transformer terminals. Do the voltage values match the transformer rating plate? YES: replace the card PS-DR16. Go to step #5 NO: replace the transformer T10
5.
Is the problem solver after replacing the card PS-DR16? YES: END NO: replace the card DR-16
6.
Is the variable RMSOK active on the DR16-Test software? YES: go to step #7 NO: check the phase sequence
7.
Is the variable FROK active on the DR16-Test software? YES: replace the card DR-16 NO: go to step #8
8.
Measure the rectifier input frequency. Is it within the tolerance limits? YES: replace the card DR-16 NO: check and/or adjust the input frequency window
2.2 A2 – RECT BLOWN FUSES This alarm normally indicates that there is at least one rectifier input fuse blown. The normally closed contact of the fuses is connected to the connector M18 (13-14) of the back panel card BP-DR16 (N_FS3004). For the 12-pulse configuration the contact of the protection fuses of the slave bridge is connected to the connector M18 (9-10).
2.2.1 Troubleshooting procedure 1.
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Check the rectifier input fuses. Are they OK? YES: go to step #2 NO: replace the broken fuse(s) JUD411299
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AC UPS Troubleshooting procedures 2.
Check the connection between the auxiliary contact of the fuses and the connector M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable
2.3 A3 – RECT HIGH TEMPERATURE This alarm indicates that the thermal switch on the bridge heatsink has stopped the rectifier. The thermal switch(es) TH1 (TH1÷TH3) mounted on the rectifier bridge heatsink(s) is normally closed, as the temperature exceeds 90°C the thermal switch opens. The signal comes directly from the switch to the connector M18 (11-12) of the back panel card BP-DR16. For the 12-pulse configuration the contact of the thermal switch of the slave bridge is connected to the connector M18 (7-8).
2.3.1 Troubleshooting procedure 1.
Is the temperature of the heatsink lower than 80°C? YES: go to step #2 NO: go to step #4
2.
Check the thermal switch contact. Is it OK? YES: go to step #3 NO: replace the faulty thermal switch
3.
Check the connection between the thermal switch(es) and the connector M18 of the card BP-DR16. Is it OK? YES: replace the DR-16 NO: re-connect or replace the interconnection cable
4.
Are the cooling fans correctly working? YES: check the load. Repeated overloads (alarm A4) have caused the rectifier overheating NO: replace the faulty fan(s)
2.4 A4 – RECT OVERLOAD / THERMAL IMAGE This alarm normally indicates that the rectifier is overloaded, and after a certain time (basing on the overload rate) the rectifier is stopped by the thermal image protection (the status “S1rectifier OK” disappear). The output current transformer measures a current exceeding the nominal output current. The alarm is activated and the microprocessor starts to calculate the energy pulse I2t.
2.4.1 Troubleshooting procedure 1.
Measure the output current with a current clamp. Does it exceed the rectifier nominal current? YES: END. A overload is present. Check and/or reduce the load. NO: go to step #2
2.
Compare the measure with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the card DR-16 NO: replace the output current transformer TA1 and re-adjust the output current reading with the DR16-Test software. Go to step #3
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Repeat the step #2. Is the value shown equal to the measured one? YES: END. Check that the load doesn’t exceed the nominal load. NO: replace the card DR-16
2.5 A5 – MAX DC VOLTAGE This alarm normally indicates that the rectifier output voltage is higher than the set limit. The value can be checked through the front panel under SPECIAL-->UPS SETTINGS. The alarm provides to switch the rectifier off and remains stored. It can be reset manually from the front panel.
2.5.1 Troubleshooting procedure 1.
Reset the alarm and measure the rectifier output voltage after the start-up. Is it higher than the limit? YES: replace the CARD DR-16 NO: go to step #2
2.
Compare the measure with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VRECxxx. Go to step #3
3.
Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
2.6 A6 – MIN DC VOLTAGE This alarm normally indicates that the rectifier output voltage is lower than the set limit. The value can be checked through the front panel under PARAMETERS.
2.6.1 Troubleshooting procedure 1.
Open the battery breaker and measure the rectifier output voltage. Does the alarm disappear? YES: the rectifier was in current limitation mode. Check the battery NO: go to step #2
2.
Check the measure on the DR16-Test screen (or front panel). Is the value shown equal to zero? YES: go to step #3 NO: go to step #4
3.
Check the fuses F13. Is there any fuse blown? YES: replace the broken fuse(s) NO: replace the CARD DR-16
4.
Compare the measure with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VRECxxx. Go to step #5
5.
Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
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AC UPS Troubleshooting procedures 2.7 A7 – CHARGING FAULT This alarm normally indicates that there’s something wrong with the batteries and the rectifier is not capable of providing a suitable charge. It depends on three different alarm conditions, all of them shown in the front panel under the alarm row.
2.7.1 Troubleshooting procedure (Wrong Floating Low) 1.
Check the battery voltage measure on the DR16-Test screen (or front panel). Is the value shown equal to zero? YES: go to step #3 NO: go to step #4
2.
Check the fuses F14. Is there any fuse blown? YES: replace the broken fuse(s) NO: replace the CARD DR-16
3.
Measure the battery voltage and compare the value with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VBATxxx. Go to step #5
4.
Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
2.7.2 Troubleshooting procedure (Wrong Floating High) 1.
Measure the battery voltage and compare the measure with the reading on the DR16Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VBATxxx. Go to step #5
2.
Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
2.7.3 Troubleshooting procedure (Safety timer) When the alarm A7 depends on the operation of the safety timer the batteries are probably old or worn out and need to be checked carefully. If the batteries are in order the problem is probably in the rectifier control loop, so we suggest to replace the card DR-16.
2.8 A8 – RICB OPEN This alarm indicates that the rectifier input circuit breakers is open. The auxiliary contacts of the circuit breaker is connected to the connector M18 of the back panel card BP-DR16, to the pins 1-2.
2.8.1 Troubleshooting procedure 1.
Is the breaker open? YES: END NO: go to step #2
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Check the connection between the auxiliary contact of the breaker and the connector M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable
2.9 A9 – BCB OPEN This alarm indicates that the battery circuit breakers is open. The auxiliary contacts of the circuit breaker is connected to the connector M18 of the back panel card BP-DR16, to the pins 3-4.
2.9.1 Troubleshooting procedure 1.
Is the breaker open? YES: END NO: go to step #2
2.
Check the connection between the auxiliary contact of the breaker and the connector M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable
2.10 A10 – BATTERY DISCHARGING This alarm is generated by the software and indicates that the battery is discharging; it always occurs together with the alarm “A1 – mains fault”.
2.10.1 Troubleshooting procedure 1.
Is the input voltage present and within the tolerance? YES: follow the procedures described at 2.1 NO: END. There’s a mains failure and the inverter draws energy from the battery
2.11 A11 – BATTERY LOW This alarm normally indicates that the battery has discharged to the pre-alarm level.
2.11.1 Troubleshooting procedure (Wrong Floating Low) 1.
Measure the battery voltage and compare the value with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VBATxxx. Go to step #5
2.
Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
2.12 A12 – BATTERY IN TEST This alarm indicates that the UPS is testing the battery. The test is carried out reducing the rectifier output voltage thus letting the battery discharge. The rectifier microprocessor controls the battery conditions verifying the voltage during the discharge. If the test fails the alarm “A13 – Battery fault” is activated.
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AC UPS Troubleshooting procedures 2.13 A13 – BATTERY FAULT This alarm indicates that the UPS has tested the battery and the test has failed (see alarm A12 – Battery in test). In case this alarm occurs after a battery test check the battery (connection, status of the cells, voltage and so on). This alarm must be cleared by entering the special menu in the UPS front panel.
2.14 A14 – INV VDC FAULT This alarm normally indicates that the inverter input DC voltage is out of the limits programmed for the correct operation of the inverter. These limits can be checked on the test software. The measure of the DC voltage comes from the POWER SUPPLY connector CN4 (pins 1-23-4: Ground; pin 5-6: Measure) to the I/S-CL through the diode D23 (K).
2.14.1 Troubleshooting procedure 1.
Measure the inverter input voltage. Is it within the limits shown on the UPSTest software, under VDC data? YES: go to step #2 NO: END. Check the inverter DC supply
2.
Check the measure of the DC voltage on the test software and adjust it by the TVBA command. Does the measure change? YES: go to step #3 NO: replace the card I/S-CL
3.
Put the unit in manual by-pass (or switch it off if permitted) and switch it on again. Is the measure correct? YES: END NO: replace the POWER SUPPLY card (see procedure at 3.1.1). Go to step #4
4.
After replacing the POWER SUPPLY, is the measure correct? YES: END NO: replace the card I/S-CL
2.15 A15 – INV HIGH TEMPERATURE This alarm indicates that the thermal switch on the bridge heatsink has stopped the inverter. The thermal switch(es) mounted on the inverter bridge heatsink(s) is normally closed, as the temperature exceeds 80°C the thermal switch opens. The signal comes directly from TH1 to the I/S-CL M3 pins 15-16.
2.15.1 Troubleshooting procedure 1.
Is the temperature of the heatsink lower than 80°C? YES: go to step #2 NO: go to step #3
2.
Check the status of the pins 15-16 of M3 in the Card I/S-CL. Is the contact closed? YES: replace the card I/S-CL NO: replace the faulty thermal switch
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AC UPS Troubleshooting procedures 3.
Are the cooling fans correctly working? YES: check the load. Repeated overloads (alarms A14, A4) have caused the UPS overheating NO: replace the faulty fan/fans
2.16 A16 – INVERTER OUT OF TOLERANCE This alarm indicates that the inverter output voltage is outside the tolerance values (see UPSTest screen for details). This alarm generally occurs together with other alarms.
2.16.1 Troubleshooting procedure 1.
Is the inverter ON? (red LED’s on the driver boards ON) YES: go to step #2 NO: go to step #4
2.
Measure the inverter output voltage (upstream the inverter static switch) and compare the measure with the reading on the UPSTest screen (or front panel). Are the values shown equal to those measured? YES: go to step #3 NO: re-adjust the inverter voltage reading with the UPSTest (see chapter JUD411293 – UPS test software for details on the software commands). Go to step #4
3.
Is the inverter output voltage over the higher limit? YES: replace the card INV-AV-1F NO: check the inverter settings on the card I/S-CL (nominal power, nominal voltage)
4.
Switch off the inverter, switch it on again and check the measures on the UPSTest screen. Are the values shown equal to those measured? YES: END NO: replace the card I/S-CL
5.
Is the alarm A4 – Thermal image present? YES: follow the procedure described at 2.1.1 NO: go to step #6
6.
Is the alarm A5 – AC/DC fault present? YES: follow the procedure described at 2.2.1 NO: go to step #7
7.
Is the alarm A18 – Manual bypass closed present? YES: follow the procedure described at 2.9.1 NO: go to step #9
8.
Is the alarm A21 – High temperature present? YES: follow the procedure described at 2.12.1 NO: go to step #10
9.
Is the alarm A23 – EPO bus present? YES: follow the procedure described at 2.14.1 NO: go to step #11
10.
Is the alarm A24 – Current stop present? YES: follow the procedure described at 2.15.1 NO: go to step #12
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In case the inverter turn-on and off cyclically check for the alarm A25 in the alarms History and follow the procedure described at 2.16.1.
2.17 A17 – INV CURRENT STOP This alarm indicates that the maximum current monitor has detected a fault on the inverter bridge. The hall effect transducer(s) at the inverter input measures the inverter bridge current and send the signal to the I/S-CL on the connector M1. If the current on the bridge exceeds the 250% of the nominal current the current stop protection activates and the inverter is stopped.
2.17.1 Troubleshooting procedure 1.
Check the IGBT’s by following the procedure described at 3.2.1. Is there any IGBT or driver board broken? YES: replace the broken components, repeat the checks and re-start the unit. NO: go to step #2
2.
Check the status of the battery. If the battery life has almost expired and its voltage drops quickly it might cause the current on the bridge to exceed the current stop protection during short mains failures. Are the batteries OK? YES: go to step #3 NO: replace the batteries
3.
Check the IGBT’s turn-on signal (see picture 3). Is it OK? YES: follow the procedure described at 2.16.1 NO: adjust it by turning the potentiometer P2 on the POWER SUPPLY board. Go to step #4
4.
Re-start the inverter. Does the alarm occur again? YES: replace the POWER SUPPLY board. Go to step #5 NO: END
5.
Re-start the inverter. Does the alarm occur again? YES: replace the card I/S-CL NO: END
2.18 A18 – INV NO SYNCHR This alarm normally indicates that the inverter can’t stay synchronised with the bypass line; it might depend on the mains frequency slew-rate which is faster than what accepted by the control.
2.18.1 Troubleshooting procedure 1.
Check the bypass line, waveform and frequency variations. Is the slew-rate faster than 1Hz/sec? YES: END; the mains variations are too fast. Check the UPS supply line. NO: replace the card I/S-CL
2.19 A19 – INV OVERLOAD This alarm normally indicates that load at the output of the inverter exceeds the nominal power. The output current transformers measure an output current exceeding the nominal output current. The alarms is activated and the thermal image protection (see the alarm A4 – Thermal image) starts to calculate the thermal pulse.
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AC UPS Troubleshooting procedures 2.19.1 Troubleshooting procedure 1.
Measure the output current with a current clamp. Does it exceed the inverter nominal current? YES: END; A overload is present. Check and/or reduce the load. NO: go to step #2
2.
Compare the measure with the reading on the UPSTest screen (or front panel). Are the values shown equal to those measured? YES: check the inverter settings on the card I/S-CL (nominal power, nominal voltage) NO: replace the INV-AV-1F and re-adjust the output current reading with the UPSTest (see chapter JUD411293 – UPS test software for details on the software commands). Go to step #3
3.
Repeat the step #2. Are the values shown equal to those measured? YES: END. Check that the load doesn’t exceed the nominal load. NO: replace the I/S-CL
4.
With the inverter on and SBCB off, measure the voltage upstream the by-pass thyristors. Is it equal to zero? YES: replace the card I/S-CL NO: replace the bypass static switch thyristor (the thyristor is in short circuit).
2.20 A20 – BYPASS FAULT This alarm indicates that emergency line is not available. The emergency line is connected to the UPS through the SBCB circuit breaker to the VOLTREF-1F CN1 which adapts the signal to the microprocessor and send it through the connector CN4 to the I/S-CL CN13. This signal can be checked on the I/S-CL in the following point (picture 2 shows the waveform): Microprocessor ground Æ Cathode of D65 The emergency line is checked as frequency (the frequency limits can be programmed through the command TFFR; if the frequency is ok the variable FROK is active), as RMS value (if the RMS value is ok the variable RMSOK is active) and instantaneous value.
Picture 2 – Signal on cathode of D65
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Is the input voltage present and within the tolerance? YES: go to step #2 NO: check the bypass supply line
2.
Check the bypass protection fuse. Is it OK? YES: go to step #3 NO: replace the fuse
3.
Measure the by-pass input voltage and compare the measure with the reading on the UPSTest screen (or front panel). Are the values shown equal to those measured? YES: go to step #5 NO: replace the card VOLT-REF-1F. Go to step #4
4.
After replacing the VOLT-REF board, are the values shown equal to those measured? YES: END NO: replace the card I/S-CL
5.
Is the variable RMSOK active on the UPSTest program? YES: go to step #6 NO: check the phase sequence
6.
Is the variable FROK active on the UPSTest program? YES: replace the card I/S-CL NO: go to step #7
7.
Measure the by-pass input frequency. Is it within the tolerance limits? YES: replace the card I/S-CL NO: check and/or adjust the input frequency
2.21 A21 – BYPASS FEED LOAD This alarm indicates that the emergency line (by-pass) is feeding the load. Normally this alarm occurs if the inverter is switched off (check for the alarm A13 – Inverter out of tolerance). In this case the reason for the inverter failure must be investigated (refer to the procedure described at 2.4.1).
2.21.1 Troubleshooting procedure 1.
Is the alarm A13 present? YES: follow the procedure described at 2.4.1 NO: go to step #2
2.
Is the alarm A22 present? YES: follow the procedure described at 2.13.1 NO: go to step #3
3.
Measure the E2001.E output voltage. Is it within the tolerance limits? YES: go to step #4 NO: check the static switch thyristors
4.
Compare the measure with the reading on the UPSTest screen (or front panel). Are the values shown equal to those measured? YES: replace the card I/S-CL NO: replace the card VOLT-REF-1F. Go to step #5
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5.
After replacing the VOLT-REF board, are the values shown equal to those measured? YES: END NO: replace the card I/S-CL
2.22 A22 – BYPASS SWITCH The E2001.E is equipped with a bypass switch that forces the load to bypass. If this switch is in the Bypass position the alarm A22 is activated and the load is transferred to bypass (see alarm A16 – Bypass feeds load). This signal comes directly from the switch SW1 to the I/S-CL M3 pins 11-12.
2.22.1 Troubleshooting procedure 1.
Is the switch in NORMAL position? YES: go to step #2 NO: END; move it to NORMAL
2.
Check the status of the pins 11-12 of M3 in the Card I/S-CL. Is the contact closed? YES: replace the card I/S-CL NO: replace the switch SW1
2.23 A23 – RETRANSFER BLOCKED This alarm indicates that the load is blocked on the emergency line (by-pass) after 6 transfers to by-pass in 2 minutes. Normally it occurs when there are several heavy load steps (like motors starting, printers and so on) in a very short time. In this case, as the current exceeds two times the nominal value, the short circuit monitor (see alarm A25 – Short circuit) transfers automatically the load to by-pass, and after a few seconds the inverter takes back the load. If this situation happens six times in two minutes, the E2001.E protect itself by blocking the load to by-pass and the alarm is activated. This condition can be reset by sending the command RESE000 or by resetting the system from the special menu in the front panel.
2.23.1 Troubleshooting procedure 5.
Are there heavy load steps exceeding two times the nominal output current? YES: check and/or reduce the load NO: go to step #2
6.
Open SBCB (by-pass line breaker), turn on the inverter only and check the output voltage waveform (downstream the inverter static switch). Is it sinusoidal? YES: go to step #3 NO: replace the inverter static switch thyristor
2.24 A24 – FANS FAILURE This alarm normally indicates that there is at least one defective cooling fan. The normally closed contact coming from the fans monitoring card FMC is connected to the connector M3 (3-4) of the card I/S-CL.
2.24.1 Troubleshooting procedure 2.
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Check the fans monitoring card FMC. Is there any red LED lit? YES: replace the fan connected to the channel indicated by the RED led. Go to step #2 NO: go to step #3
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AC UPS Troubleshooting procedures 3.
Re-start the inverter. Does the alarm occur again? YES: replace the card FMC NO: END
4.
Is the green LED DL5 lit? YES: go to step #4 NO: replace the card FMC
5.
Check the connection between the card FMC and the connector M3 of the card I/S-CL. Is it OK? YES: replace the card I/S-CL NO: re-connect or replace the interconnection cable
2.25 A25 – UPS OCB OPEN This alarm indicates that the E2001.E output circuit breaker is open. This signal comes from the OCB circuit breaker auxiliary contact to the I/S-CL M3 pins 9-10.
2.25.1 Troubleshooting procedure 1.
Is the output breaker OCB open? YES: END NO: go to step #2
2.
Check the status of the pins 9-10 of M3 in the Card I/S-CL. Is the contact closed? YES: replace the card I/S-CL NO: replace the OCB auxiliary contact
2.26 A26 – MANUAL BYPASS CLOSED This alarm indicates that the manual bypass circuit breaker is closed. This signal comes from the MBCB circuit breaker auxiliary contact to the I/S-CL M3 pins 13-14. When MBCB is closed together with OCB the electronic protection turn off the inverter generating the alarm A13.
2.26.1 Troubleshooting procedure 1.
Is the manual by-pass breaker MBCB closed? YES: END NO: go to step #2
2.
Check the status of the pins 13-14 of M3 in the Card I/S-CL. Is the contact open? YES: replace the card I/S-CL NO: replace the MBCB auxiliary contact
2.27 A27 – EPO PRESSED The E2001.E is equipped with two terminals (Eac1-Eac2) for connection of the remote emergency shutdown push-button. If the remote push-button is pressed the systems is stopped, the alarm A23 is activated and there is no voltage at the output of the E2001.E. This signal comes directly from the terminals Eac1-Eac2 to the I/S-CL M3 pins 5-6. WARNING This push button doesn’t insulate the system from the input supplies. For maintenance disconnect the E2001.E as indicated in the manual by-pass procedure.
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AC UPS Troubleshooting procedures 2.27.1 Troubleshooting procedure 1.
Is the EPO push-button pressed? YES: END. Check the reason why the button has been pressed; before pressing it again check that no danger to persons or things will be caused by the E2001.E re-start. NO: go to step #2
2.
Check the status of the pins 5-6 of M3 in the Card I/S-CL. Is the contact closed? YES: replace the card I/S-CL NO: replace EPO push-button
2.28 A28 – THERMAL IMAGE This alarm normally indicates that the thermal protection has stopped the inverter. The output current transformers measure an output current exceeding the nominal output current (see the alarm A19 – Inverter overload). The microprocessor starts to calculate the energy pulse I2t. As this pulse reaches the 100% the inverter is stopped for 30' and the load is transferred to the bypass.
2.28.1 Troubleshooting procedure 1.
Measure the inverter output current and compare the measure with the reading on the UPSTest screen (or front panel). Are the values shown equal to those measured? YES: go to step #2 NO: replace the card INV-AV-1F and re-adjust the output current reading with the UPSTest (see chapter JUD411293 – UPS test software for details on the software commands). Go to step #3
2.
Is the alarm A19 - Overload present? (The output current exceeds the UPS nominal current) YES: the overload is still present. Reduce the load. NO: the overload has finished and the load is supplied by by-pass. Check that the gauge ACCUMU on the UPSTest software is decreasing to zero. As soon as it reaches zero the inverter is switched on again.
3.
Repeat the step #1. Are the values shown equal to those measured? YES: END. Check that the load doesn’t exceed the nominal load. NO: replace the card I/S-CL
2.29 A29 – INVERTER SHORT CIRCUIT This alarm indicates that the short circuit monitor has detected a short at the output of the inverter. The hall effect transducer(s) at the inverter input measures the inverter bridge current and send the signal to the I/S-CL on the connector M1. This signal is amplified on the test point TP2 and can be set at 4Vpeak at 100% load by rotating the potentiometer P2. As this signal exceeds two times the nominal output current, the current limitation starts to work and the alarm A25 is activated. This happens if the emergency line is not available, otherwise the load is automatically transferred to bypass. Normally the alarm A29 can be found in the alarm history, as it is automatically reset as the short circuit is removed.
2.29.1 Troubleshooting procedure 1.
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Are there heavy load steps exceeding two times the nominal output current? YES: check and/or reduce the load NO: go to step #2
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AC UPS Troubleshooting procedures 2.
Check the inverter input current waveform on test point TP2 (see picture 4). Is there any spike or distortion? YES: replace the IGBT driver boards. Go to step #3 NO: replace the card I/S-CL
3.
After replacing the IGBT driver boards, is the waveform on TP2 correct? YES: END NO: replace the POWER SUPPLY board. Go to step #4
4.
After replacing the POWER SUPPLY board, is the waveform on TP2 correct? YES: END NO: replace the IGBT’s of the inverter bridge
2.30 A40 – DC EARTH FAULT This optional alarm depends on the status of the external earth fault detector that may be installed on request. The normally closed contact of the external detector is connected to the connector M18 (21-22) of the back panel card BP-DR16 (PB134).
2.30.1 Troubleshooting procedure 1.
Check the external earth fault detector; is the internal alarm activated? YES: END. There’s a earth fault, check the loads and their connections to the rectifier. NO: go to step #2
2.31 A41 – ROCB OPEN This alarm indicates that the rectifier output circuit breakers (when provided) is open. The auxiliary contacts of the circuit breaker is connected to the connector M18 of the back panel card BP-DR16, to the pins 5-6.
2.31.1 Troubleshooting procedure 1.
Is the breaker open? YES: END NO: go to step #2
2.
Check the connection between the auxiliary contact of the breaker and the connector M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable
2.32 PROGRAMMABLE ALARMS The alarms from A50 to A59 can be programmed during the engineering phase, in case the technical specification requires additional signalisations. They can either be generated by mixing the standard UPS alarms or depend on the four digital inputs available (connector M1 of the front panel card FP-ACUPS). Considering the wide number of possible combinations a troubleshooting procedure cannot be given.
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3 PCB’S AND COMPONENTS SUBSTITUTION This chapter describes in detail all the checks that have to be done after the substitution of electronic boards or power components installed in the E2001.E systems, giving all the instructions to check the operation parameters or to change E2001.E settings.
3.1 PCB’S SUBSTITUTION 3.1.1 PS-DR16 – (RECTIFIER POWER SUPPLY) 1. Re-connect carefully the card to the back panel. 2. Re-start the rectifier and check that all the green LED on the front of the card are steady lit.
3.1.2 DR-16 – (RECTIFIER μPROCESSOR CONTROL) 1. Check the setting of SW1 according to the following table. Check that the dip-switches are in the same position as the old board. Dip n. 1 2 3 4
Status Off On Off On Off On Off On
Description Battery test disabled Battery test enabled Rapid Charge disabled Rapid charge enabled Manual Charge disabled Manual Charge enabled Parallel configuration disabled Parallel configuration enabled
The dip switches 5-6-7-8 are not used and must be set to OFF. 2. Check the software version installed and, if necessary, replace the FLASH memory in the microprocessor card MC16 (installed on the solder side of the card DR-16). 3. Check the setting of the jumpers JP1-JP2-JP3-JP8-JP9 according to the following table. Check that they are in the same position as the old board. Iout nominal 50 A 100 A 150 A 200 A 250 A 300 A 500 A 750 A >950 A
JP1
JP2
JP8
JP9
JP3
Yes No Yes No Yes Yes No Yes No Yes No Yes No Yes Yes No Yes No Yes Yes Yes Yes Yes Yes Yes No Yes No Yes Yes No Yes No Yes Yes Yes Yes Yes Yes Yes Please refer to Operating Instructions PB132008
4. Set the jumpers JP10-JP11-JP12-JP13 according to the following table. Nominal Voltage
JP10
JP11
JP12
JP13
24-48-110 Vdc 220-380 Vdc
No Yes
No Yes
No Yes
No Yes
5. Close the input breaker and start-up completely the rectifier.
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AC UPS Troubleshooting procedures 6. Check that all the measure on the DR16-Test screen, or on the front panel, are equal to the values measured; on the contrary modify the value read on the screen with the following commands: TIFRxxx (input voltage setting phase R; xxx is the value measured) TIFSxxx (input voltage setting phase S; xxx is the value measured TIFTxxx (input voltage setting phase T; xxx is the value measured) TCIRxxx (input current setting phase R; xxx is the value measured) TCISxxx (input current setting phase S; xxx is the value measured TCITxxx (input current setting phase T; xxx is the value measured) VRECxxx (output voltage setting; xxx is the value measured). VBATxxx (output current setting; xxx is the value measured). CRECxxx (battery voltage setting; xxx is the value measured). CBATxxx (battery current setting; xxx is the value measured). Store all the settings by sending the command MEEE000. 7. Check in the front panel that all the operating parameters (charging voltages and current, voltage and current thresholds, and so on) match the requirements of the technical specification. 8. Check the setting of the date and time on the front panel Reset the history log.
3.1.3 PS-LV / PS-MV / PS-SAT – (INVERTER POWER SUPPLY) 1. On the card I/S-CL move the DIP6 SW1 in position OFF. 2. Disconnect the connector CNB and connect the external power supply. 3. On the card I/S-CL check that the signal between ground and cathode of D23 is: For 110Vdc E2001.E: 0,9Vdc with external PS supplying 120Vdc For 220Vdc E2001.E: 1,2Vdc with external PS supplying 320Vdc To modify the amplitude of the signal move the potentiometer P1 on the board PB001. 4. Select the “manual” operating mode on the card I/S-CL, moving the jumper J1 on the card VCB in position 2-3. 5. Connect a PC to the serial port RS232, run the UPSTest software and press F6 to start the IGBT bridge modulation (in alternative send the command INON000). 6. Check the signal between Gate and Source of the IGBT’s according to the following picture:
Picture 3 – IGBT turn-on signal
If necessary modify the amplitude of the positive part of the waveform until it reaches 16V, moving the potentiometer P2 on the POWER SUPPLY board. REV.A JSE411881 08/06/09
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AC UPS Troubleshooting procedures 7. Turn-off the inverter by pressing F7 (in alternative send the command INOF000) and disconnect the external power supply. 8. Select the “Automatic” operating mode on the card I/S-CL, moving the jumper J1 on the card VCB in position 1-2 9. Move the DIP6 SW1 in position ON on the card I/S-CL. 10. Re-connect the connector CNB on the power supply PB001.
3.1.4 I/S-CL – (INVERTER μPROCESSOR CONTROL) 3. Check the setting of DSW1 and DSW2 comparing them with the old board. For further information the setting table is given below. Dip n. 1 2 3 4 5 4 5 4 5 4 5 6 7 8
Status Off On Off On Off On On On Off On On Off Off Off Off On Off On Off On
Description Single Parallel Frequency 50Hz Frequency 60Hz Single/Parallel Hot Standby Nominal Vout 220V (110V) Nominal Vout 208V (127V) Nominal Vout 230V (115V) Nominal Vout 240V (120V) Test Normal Buzzer disabled Buzzer enabled Three-phase output (not used) Single-phase output
Table 1 – DSW 1 Dip n. 1 3 4 5 6
Status On Off On Off On Off On Off On Off
Description ON/OFF inverter by external switch ON/OFF inverter automatic INT-5 ARC interface Single ARC board Output range: 110-115-120-127 Vac Output range: 208-220-230-240 Vac Rotary switch installed Rotary switch NOT installed “E2001.E” LCD panel Standard LCD panel
Table 2 – DSW 2
4. Install the same software version (EPROM) that was installed in the old board.
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AC UPS Troubleshooting procedures 5. Check the setting of the jumpers J3-J4-J5-J6 according to the following table Jumper
J1
J2
Used for
1Ph output
Back-up battery ON
Position
1-2
1-2
J3
J4
J5
J6
1-2
2-3
J7 Watchdog protection
EPROM’s setting
1-2
2-3
Closed
6. Check the resistor R66 (triangle amplitude) Æ 6k81+6k81 7. Check the setting of the resistors R39-R40-R18 (current control circuit) according to the following table. VDCNOM
Resistors on I/S-CL
J9
J10
J100
110
22+47
Closed
Open
Open
220
100+33
Open
Closed
Open
110
33
Open
Closed
Closed
220
22+47
Closed
Open
Open
110
33
Open
Closed
Closed
220
22+33
Open
Closed
Open
110
47
Closed
Open
Closed
220
33
Open
Closed
Closed
110
33
Open
Closed
Closed
220
33
Open
Closed
Closed
110
22
Closed
Closed
Open
220
47
Closed
Open
Closed
110
22
Closed
Closed
Open
220
47
Closed
Open
Closed
60
220
33
Open
Closed
Closed
80
220
22
Closed
Closed
Open
100
220
22
Closed
Closed
Open
UPS [kVA] 5
10
15
20
30
40
50
JUMPERS
R18 (J100) = 22R 2W; R39 (J10) = 47R 2W; R40 (J9) = 33R 2W 8. Measure the resistance between ground and TP2 (current protection) and set the same value on the new board by means of the potentiometer P2. Take into account that the peak value of the signal, adjustable by means of the potentiometer P2, must be equal to 4V at 100% of load. Check the waveform, and adjust the peak value (see picture 4) according to the available load (load 100% Vp=4V, load 50% Vp=2V).
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Picture 4 – Current signal on TP2 at 100% of load
9. Check that the jumper J2 on the card VCB boards is closed (voltage correction inserted) and that the jumper J1 is in position 1-2 (voltage loop closed). 10. Check the setting of the jumpers of the board SCB according to those of the old board. NOTE Generally only the substitution of the card I/S-CL is required, unless the failure can’t be easily identified, or depends on the interface circuits with the auxiliary boards (VCB, RCB, SCB). 11. In case the card comes from a general purpose spares kit, it will be necessary to set all the operating parameters before starting-up the inverter. In case the card is a specific spare part for the system, jump to step 14. 12. Set the card in TEST mode by moving the DIP6 SW1 in OFF position. 13. Precharge the capacitors, close the input switch and supply the electronics. 14. Connect the UPSTest software and send the following commands (the tables below the command give the suggested values): LOBAxxx – Low battery pre-alarm VDC NOM 110 220
LOBA100 LOBA200
PHASxxx – Internal frequency reference OUT FREQ 50 Hz 60 Hz
Single E2001.E PHAS270 PHAS300
Parallel E2001.E PHAS400 PHAS450
SVDCxxx – Nominal DC voltage VDC NOM 110 220
SVDC110 SVDC220
SHDCxxx – High DC voltage fast shutdown VDC NOM 110 220
SHDC165 SHDC330
SLDCxxx – Low DC voltage shutdown VDC NOM 110 220
SLDC092 SLDC184
SMRDxxx – High DC voltage slow shutdown (must be < SHDC) 24 of 31
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SMRD150 SHDC300
SOOVxxx – Output Overvoltage SBOVxxx – Bypass Overvoltage VOUT NOM 110 115 120 127 208 220 230 240
Output SOOV127 SOOV132 SOOV138 SOOV146 SOOV239 SOOV253 SOOV265 SOOV276
Bypass SBOV132 SBOV138 SBOV144 SBOV152 SBOV249 SBOV264 SBOV276 SBOV288
SOUVxxx – Output Undervoltage SOUVxxx – Bypass Undervoltage VOUT NOM 110 115 120 127 208 220 230 240
15. 16. 17. 18.
19. 20.
21. 22. 23.
Output SOUV093 SOUV098 SOUV102 SOUV108 SOUV177 SOUV187 SOUV195 SOUV204
Bypass SBUV088 SBUV092 SBUV096 SBUV102 SBUV166 SBUV177 SBUV184 SBUV192
SEPOxxx – Nominal output power (ex: for a 10kVA the command is SEPO010) Store all the settings by sending the command MEEE000, or pressing F4. Opem the input switch and switch off the E2001.E. Precharge the capacitors, close the input switch and start-up completely the UPS. Measure the output voltage and, if necessary, adjust it by means of the potentiometer P1 on the card VCB. Check that all the measure on the UPSTest screen, or on the front panel, correspond to the values measured; on the contrary modify the value read on the screen with the following commands: TIFRxxx (inverter voltage setting phase R; xxx is the value measured) TUFRxxx (output voltage setting phase R; xxx is the value measured). TBFRxxx (by-pass voltage setting phase R; xxx is the value measured). TCFRxxx (output current setting phase R; xxx is the value measured). TVBAxxx (DC voltage setting; xxx is the value measured) TCBAxxx (DC current setting; xxx is the value measured) Store all the settings by sending the command MEEE000, or pressing F4. Carry out some mains failure tests and commutations to by-pass. Personalize the UPS with the following commands: BATCxxx (Set production year, for example: 2008=080) NUMBxxx (Set serial number) Store all the settings by sending the command MEEE000, or pressing F4. Check the correct operation of the front panel and the relay cards (if installed). Check the setting of the date and time on the front panel. Reset the history log.
3.1.5 INV-AV-1F – (INVERTER VOLTAGE FEEDBACK) 1. Measure the inverter output voltage, connecting the multimeter between the neutral and the inverter static switch (upstream). REV.A JSE411881 08/06/09
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AC UPS Troubleshooting procedures If the value shown doesn’t correspond to that measured, modify the reading with the following command (UPSTest software): TIFRxxx (inverter voltage setting phase R; xxx is the value measured) Store the settings by pressing F4. 2. Measure the output current; If the value shown doesn’t correspond to that measured, modify the reading with the following command (UPSTest software): TCFRxxx (output current setting phase R; xxx is the value measured) Store the settings by pressing F4.
3.1.6 VOLT-REF-1F – (BYP/OUT VOLTAGE FEEDBACK) 1. Measure the by-pass voltage, connecting the multimeter between the neutral and the bypass static switch (upstream). If the value shown doesn’t correspond to the measured one, modify the reading with the following command (UPSTest software): TBFRxxx (by-pass voltage setting phase R; xxx is the value measured) Store the settings by pressing F4. 2. Measure the output voltage; if the value shown doesn’t correspond to the measured one, modify the reading with the following commands (UPSTest software): TUFRxxx (output voltage setting phase R; xxx is the value measured) Store the settings by pressing F4.
3.2 COMPONENTS SUBSTITUTION 3.2.1 RECTIFIER BRIDGE THYRISTORS 1. Re-connect carefully the component to the firing board. 2. Check that the input current waveform, relevant to the phase controlled by the thyristors that has been substituted, is symmetric (see picture, given for a 6-pulse system).
Picture 5 – Rectifier input current waveform
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AC UPS Troubleshooting procedures 3.2.2 INVERTER BRIDGE IGBT’S 1. 2. 3. 4. 5.
6. 7.
8. 9.
10. 11. 12. 13.
Change the IGBT driver board and check the connection with the IGBT’s. On the card I/S-CL move the DIP6 SW1 in OFF position (test mode). On the card VCB move the jumper J1 in position 2-3 (manual). Connect the external power supply to the POWER SUPPLY board, connect a PC to the UPS and run the UPSTest software With the external power supply the DC voltage is outside the nominal range, so the variable VDC_OK is not active (blue). The variable can be activated changing the DC voltage measure to be within the range sending the command TVBAxxx where xxx is the value desired. Turn on the inverter sending the command INON000, or pressing F6. Check that all the red LED’s on the driver boards are ON and verify the voltage waveform between emitter (E) and gate (G) of the IGBT’s (see picture 3). If necessary modify the amplitude of the positive part of the waveform until it reaches 16V, moving the potentiometer P2 on the POWER SUPPLY board. Turn off the inverter sending the command INOF000, or pressing F7, and re-connect the POWER SUPPLY board to the internal supply. Precharge the capacitors, close the input switch, start-up the inverter by sending the command INON000, or pressing F6, and increase the modulation by means of the potentiometer P1 on the card I/S-CL. Check that the output waveform increases regularly up to the nominal value. Reduce the modulation to zero by rotating back the potentiometer, send the command INOF000, or press F7, to turn off the inverter and open the input switch. On the card I/S-CL move the DIP6 SW1 in ON position (automatic mode). On the card VCB move the jumper J1 in position 1-2 (automatic). Precharge the capacitors, close the input switch, start-up the E2001.E and check the inverter operation under load.
3.2.3 STATIC SWITCH THYRISTORS 1. Re-connect carefully the component to the firing board. 2. Check that the output waveform, relevant to the phase controlled by the thyristors that has been substituted, is correct. Repeat this check with the load connected.
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4 ON-FIELD TEST PROCEDURES This chapter describes the most common operating procedures used to test the various sections of the UPS during repairing or maintenance operations. These procedures assumes that all the power components (fuses, thyristors, cables, etc.) are OK, no modifications have been made in the power and auxiliary circuitry and that the unit is switched off or in manual by-pass (all the control circuits are off).
4.1 INVERTER 4.1.1 General notes on the TEST mode The TEST mode is a operating condition where the inverter doesn’t start-up automatically but waits for the commands sent by the operator through the UPSTest software. In this condition some alarms are hidden and the UPS can be tested completely. When the UPS is in manual bypass for example, just setting the unit in TEST mode allows the operator to check the UPS operation. The TEST mode can be set by moving the DIP6 SW1 in position OFF in the card I/SCL. The microprocessor acquires the position of the dip-switch only after it has been reset (switching off the E2001.E or by pressing the push-button SW3 in the I/S-CL).
4.1.2 EXTERNAL POWER SUPPLY It’s a special tool used to supply the microprocessor without switching on the rectifier, so that the unit can be tested in safety. NOTE The standard external power supply is suitable for the use with E2001.E systems having 220Vdc nominal input voltage, as its output voltage is about 320Vdc. For 110Vdc systems it is necessary to reduce the supply voltage of the external PS to 150Vdc maximum.
4.1.3 Blank test of the card I/S-CL The procedure that follows is part of the factory test procedure, related to the preliminary checks carried out on the microprocessor board I/S-CL before proceeding with the inverter startup. It’s useful when, after an inverter failure, the operator wants to be sure that no damage occurred to the control section. 1. Choose the inverter TEST mode, moving the DIP6 SW1 in position OFF in the card I/SCL. 2. Select the “manual” voltage regulation, moving the jumper J1 on the card VCB in position 2-3. This setting disable the voltage loop, and the inverter voltage regulation signal is adjusted with the potentiometer P1 of the card I/S-CL. 3. On the POWER SUPPLY board disconnect the connector CNB and connect the external power supply. The microprocessor is now supplied and after some seconds the front panel will show all the alarms present at that moment. 4. Connect the oscilloscope probe between analog ground and pin 6 of U17 and check the presence of a signal as in picture 6:
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Picture 6 – Triangle waveform
NOTE For all E2001.E range the commutation frequency is set at 4kHz, so the period of the triangle waveform must always be 250μs. This waveform is compared with the reference sine-wave generated by the microprocessor to create the IGBT’s PWM signals. In the following steps the sine-wave generated by the microprocessor and the IGBT’s turn-on signals will be checked. The inverter can be turned-on only if all the software conditions are fulfilled, so it’s necessary to change the DC voltage reading (now coming from the external power supply) to enable the variable VDC_OK. 5. Change the DC voltage reading sending the command TVBAxxx, where xxx is the desired value, and check that the command is acquired by the microprocessor and that the variable VDC_OK is activated. 6. Turn-on the IGBT modulation by sending the command INON000 or pressing F6. 7. Place the oscilloscope probe between the analog ground and pin 7 of U2 (card VCB), rotate P1 of the card I/S-CL («) and check that the amplitude of the generated sine-wave increases, and then turn back P1 until the same is at zero again (¬). 8. Check that the red LED’s on the IGBT driver boards are correctly lit. 9. Verify the turn-on signal between emitter (E) and gate (G) of the IGBT’s (see picture 3). 10. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7. 11. Disconnect the external power supply. After disconnecting the external power supply the microprocessor is reset and the DC voltage setting modified before is cleared, so at the following start-up the unit will show the exact DC voltage value.
4.1.4 Inverter manual start-up This procedures assumes that all the power components in the inverter bridge have been previously checked (see paragraph 4.1.3). The inverter output voltage is increased starting from zero to check the behaviour of the components (AC capacitors, fans, etc.) at reduced AC voltage after having identified a failure in the inverter section. 1. Choose the inverter TEST mode, moving the DIP6 SW1 in position OFF in the card I/SCL. REV.A JSE411881 08/06/09
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AC UPS Troubleshooting procedures 2. Select the “manual” voltage regulation, moving the jumper J1 on the card VCB in position 2-3. This setting disable the voltage loop, and the inverter voltage regulation signal is adjusted with the potentiometer P1 of the card I/S-CL. 3. Precharge the capacitors, close the input switch and supply the unit. After some seconds the front panel will show all the alarms present at that moment. 4. Turn-on the IGBT modulation by sending the command INON000 or pressing F6. 5. Verify that, after some seconds, the inverter static switch closes by checking the green LED’s in the firing boards SCRSF-1F or 2SCR FIR. 6. Rotate P1 of the card I/S-CL («) and increase the inverter output voltage. Check that the sine wave is present downstream the inverter static switch and that the shape is correct. 7. Place the oscilloscope probe between the analog ground and the test point TP2 and check that the shape of the inverter bridge current is correct (see picture 3). 8. Rotate P1 of the card I/S-CL (¬) to set the modulation signal to zero. 9. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7. 10. Open the input switch and switch off the unit.
4.1.5 Inverter automatic start-up This procedures follows the previous one and it’s used to check the correct operation of the inverter with the voltage loop closed. 1. Choose the inverter TEST mode, moving the DIP6 SW1 in position OFF in the card I/SCL. 2. Select the “automatic” voltage regulation, moving the jumper J1 on the card VCB in position 1-2. This setting enable the voltage loop, and the inverter voltage regulation signal is adjusted with the potentiometer P1 of the card VCB. 3. Precharge the capacitors, close the input switch and supply the unit. After some seconds the front panel will show all the alarms present at that moment. 4. Turn-on the IGBT modulation by sending the command INON000 or pressing F6. 5. Verify that the inverter output voltage increases up to the nominal value. If necessary adjust it by rotating (¬) the potentiometer P1 of the card VCB. 6. Verify that, after some seconds, the inverter static switch closes by checking the green LED’s in the firing boards SCRSF-1F or 2SCR FIR. 7. Place the oscilloscope probe between the analog ground and the test point TP2 and check that the shape of the inverter bridge current is correct (see picture 3). 8. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7. 9. Open the input switch and switch off the unit.
4.2 STATIC SWITCH 4.2.1 Check of the redundant supply The VOLT-REF board provides a redundant supply for the static switch control logic, so that the by-pass static switch is supplied even when the microprocessor is off (POWER SUPPLY board not supplied). 1. Close the by-pass circuit breaker and check that the LED L1 in the card SCB (additional card in the I/S-CL) is correctly lit (green). 2. Verify that, after some seconds, the by-pass static switch closes by checking the red LED’s in the firing boards SCRSF-1F or 2SCR FIR.
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AC UPS Troubleshooting procedures 4.2.2 Commutation tests The commutation tests are useful to check the correct operation of the static switch. 1. Start-up the inverter in automatic mode (see procedure at 4.1.5) and verify that the inverter static switch closes. 2. Close the bypass breaker, wait for the status S6 – BYPASS OK is activated. 3. Measure with a multimeter the voltage difference between the by-pass input and the inverter output and verify that it doesn’t exceed 20Vac. The inverter is now synchronised with the by-pass. 4. Move the NORMAL-BYPASS switch SW1 in by-pass position and verify that the load is transferred to the by-pass static switch. Then move it back and verify that the load is supplied again by the inverter. 5. Repeat the previous and verify that at the sixth time the load remains supplied by the bypass and the alarm A17 – Retransfer blocked is activated. 6. Reset the blocking condition by sending the command RESE000 or entering the special menu in the front panel.
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RTB_e MAINTENANCE MANUAL
RTB.e maintenance
RTB_E MAINTENANCE MANUAL
Index 1
MAINTENANCE OPERATIONS............................................................ 2
1.1
VISUAL INSPECTION OF ELECTRICAL CONNECTIONS .....................................2
1.2
CHECK OF ALARMS ON FRONT PANEL DISLPAY..............................................2
1.3
AIR FILTER CHECK AND CLEANING ....................................................................3
1.4
FANS CONTROL AND CLEANING .........................................................................3
1.5
CHECK OF INPUT VOLTAGE .................................................................................3
1.6
CONTROLS ON DC VOLTAGE & BATTERY CHARGE FACILITIES.....................3
1.7
CURRENT ABSORBED BY DC FILTER .................................................................4
1.8
BATTERY TEST .......................................................................................................4
1.9
MEASURE OF OUTPUT VOLTAGE RIPPLE ..........................................................4
1.10
CLEANING OF MAGNETIC PARTS ........................................................................4
1.11
CLEANING OF ELECTRONIC BOARDS.................................................................4
2
MAINTENANCE PROGRAM ................................................................ 5
Index of pictures Picture 1 – Front panel …………………………………………………………………………………………….2
Rev.
/
Descrizione Description
Emissione
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
09.03.09
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
I
1
di Pag. of Pag.
5
Codice / Code
JUD411546
RTB.e maintenance
1
MAINTENANCE OPERATIONS
1.1
VISUAL INSPECTION OF ELECTRICAL CONNECTIONS
Make sure all cables and / or bars are firmly tightened the clamps connection and that no connection has loosened. A link not perfectly executed can increase the resistance of contact with all its consequences such as heating connection and increased voltage drop of the line. 1.2
CHECK OF ALARMS ON FRONT PANEL DISLPAY
In order to verify the proper functioning of the system is advisable to check the history of alarms. This can be done through the front panel (see Operatingl Manual). If necessary, it is possible even simulate a condition of alarm (or an indication) to test the effective functioning of signalization.
Picture 1 – Front panel First Issue 09/03/09
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RTB.e maintenance
LED 1
⇒
Green light on = Rectifier Mains presence Red light on = Otherwise
LED 2
⇒
Green light on = RTB.e operating. Red light on = RTB.e failure or blocked Switched off for mains failure.
LED 3
⇒
Green light on = Rectifier in floating charge. Orange light on = Rectifier in rapid charge.
LED 4
⇒
Green light on = Battery in recharge and ok. Orange light on = Battery in discharge or battery test. Red light on = Battery KO.
LED 5
⇒
Green light on = Output OK and ROCB closed. Red light on = Otherwise
The meanings of Leds from 6 to 15 are depending from applications and are written beside the leds on the front panel. 1.3
AIR FILTER CHECK AND CLEANING
Check whether the air input / output is blocked by dirt. If so clean them with compressed air blowing from the inside of the cabinet 1.4
FANS CONTROL AND CLEANING
Monitoring the correct operation of fans (if presents) can be done with the rectifier on, making sure that does not appear on the display the alarm "A8 FAN Failure." In any case it is advisable to remove dust possibly deposited on the fans through a brush and blow with compressed air. This operation should be done with the rectifier turned off. 1.5
CHECK OF INPUT VOLTAGE
Check with a multimeter C.A. that the input voltage is within the parameters defined in the data sheet. 1.6
CONTROLS ON DC VOLTAGE & BATTERY CHARGE FACILITIES •
Check of Floating Voltage
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RTB.e maintenance Measure with a D.C. multimeter the voltage at the rectifier output terminals and verify that the value is correct. • Check of boost charge Start quick charge by pressing the button "BOOST" on the front panel and check that the LED 3 takes the color orange. 1.7
CURRENT ABSORBED BY DC FILTER
Measure with D.C.current clamp the current absorbed by the DC capacitors; the value to ensure a longer life to capacitors must not exceed 25 amperes / capacitor. 1.8
BATTERY TEST
In order to test the battery the battery test should be activated [see Operating Manual, chapter JUD407770 (“Front Panel”) par. 3.2.9 ]. If the rectifier is equipped with discharge facility the battery shall be discharged following a customized discharge profile (setted manually by service engineer) 1.9
MEASURE OF OUTPUT VOLTAGE RIPPLE
Place the oscilloscope probe on the rectifier output terminals; measure the value peak to peak alternating component (AC) superimposed on the DC voltage and make sure that does not exceed 5 Volt (with battery connected). 1.10
CLEANING OF MAGNETIC PARTS This operation should be done with rectifiers off
Open the doors of rectifier cabinets. Remove protection by removing the screws. Remove dust deposited on the magnetic parts through a brush and blow with compressed air inside the gorges of the windings to remove any deposits. 1.11
CLEANING OF ELECTRONIC BOARDS This operation should be done with rectifiers off.
Open the front doors of rectifier cabinets. Remove the protections by removing the screws. Using a brush and / or blowing compressed air, eliminate dust deposited on the cards
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RTB.e maintenance
2
MAINTENANCE PROGRAM
Equipment
RTB_e
Operation Visual inspection of electrical connections Check of alarms Air filter check and cleaning Fans control and cleaning Check of input voltage Control on DC voltage & Battery charger facilities Check of current absorbed by DC Filter Battery Test Measure of output voltage ripple Cleaning of magnetic parts Cleaning of electronic boards
Frequency 1 Year 6 Months 1 Year (*) 1 Year (*) 1 Year 1 Year 1 Year 1 Year 1 Year 2 Year (*) 2 Year (*)
(*) In case of equipment operating in places particularly dusty increase the frequency of operation
WARNING If the values found or the result of tests made following the procedures described on Chapter 2( Maintenance ) are different from those expected please contact the customer service. The manufacturer declines any responsibility for damage to people or things, deriving from the non-fulfilment of the instructions or from wrong manoeuvres made by not qualified personnel.
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ITB_e / IMB_e MAINTENANCE MANUAL
ITB.e / IMB.e Maintenance
ITB.e / IMB.e MAINTENANCE MANUAL Index 1
MAINTENANCE .................................................................................... 2
1.1 MAINTENANCE OPERATIONS ...............................................................................2 1.1.1 Visual inspection of electrical connections ......................................................2 1.1.2 Check of alarms on front panel display.............................................................2 1.1.3 Air Filter check and cleaning..............................................................................3 1.1.4 Check of DC filter capacitors..............................................................................3 1.1.5 Fan control and cleaning ....................................................................................3 1.1.6 Check of input voltage ........................................................................................4 1.1.7 Check of input current ........................................................................................4 1.1.8 Check of output voltage......................................................................................4 1.1.9 Check of bypass functionality............................................................................4 1.1.10 Cleaning of magnetic parts.................................................................................4 1.1.11 Cleaning of electronic boards ............................................................................4
2
MAINTENANCE PROGRAM ................................................................ 5
Index of pictures Picture 1 – Front panel …………………………………………………………………………………………….2
Rev.
/
Descrizione Description
Emissione
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
09.03.09
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
I
1
di Pag. of Pag.
5
Codice / Code
JUD411547
ITB.e / IMB.e Maintenance
1
MAINTENANCE
The following paragraphs describe the operations of preventive maintenance to be carried out on single-phase inverters (IMB.e) and three-phase inverters (ITB.e). 1.1
MAINTENANCE OPERATIONS
To carry out maintenance work safely the inverter (both inverters in case of parallel redundant systems) will be put in manual By-Pass allowing to supply loads directly with the emergency line. 1.1.1 Visual inspection of electrical connections Make sure all cables and / or bars are firmly tightened to the clamps connection and that no connection has loosened. A link not perfectly executed can increase the resistance of contact with all its consequences such as heating connection and increased voltage drop of the line. 1.1.2 Check of alarms on front panel display In order to verify the proper functioning of the system is advisable to check the history of alarms. This can be done through the front panel (see Operational Manual ITB.e) If necessary, it is possible even simulate a condition of alarm (or an indication) to test the effective functioning of signalization.
1
2 7
3
=
˜ ˜ ˜
9
ALARM/STATUS 1
10
ALARM/STATUS 2
11
ALARM/STATUS 3
12
ALARM/STATUS 4
13
ALARM/STATUS 5
14
ALARM/STATUS 6
15
ALARM/STATUS 7
16
ALARM/STATUS 8
17
ALARM/STATUS 9
18
ALARM/STATUS 10
4 6 5
EPO
8
ENT
UP
DOWN
ENTER
R BUZ. OFF
RESET
LED TEST
Picture 1 – Front panel
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ITB.e / IMB.e Maintenance
LED 1
⇒
Lit-up green = DC voltage present Otherwise off.
LED 2
⇒
Lit-up green = Emergency line present Otherwise off.
LED 3
⇒
Lit-up green = DC voltage in tolerance. Lit-up red = DC voltage out of tolerance.
LED 4
⇒
Lit-up green = Inverter static switch closed. Otherwise off.
LED 5
⇒
Lit-up orange = Emergency line static switch closed. Otherwise off.
LED 6
⇒
Lit-up green = Voltage present on the load. Lit-up orange = OCB circuit breaker open.
LED 7
⇒
Lit-up orange = Manual by-pass closed. Otherwise off.
LED 8
⇒
Lit-up red = EPO (Emergency Power Off) activated.
The meanings of Leds from 9 to 18 are depending from applications and are written beside the leds on the front panel. 1.1.3 Air Filter check and cleaning Check whether the air input / output is blocked by dirt. If so clean them with compressed air blowing from the inside of the cabinet 1.1.4 Check of DC filter capacitors Remove the front protections of inverter removing the screws. Check that the DC capacitors present no swelling or loss of electrolyte. On the capacitors there is a dangerous voltage so we recommend making this check with the inverter off. 1.1.5 Fan control and cleaning Monitoring the proper functioning of fans can be done with inverters switched on ensuring that on front panels not to appear the alarm "A20 FAN FAILURE." In any case it is advisable to remove dust possibly deposited on the fans through a brush and blow with compressed air. To do this the inverters shall be put on manual bypass and the protections removed for gaining access to fans.
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ITB.e / IMB.e Maintenance 1.1.6 Check of input voltage Check with a DC multimeter that the input voltage is within the limits defined in the data sheet. 1.1.7 Check of input current Check with a DC current clamp that the input current is within the permitted range. 1.1.8 Check of output voltage Check through an oscilloscope connected to the output terminal that the output voltage waveform does not have excessive distortion. 1.1.9 Check of bypass functionality Place the “NORMAL-BYPASS” selector on " Bypass " position. Verify that the load is fed by the emergency line through the bypass static switch. Return the selector NORMAL-BYPASS " on " Normal " position and verify that the Inveter return to supply the load. 1.1.10
Cleaning of magnetic parts
This operation should be done with Inverters off . Open the doors of inverter cabinets. Remove protection by removing the screws. Remove dust deposited on the magnetic parts through a brush and blow with compressed air inside the gorges of the windings to remove any deposits. 1.1.11
Cleaning of electronic boards
This operation should be done with Inverters off. Open the front doors of inverter cabinets. Remove the protections by removing the screws. Using a brush and / or blowing compressed air, eliminate dust deposited on the cards
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ITB.e / IMB.e Maintenance
2
MAINTENANCE PROGRAM
Equipment
ITB_e IMB_e
Operation Visual inspection of electrical connections Check of alarms on front panel dislpay Air Filter check and cleaning Check of DC filter capacitors Fan control & cleaning Check of input voltage Check of input current Check of output voltage Check of bypass functionality Cleaning of magnetic parts Cleaning of electronic boards
Frequency 1 Year 6 Months 1 Year (*) 1 Year 1 Year (*) 1 Year 1 Year 1 Year 1 Year 2 Year (*) 2 Year (*)
(*) In case of equipment operating in places particularly dusty increase the frequency of operation
WARNING If the values found or the result of tests made following the procedures described on Chapter 2( Maintenance ) are different from those expected please contact the customer service. The manufacturer declines any responsibility for damage to people or things, deriving from the non-fulfilment of the instructions or from wrong manoeuvres made by not qualified personnel.
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RTB.e Configuration
RTB.e CONFIGURATION
Index 1.
INTRODUCTION.................................................................................. 2
2.
CONFIGURATION VIA DIP SWITCHES............................................. 2
3.
TEST AND MONITORING SOFTWARE ............................................. 3 3.1
CONNECTION CABLE.....................................................................................3
3.2
SOFTWARE INSTALLATION...........................................................................3
3.3
SOFTWARE DESCRIPTION ............................................................................4
3.4
SERIAL MESSAGES FOR RTB.e SETTING ...................................................5
3.5
SERIAL MESSAGES FOR RTB.e SETTING ...................................................6
3.6
SERIAL MESSAGES TO SEND COMMANDS TO RTB.e ...............................8
3.7
SERIAL MESSAGES FOR LOOP CONTROL .................................................9
Index of pictures Fig. 1 – Dip Switches on card DR16-COMP ................................................................................................ 2 Fig. 2 – Connection cable............................................................................................................................. 3 Fig. 3 – Typical screen ................................................................................................................................. 4
Rev.
/
Descrizione Description
First Issue
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
24.01.09
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
E
1
di Pag. of Pag.
9
Codice / Code
JUD411353
RTB.e Configuration
1.
INTRODUCTION
A test and monitoring software RCN-Monitor is available for the RCN unit that allows to check all the measurements and the operating statuses of the unit via an RS232 connection, as well as to carry out settings and configuration changes on the RCN unit.
2.
CONFIGURATION VIA DIP SWITCHES
Some operating parameters are configured via Dip Switches on card DR16-COMP. The setting of the Dip Switches depends on the RTB.e size. Dip no. 1 2 3 4 5 6 7 8
Status Off On Off On Off On Off On Off On Off On Off On Off On
Description Battery test disabled Battery test enabled Boost charge disabled Boost charge enabled Manual charge disabled Manual charge enabled Parallel disabled Parallel enabled
Fig. 1 – Dip Switches on card DR16-COMP
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RTB.e Configuration
3.
TEST AND MONITORING SOFTWARE
RCN-Monitor software is connected from the serial port RS-232 of the PC, properly configured, to the serial port RS-232 of the RTB.e unit. For the connection a dedicated cable must be used, with the connections as indicated in the figure below. 3.1 CONNECTION CABLE
Fig. 2 – Connection cable
3.2 SOFTWARE INSTALLATION The software installation is performed like any other WINDOWS application. The software can be supplied on several floppy disks. In this case the software will be installed starting from DISK1, or via a CD-ROM. Start the Setup program from the START menu, then follow the instructions as they are requested by the installation software.
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RTB.e Configuration 3.3 SOFTWARE DESCRIPTION The software allows to check values variables and system parameters, as well as to perform settings. Therefore it is a necessary testing tool, whereas parameters can also be changed using the front panel. As a rule, the software allows to display the status of the system updated in real time. Communication is therefore unidirectional from RTB.e to the PC. When the communication is properly performed, the window named N. Bytes contains a number ranging from 1 to 250.
Fig. 3 – Typical screen
The user can send one of the messages listed below entering the text in the appropriate window.
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RTB.e Configuration NOTE Before sending any message, make sure the computer is writing in capital letters (CAPS). All the controls consist of 4 letters and 3 numbers LLLLXXX. After sending a message, wait for the acoustic confirmation signal (double BEEP) before sending a new string. If the signal is not received, it means the operation has failed and the last message must be sent once again. IMPORTANT Ratings and settings are not stored by RTB.e until the MEEE000 command is entered. 3.4 SERIAL MESSAGES FOR RTB.e SETTING The following messages allow to set the measurements made by RTB.e. MAINS INPUT TIFRXXX TIFSXXX TIFTXXX
(XXX=161/279) (XXX=161/279) (XXX=161/279)
phase R voltage phase S voltage phase T voltage
TCIRXXX TCISXXX TCITXXX
(XXX=001/998) (XXX=001/998) (XXX=001/998)
phase R current phase S current phase T current
(Phase - Neutral) (Phase - Neutral) (Phase - Neutral)
DC VOLTAGE VRECXXX VBATXXX
(XXX=000/999) (XXX=000/999)
RTB.e output voltage battery voltage
(Feedback) (Measurement)
ZCTO000 CTOTXXX
(XXX=005/999)
Zero total output current Setting of total output current
ZCBT000 CBATXXX
(XXX=005/999)
Zero battery current battery current setting
ZCBL000 CBALXXX
(XXX=005/999)
Zero 12p balancing current Setting of 12p balancing current
SPECIAL POTAXXX
(XXX=010/300)
Adjustment range of manual charge pot. (Vdc)
TEMPXXX
(XXX=000/100)
Temperature in degrees (from thermal probe)
SBATXXX
(XXX=000/999)
charging current (parallel config.)
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setting
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second
battery
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RTB.e Configuration 3.5 SERIAL MESSAGES FOR RTB.e SETTING The following messages allow to set the operating parameters of RTB.e by working on the internal variables that are also altered via the PARAMETERS menu on the front panel. BOOST CHARGE PARAMETERS Setting MTMFXXX SFTYXXX BOOSXXX FLBOXXX BOFLXXX VFLBXXX VBFLXXX TIBOXXX STTB001 SETBXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) / (XXX=000/999)
TIMER_AFTER_MAINS_FAULT
SAFETY_TIME_B SETP_VDC_BOOST CORR_FLOAT_BOOST CORR_ BOOST_FLOAT VOLT_FLOAT_BOOST VOLT_BOOST_FLOAT MAXTEMPO_BOOST_FLOAT / MaxTimeForced
Description Mains failure delay (sec) Safety timer (min) Boost charge voltage (V) Float → Boost switching current (A) Boost → Float switching current (A) Float → Boost switching voltage (V) Boost → Float switching voltage (V) Return-to-float timer (min) Timed Boost cycle start Timed Boost cycle timer (min)
MANUAL CHARGE PARAMETERS Setting EQUAXXX CLEQXXX MTEQXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=000/999)
SETP_VDC_EQUAL CORR_LIM_EQUAL MAXTIME_EQUAL
Description Starting voltage (V) Maximum battery current (A) Safety timer (min)
BATTERY CHARGING AND DISCHARGING PARAMETERS Setting SPDCXXX CLBAXXX WRLOXXX WRHIXXX MTWHXXX COSTXXX LEVAXXX LEVBXXX LEVCXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/198) (XXX=000/060) (XXX=000/999) (XXX=000/999) (XXX=000/999)
SETP_VDC_FLOAT CORR_LIM_AUTO MIN_VBAT MAX_VBAT TEMPO_MAX_BAT CONST_CMP_TEMP LIVELLO1 LIVELLO2 LIVELLO3
Description Floating voltage (V) Maximum battery current (A) Minimum floating voltage (V) Maximum floating voltage (V) Delay due to max. float. volt. (sec) Battery thermal comp. (mV/°C)*Cell 1st discharge level (V) 2nd discharge level (V) 3rd discharge level (V)
INPUT PARAMETERS Setting FSUPXXX FRNOXXX FINFXXX VIMAXXX VINNXXX VIMIXXX 6 of 9
Range
Variable
(XXX=000/005) (XXX=050/060) (XXX=000/005) (XXX=000/015) (XXX=000/999) (XXX=000/015)
FREQ_RETE_SUP FREQ_RETE_NOMI FREQ_RETE_INF MAX_VIN VIN_NOM MIN_VIN
JUD411353
Description Upper frequency limit (%) Nominal frequency (Hz) Lower frequency limit (%) Upper voltage limit (%) Nominal input voltage (V) Lower voltage limit (%)
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RTB.e Configuration OUTPUT PARAMETERS Setting VOUNXXX IOUNXXX * CLTOXXX ** DRPOXXX DRNEXXX MAXRXXX MTMRXXX MINRXXX LEVDXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=001/998) (XXX=001/050) (XXX=001/050) (XXX=000/999) (XXX=000/198) (XXX=000/999) (XXX=000/999)
NOM_OUT_V NOM_OUT_I TOT_LIM_CURR CONST_CMP_DROOP CONST_CMP_DROOP MAX_RECT_V RECT_MAX_TIME MIN_RECT_V LEVEL4
Description Nominal output voltage (V) Nominal output current (A) Maximum output current (A) Positive compensation of cable drop (%) Negative compensation of cable drop (%) Maximum output voltage (V) Delay due to max. output volt. (sec) Minimum output voltage (V) Emergency output level (V)
* : Example: IOUN020 ⇒ Nominal output current = 200A **: Example: CLTO020 ⇒ Maximum output current = 200A
BATTERY PARAMETERS (Battery Info) Setting TYBAXXX /
Range
Variable
Description
(XXX=000/999) /
BATTERY_SIZE BATTERY_DATE
FULL000
/
Batt_Energy
FULL100
/
Batt_Energy
Battery capacity (Ah) Battery installation date Forces the capacity stored in the battery to 0% Forces the capacity stored in the battery to 100%
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RTB.e Configuration 3.6 SERIAL MESSAGES TO SEND COMMANDS TO RTB.e The following messages allow to send commands to RTB.e. Such commands cause actions. LIST OF COMMANDS EQUIVALENT TO BUTTONS Command RBOO000 MANU000 EEDF000 RESE000 HIZE000 ONOF000 TEBA001 TEBA002 TEBA000
Action on RTB.e Retrieves the boost charge level for 30 seconds If the unit is in automatic charge, it forces the manual charge and vice versa Retrieves default parameters Resets the unit Sets the alarm log to zero Shuts the RTB.e down when started, and vice versa Starts the Deep Battery Test Starts the Quick Battery Test Interrupts the Battery Test
ALARM LOG READING The alarm log can be transferred to the computer by entering the following command: READXXX
XXX = 000 XXX = 001 ………….. XXX = 004
the latest 100 events the 100 previous events …………………… The first 100 events
FORCING OF CONDUCTION ANGLE AND 12P BRIDGE BALANCING The conduction angle of the SCR’s can be forced (eliminating the regulation loops) via the following command (to be only used during test): ADEGXXX ADEG000 BPORXXX BNERXXX
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XXX = 001/179 XXX = 000/400 XXX = 000/400
forces the angle restores the loops Setting of the pos. phase difference of 12p bridges Setting of the neg. phase difference of 12p bridges
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RTB.e Configuration 3.7 SERIAL MESSAGES FOR LOOP CONTROL The following messages allow to set the control parameters of RTB.e regulation loops by working on the internal variables that cannot be altered via the PARAMETERS menu on the front panel. PID VOLTAGE REGULATOR Setting KCFRXXX KIFRXXX KDFRXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=000/999)
KC_COS KBI_COS KBD_COS
Description Proportional constant Integrating constant Derivative constant
PID TOTAL CURRENT REGULATOR Setting KCTOXXX KITOXXX KDTOXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=000/999)
TOT_KC_COS TOT_KBI_COS TOT_KBD_COS
Description Proportional constant Integrating constant Derivative constant
PID BATTERY CURRENT REGULATOR Setting KCBAXXX KIBAXXX KDBAXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=000/999)
BATT_KC_COS BATT_KBI_COS BATT_KBD_COS
Description Proportional constant Integrating constant Derivative constant
PID PARALLEL REGULATOR Setting KCSHXXX KISHXXX KDSHXXX
Range
Variable
(XXX=000/999) (XXX=000/999) (XXX=000/999)
SH_KC_COS SH_KBI_COS SH_KBD_COS
Description Proportional constant Integrating constant Derivative constant
RCN POSITION IN A PARALLEL SYSTEM In a parallel redundant system, each RTB.e unit is given a position by entering the following command: POSIXXX
XXX = 001 XXX = 002
Position 1 Position 2
STORAGE MEEE000
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Stores the ratings and the settings made. (They become permanent).
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UPS test software
UPS TEST SOFTWARE
Index 1.
INTRODUCTION.................................................................................. 3
2.
TEST AND MONITORING SOFTWARE ............................................. 3 2.1
SOFTWARE INSTALLATION...........................................................................4
2.2
SERIAL PORT CONFIGURATION ...................................................................4
2.3
UPS TEST PANEL............................................................................................5
2.3.1
MEASURES...............................................................................................6
2.3.2
UPS DATA.................................................................................................6
2.3.3
VARIABLES ..............................................................................................7
2.3.4
OUTPUTS ..................................................................................................7
2.3.5
INPUTS ......................................................................................................7
2.3.6
ALARMS AND STATUS............................................................................8
2.3.7
ACTIVE KEYS ...........................................................................................8
2.3.8
GAUGES ...................................................................................................8
2.3.9
CONTROLS ...............................................................................................8
2.3.10
PARALLEL ............................................................................................8
BOOST OPERATION .............................................................................................8 2.4
Rev.
/
SERIAL MESSAGES FOR PERSONALISATION AND SETTING...................9
2.4.1
BYPASS ..................................................................................................10
2.4.2
OUTPUT ..................................................................................................10
2.4.3
INVERTER ...............................................................................................10
Descrizione Description
First Issue
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
24.01.09
P.Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
di Pag. of Pag.
E
1
12
Codice / Code
JUD411293
UPS test software 2.4.4
BATTERY ............................................................................................... 10
2.4.5
BATTERY TEST ..................................................................................... 10
2.4.6
BOOST CHARGE ................................................................................... 10
2.4.7
GENERAL COMMANDS ........................................................................ 11
2.4.8
IDENTIFICATION.................................................................................... 11
2.4.9
TIMER SETTING..................................................................................... 12
2.5
HYSTORY OF ALARMS................................................................................ 12
2.6
SHORTCUT KEYS......................................................................................... 12
Index of pictures Picture 1 – RS232 connection cable ............................................................................................................ 3 Picture 2 – Communication configure panel................................................................................................. 4 Picture 3 – Modem setup.............................................................................................................................. 5 Picture 4 – UPS Test screen ........................................................................................................................ 5
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JUD411293
First Issue 24/01/09
UPS test software
1.
INTRODUCTION
The monitoring and test software of the UPS, UPS-Test allows, by means of RS232 connection, to control all the measures and status of the equipment and to carry out settings and modifications of the UPS configuration.
2.
TEST AND MONITORING SOFTWARE
The UPS-Test software is connected through the RS232 serial port of the PC to the RS232 serial of the UPS. The RS232 connection cable is built according to the picture 1.
Picture 1 – RS232 connection cable
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UPS test software 2.1 SOFTWARE INSTALLATION The installation of the software is carried out like a standard WINDOWS application. The software can be supplied on several floppy disks, in this case proceed to install the program starting from DISK 1, or by means of a CD-ROM. From the menu, start the Set-up program and carry out the instructions required by the installation software.
2.2 SERIAL PORT CONFIGURATION From the menu configure it is possible to configure the serial port RS232 for the connection to the UPS.
Picture 2 – Communication configure panel
Port adress: Set the serial COM where the UPS is connected. Baud rate: Set the speed of the serial communication. Set to 2400 baud. Stop bits: Select “1”. Data bits: Select “8”. Parity: Select “None”. Flow Control: Select “None”. Connection: Select “Local” to connect the PC to the UPS. Select “Remote” to connect the PC to the UPS trought a mode connection. Syncro_Key: Select “No”.
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First Issue 24/01/09
UPS test software From the “Modem” button it is possible to set the parameter for remote connection.
Picture 3 – Modem setup
Init. string: Set the initialization string for the modem. Dial string: Set the command string for the modem to dial the UPS. Hang upp string: Set the command string for the modem to close the connection.
2.3 UPS TEST PANEL All the following paragraphs, describing the software functions, refer to the picture 4, where the UPS Test screen is shown.
Picture 4 – UPS Test screen
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UPS test software 2.3.1 MEASURES On the area “Measures” all the analog measurements inherent to the UPS are shown, in the following order: BYP_V_R BYP_V_S BYP_V_T
Æ Emergency bypass voltage Ph. R (V) Æ Emergency bypass voltage Ph. S (V) Æ Emergency bypass voltage Ph. T (V)
OUT_V_R OUT_V_S OUT_V_T
Æ UPS output voltage Ph. R (V) Æ UPS output voltage Ph. S (V) Æ UPS output voltage Ph. T (V)
INV_V_R INV_V_S INV_V_T
Æ Inverter voltage Ph. R (V) Æ Inverter voltage Ph. S (V) Æ Inverter voltage Ph. T (V)
ACDC_V
Æ Battery voltage (V)
DC_CUR
Æ Inverter Input current (A)
IB_BOO
Æ Battery Recharging Current ( A )
F_BYP
Æ Emergency bypass frequency (Hz)
F_INV
Æ Inverter frequency (Hz).
In the area below, the field “NUMBER” represents the serial n° of the equipment and the field “VER. SW.” represents the revision of the UPS control software installed. On the area “TX Check” the transmission control indicator is represented. If the connection is correct the figures increases cyclically up to 250 automatically.
2.3.2 UPS DATA The area titled “UPS data” represents the relevant characteristics and settings. The first 7 lines contain the nominal values for: POT_NOM VOLT_NOM CURR_NOM VDC_NOM IDC_NOM BAT_TYP AUT_NOM
Æ Æ Æ Æ Æ Æ Æ
UPS nominal power (kVA). UPS nominal output voltage (V). UPS nominal output current (A). Battery nominal voltage (V). Inverter nominal input current at full load (A). Battery capacity (Ah). Nominal autonomy (min).
The following 4 groups represent the limit values (for the voltage to be declared available) and the histeresys for: BYP INV OUT VDC
Æ Æ Æ Æ
Emergency bypass (V) Inverter Output (V) UPS Output (V) Inverter input (V)
#1 #2 #3 #4
The following 3 groups represent the limit values (for the frequency to be declared in tolerance) and the histeresys for emergency bypass as follows: 6 of 12
JUD411293
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UPS test software FREQ FREQ MIN FREQ MAX
Æ Emergency bypass nominal frequency (Hz) Æ Emergency bypass lower frequency (Hz) Æ Emergency bypass higher frequency (Hz)
#5
The last 2 lines contain the following information: AUT. MIN AUT. %
Æ Residual Battery autonomy (min) Æ Residual Battery autonomy (as % of the nominal).
2.3.3 VARIABLES The area titled “Variables” represents the relevant internal status variables of the UPS. The meaning of each variable is described below: INV_ON SSW_ON IOK ROK_X O_LOAD HITE FROK RMS_OK COK VUOK SYNCOK I_OVER IMTERM VDC_OK
Æ Æ Æ Æ Æ Æ Æ Æ Æ Æ Æ Æ Æ Æ
When active the command inverter on is active too When active the command inverter SSW on is active too If active the inverter is ready to supply the load If active the bypass is in tolerance (ROK = RMSOK+FROK) If active an overload has stopped the inverter If active an over temperature (thermal protection) is active too If active the emerg. byp. frequency is in tolerance (see limit group #5) If active the emerg. byp. voltage is in tolerance (see limit group #1) If active the UPS output voltage is in tolerance (see limit group #3) If active the Inverter output voltage is in tolerance (see limit group #2) If active the inverter is synchronized with the emergency bypass If active an overload (output current > nominal) is active too If active the thermal image counter (time vs current) is active too If active the Inverter input voltage is in tolerance (see limit group #4)
2.3.4 OUTPUTS The area titled “Outpus” represents the relevant digital outpus of the UPS. The meaning of each variable is described below: COK BY_BL IFL CONAC RESET_RITR_BL R3_INV_FEED R4_BYP_FEED R5_LOW_BATT R6_MAINS_FAU
Æ Æ Æ Æ Æ Æ Æ Æ Æ
If active the UPS output voltage is in tolerance (see limit group #3) When active the load is blocked on the emergency bypass When active the inverter SSW is closed When active the PWM of the inverter IGBT bridge is on When active the BY_BL condition is reset When active relay Inv. Feeds Load is active too (ARC card) When active relay Bypass Feed Load is active too (ARC card) When active relay Low Battery is active too (ARC card) When active relay Mains Fault is active too (ARC card)
2.3.5 INPUTS The area titled “Inputs” represents the relevant digital inputs of the UPS. The meaning of each variable is below described: MBY_CLOSE EPO_BUS BO_BUS BYP_SW (FUSE) TERMO_SW OCB MCS First Issue 24/01/09
Æ Æ Æ Æ Æ Æ Æ
When active the MBCB (manual bypass) is closed When active the EPO (emergency power off) is not active When active the BCB (battery breaker) is open When active the Bypass Switch (commutation test) is active When active the Thermal switch (bridge protection) is active When active the OCB (output breaker) is closed When active the IGBT’s desaturation protection is active JUD411293
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UPS test software MRR RECT_FAIL ERR_SC BF_RECT PUL_UP PUL_DOWN PUL_ENTER PUL_ BUZZ PUL_RESET
Æ Æ Æ Æ Æ Æ Æ Æ Æ
When active Mains fault signal (from the rectifier) is not active When active Rectifier fault sign. (from the rectifier) is not active When active Input wrong seq. sign. (from the rectifier) is not active When active Blown fuse sign. (from the rectifier) is active When active the up arrow key on the front panel is pressed When active the down arrow key on the front panel is pressed When active the enter key on the front panel is pressed When active the buzzer key on the front panel is pressed When active the reset key on the front panel is pressed
2.3.6 ALARMS AND STATUS On the areas named “Alarms” and “Status”, the 25 alarms and 6 operating status are represented. For a detailed explanation of them, see the Operating Manual.
2.3.7 ACTIVE KEYS The push button “Dip Sw” visualizes the mapping of the dip switches for configuration on the μP board (see foregoing paragraphs). By clicking on the relevant country on the flags area the language on the display of the UPS can be changed.
2.3.8 GAUGES The two gauges located under the third column represents the following values: EN. CAR ACCUMU
Æ Stored energy in the battery as % of the total Æ Thermal image progress as % of the total (100 % Æ inverter stopped)
2.3.9 CONTROLS The area above the flags contains the following control parameters: FEFO KF_BY KF_OU
Æ Must be 180 Æ Must be between 800 and 900 Æ Must be between 800 and 900
2.3.10 PARALLEL If the UPS is working in parallel mode the relevant area “MASTER” under the second column and the active key “Par. Data” are active. For the description of the relevant functions refers to the Parallel Redundant Operating Manual.
BOOST OPERATION If the Boost function is active, the push button “BOOST“ visualizes the parameter of the Boost Operation
IB_TR IB_RT
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Æ Battery current limit for Floating to Boost Charge ( A ) Æ Battery current limit for Boost to Float Charge ( A )
JUD411293
First Issue 24/01/09
UPS test software 2.4 SERIAL MESSAGES FOR PERSONALISATION AND SETTING WARNING Before sending any message insure that the computer writes with capital letters (CAPS). All commands consist in 4 letters and 3 numbers LLLLXXX. After having sent a message, wait for an acoustic confirmation signal (BEEP) before sending new strings. If the signal does not arrive it means that the operation has had a negative result, so the last message must be repeated. VERY IMPORTANT The usage of these messages is recommended to specialized personnel only. Don’t forget to send the command MEEE000 to store the variations on the UPS memory.
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UPS test software 2.4.1 BYPASS TBFRXXX TBFSXXX TBFTXXX
(XXX=100/250) (XXX=100/250) (XXX=100/250)
phase R voltage phase S voltage phase T voltage
(for UPS 1Ph and 3Ph) (only for UPS 3Ph) (only for UPS 3Ph)
(XXX=100/250) (XXX=100/250) (XXX=100/250)
phase R voltage phase S voltage phase T voltage
(for UPS 1Ph and 3Ph) (only for UPS 3Ph) (only for UPS 3Ph)
phase R zero current phase S zero current phase T zero current
(for UPS 1Ph and 3Ph) (only for UPS 3Ph) (only for UPS 3Ph)
phase R current phase S current phase T current
(for UPS 1Ph and 3Ph) (only for UPS 3Ph) (only for UPS 3Ph)
phase R zero voltage phase S zero voltage phase T zero voltage
(for UPS 1Ph and 3Ph) (only for UPS 3Ph) (only for UPS 3Ph)
phase R voltage phase S voltage phase T voltage
(for UPS 1Ph and 3Ph) (only for UPS 3Ph) (only for UPS 3Ph)
2.4.2 OUTPUT TUFRXXX TUFSXXX TUFTXXX ZCFR000 ZCFS000 ZCFT000 TCFRXXX TCFSXXX TCFTXXX
(XXX=005/999) (XXX=005/999) (XXX=005/999)
2.4.3 INVERTER ZIFR000 ZIFS000 ZIFT000 TIFRXXX TIFSXXX TIFTXXX
(XXX=100/250) (XXX=100/250) (XXX=100/250)
2.4.4 BATTERY TVBAXXX TCBAXXX TYBAXXX TAUTXXX LOBA XXX
(XXX=100/600) (XXX=010/999) (XXX=002/999) (XXX=100/600)
BATT000 ZCBA000
Voltage Current Battery type (i.e.: batt. 24Ah = TYBA024) Nominal auton. (i.e.: aut. 20’ = TAUT020) Low battery level Forces to the 100% battery autonomy zero current
2.4.5 BATTERY TEST TEBAXXX STDBXXX TBOF000 TBONXXX
(XXX=000/002) (XXX=000/999) (XXX=000/999)
battery test choice battery test length setting battery test stop battery test for XXX minutes
2.4.6 BOOST CHARGE TCRBXXX TBTRXXX TBRTYYY BOST000 ZCRB000
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(XXX=010/999) (XXX=000/999) (XXX=000/999)
battery current for boost adjustment current limit for floating to boost current limit for boost to floating boost charge ON zero battery current for boost charge
JUD411293
First Issue 24/01/09
UPS test software 2.4.7 GENERAL COMMANDS TFFRXXX TVLX000 MEEE000 REHI000 BUZZ000 RESE000 INON000 INOF000 PHASXXX
(XXX=010/060)
frequency window: for values see (1) fast voltage monitor Store the value in E2PROM reset HISTORY BUZZER quieting reset UPS on inverter off inverter set the phase shifting between inverter and the bypass normal setting. Single unit PHAS270 set phase = 2700 Parallel unit PHAS400 set phase = 4000
(XXX=000/999)
2.4.8 IDENTIFICATION CNAMXXX
(XXX=000/005)
Set the name of the unit
CLANXXX
(XXX=000/005)
UPS language
XXX = 000 (Italian) XXX = 001 (German) XXX = 002 (French) XXX = 003 (English) XXX = 004 (Portuguese) XXX = 005 (Spanish)
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UPS test software 2.4.9 TIMER SETTING TMINXXX THOUXXX TDAYXXX TMONXXX TYEAXXX
(XXX = 000/059) (XXX = 000/023) (XXX = 000/031) (XXX = 000/012) (XXX = 000/099)
(*)
Values not to be modified.
(1)
TFFR + 060 055 050 045 040 035 030 025 020 015 010
+/- 6% +/- 5,5% +/- 5% +/- 4,5% +/- 4% +/- 3,5% +/- 3% +/- 2,5% +/- 2% +/- 1,5% +/- 1%
minutes setting hour setting day setting month setting year setting
standard setting
2.5 HYSTORY OF ALARMS It is possible to download the alarm history on the computer by typing the following command: READ XXX
XXX = 000 XXX = 001 XXX = 002 .......... XXX = 008
last 100 events previous 100 events previous 100 events first 100 events
During the download the TX CHECK counter on the computer starts to count from 0 to 1800. To read the history on the computer the F1 key can be pressed.
2.6 SHORTCUT KEYS Key
Description
F1 F2 F3 F4 F5 F6 F7 F8 F9
After the READ000 command allows to read the history on the computer. Sends RESE000 command. Sends all the zeroes to the UPS. Sends E2PROM data storing command : MEEE000. Sends the buzzer quieting command : BUZZ000. Sends the inverter ON command : INON000. Sends the inverter OFF command : INOF000. Adjusts the limits for the bypass and the output voltage : TVLX000. Adjusts the limits for the frequency at +/- 4% : TFFR040.
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AC UPS APPENDIX SERVICE MANUAL
Index of sections
Code
1 – UPS dielectric strength test
JUD411350
2 – Setting of FMC board
JUD411351
3 – Operating instr. for thermal probe mounting on RTB.e
JRE409515
4 – Operating instr. for N_FS3011 board mounting
JRE409517
5 – Operating instr. for battery recharge LEM use
JRE409518
First Issue 03/03/09
JUD411495
1 of 1
Test di rigidità dielettrica per UPS Dielectric strength test for UPS systems
TEST DI RIGIDITÀ DIELETTRICA PER UPS Norma di riferimento: EN50091-1. Test da eseguire prima della procedura di collaudo funzionale.
Rev.
/
•
Preparazione per la prova di rigidità dielettrica.
1)
Scollegare il cavo di terra dei filtri rete oppure togliere le schede filtro rete.
2)
Chiudere RCB, SCB, MBCB, OCB, BCB.
3)
Scollegare tutti i connettori dalle schede elettroniche.
4)
Cortocircuitare tutti gli ingressi ed uscite di potenza sulle morsettiere di ingresso/uscita compreso + e – batteria.
5)
Cortocircuitare tra loro tutti i contatti di potenza del ponte inverter.
6)
Cortocircuitare tutti i connettori delle gate degli igbt del ponte inverter.
7)
Cortocircuitare tra loro tutti i contatti di potenza degli interruttori statici.
•
Precompliants resistenza di isol. eseguita con strumento: safety tester
1)
Applicare tra morsettiera ingressi/uscite e terra 500Vdc, verificare che la resistenza di isolamento sia superiore a 50Mohm.
• 1)
Test di rigidità eseguita con strumento: high voltage tester Applicare gradatamente partendo da zero fino a 2500Vac la tensione di prova per una durata di un minuto tra morsettiera ingressi/uscite e terra. Verificare che non ci siano scariche o perdite di isolamento con correnti superiori a 20mA.
Descrizione Description
First issue
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
27.01.09
P.Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
I/E
1
di Pag. of Pag.
4
Codice / Code
JUD411350
Test di rigidità dielettrica per UPS Dielectric strength test for UPS systems •
Verifica della resistenza di isol. eseguita con strumento: safety tester
1)
Applicare tra morsettiera ingressi/uscite e terra 500Vdc, verificare che la resistenza di isolamento sia superiore a 50Mohm.
•
Ripristino del dispositivo in prova.
1)
Scaricare eventuali tensioni residue ingressi/uscite a terra con l’apposito cavo.
2)
Ricollegare il cavo di terra dei filtri rete oppure rimontare le schede filtro rete.
3)
Aprire gli interruttori RCB, SCB, MBCB, OCB, BCB.
4)
Togliere tutti i cortocircuiti sulle morsettiere di ingresso/uscita compreso + e – batteria.
5)
Togliere tutti i cortocircuiti dai contatti di potenza del ponte inverter.
6)
Togliere tutti i cortocircuiti dai connettori delle gate degli igbt del ponte inverter.
7)
Togliere tutti i cortocircuiti dai contatti di potenza degli interruttori statici.
•
Continuare con la procedura di collaudo funzionale.
First Issue 27/01/09
JUD411350
cortocircuitando
la
morsettiera
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Test di rigidità dielettrica per UPS Dielectric strength test for UPS systems
DIELECTRIC STRENGTH TEST FOR UPS SYSTEMS Reference norm: EN50091-1. Test to be carried out before the functional test procedure. •
Getting ready for the dielectric strength test.
8)
Disconnect the ground wire of the mains filters, or remove the mains filter boards.
9)
Close RCB, SCB, MBCB, OCB, BCB.
10) Disconnect all the connectors from the electronic boards. 11) Short-circuit all the power inputs and outputs on the input/output terminal boards including battery + and -. 12) Short-circuit all the power contacts of the inverter bridge with one another. 13) Short-circuit all the connectors of the IGBT gates on the inverter bridge. 14) Short-circuit all the power contacts of the static switches with one another. •
Precompliants of insulation resistance carried out with the following instrument: safety tester
1)
Apply 500Vdc between the input/output terminal board and ground. Make sure the insulation resistance exceeds 50Mohm.
•
Dielectric strength test carried out with the following instrument: high voltage tester
2)
Apply the test voltage gradually between the input/output terminal board and ground starting from zero up to 2500Vac for one minute. Make sure no discharges or insulation losses occur with currents exceeding 20mA.
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Test di rigidità dielettrica per UPS Dielectric strength test for UPS systems •
Check of insulation resistance carried out with the following instrument: safety tester
2)
Apply 500Vdc between the input/output terminal board and ground. Make sure the insulation resistance exceeds 50Mohm.
•
Reset of the test device.
1)
Discharge any residual voltages to the ground by short-circuiting the input/output terminal board via the relevant wire.
2)
Reconnect the ground wire of the mains filters, or reassemble the mains filter boards.
3)
Open circuit breakers RCB, SCB, MBCB, OCB, BCB.
4)
Remove all the short-circuits on the input/output terminal boards including battery + and -.
5)
Remove all the short-circuits from the power contacts of the inverter bridge.
6)
Remove all the short-circuits from the connectors of the IGBT gates on the inverter bridge.
7)
Remove all the short-circuits from the power contacts of the static switches.
•
Continue with the functional test procedure.
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ISTRUZIONE OPERATIVA Programmazione scheda FMC IMPORTANTE Sul connettore M1 deve essere sempre collegato un ventilatore. La scheda FMC permette di monitorare i ventilatori nei seguenti casi: a)
4 ventilatori del solito modello;
b)
2 coppie di ventilatori di modelli diversi distribuendo su M1 (ed eventualmente M2) il primo modello, su M3 (ed eventualmente M4) il secondo modello;
c)
3 ventilatori di un modello ed il quarto diverso distribuendo su M1-M2-M3 i tre ventilatori uguali, su M4 il ventilatore diverso. In questo caso la scheda da utilizzare è modificata rispetto ai casi precedenti (utilizzare N_FS3079 per tensione di alimentazione a 115Vac o N_FS3080 per tensione di alimentazione a 230Vac).
La programmazione avviene partendo con tutti i jumper (JP1..JP12) aperti, per qualsiasi caso di monitoraggio sopra indicato, e prosegue come viene riportato: 1)
PROGRAMMAZIONE NEL CASO DI 4 VENTILATORI DELLO STESSO MODELLO
JP1) - Ventilatore su M1
Chiudere JP1 1-2;
JP2) - Ventilatore su M2
Chiudere JP2
JP3) - Ventilatore su M3
Chiudere JP3
JP4) - Ventilatore su M4
Chiudere JP4
JP5,6,7,8)
TAB.1 – Modello del ventilatore su M1 e/o M2 MODELLO 4650N 7855 ES 148VK W2E200
Rev.
/
Descrizione Description
First Issue
JP5 1-2 2-3
JP6 1-2 2-3 2-3
JP7 1-2 2-3
JP8 1-2 2-3
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
27/01/09
P.Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
I
1
di Pag. of Pag.
6
Codice / Code
JUD411351
JP9,10,11,12) Settaggio necessario solo in presenza di ventilatori su M3 e/o M4 TAB.2 – Modello del ventilatore su M3 e/o M4 MODELLO 4650N 7855 ES 148VK W2E200
JP9 JP10 JP11 JP12 1-2 1-2 1-2 1-2 2-3 2-3 2-3 2-3 2-3
Note: “ - “ indica “jumper aperto” 2)
PROGRAMMAZIONE NEL CASO DI VENTILATORI DI 2 MODELLI DIVERSI
JP1) - Ventilatore su M1
Chiudere JP1 2-3;
JP2) - Ventilatore su M2
Chiudere JP2
JP3) - Ventilatore su M3
Chiudere JP3
JP4) - Ventilatore su M4
Chiudere JP4
JP5,6,7,8)
TAB.1 – Modello del ventilatore su M1 e/o M2 MODELLO 4650N 7855 ES 148VK W2E200
JP5 1-2 2-3
JP6 1-2 2-3 2-3
JP7 1-2 2-3
JP8 1-2 2-3
JP9,10,11,12) Settaggio necessario solo in presenza di ventilatori su M3 e/o M4 TAB.2 – Modello del ventilatore su M3 e/o M4 MODELLO 4650N 7855 ES 148VK W2E200
JP9 JP10 JP11 JP12 1-2 1-2 1-2 1-2 2-3 2-3 2-3 2-3 2-3
Note: “ - “ indica “jumper aperto”
First Issue 27/01/09
JUD411351
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3)
PROGRAMMAZIONE NEL CASO DI 3 VENTILATORI DELLO STESSO MODELLO ED 1 DIVERSO
JP1) - Ventilatore su M1
Chiudere JP1 2-3;
JP2) - Ventilatore su M2
Chiudere JP2
JP3) - Ventilatore su M3
Chiudere JP3
JP4) - Ventilatore su M4
Chiudere JP4
JP5,6,7,8,9)
TAB.1 – Modello del ventilatore su M1-M2-M3 MODELLO 4650N 7855 ES 148VK W2E200
JP10,11,12)
JP5 1-2 2-3
JP6 1-2 2-3 2-3
JP7 1-2 2-3
JP8 1-2 2-3
JP9 1-2 2-3
TAB.2 – Modello del ventilatore su M4 MODELLO 4650N 7855 ES 148VK W2E200
JP10 JP11 JP12 1-2 1-2 1-2 2-3 2-3 2-3 2-3
Note: “ - “ indica “jumper aperto”
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JUD411351
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OPERATING INSTRUCTION FMC card programming IMPORTANT A fan must always be connected to the connector M1. The FMC card allows the fans monitoring in the following cases: a)
#4 fans of the same type;
b)
#2 couples of fans of different models, distributing on M1 and M2 the first model and on M3 and M4 the second model
d)
#3 fans of the same model and a fourth one of a different type connected to the connector M4. In this case the card has a different code (use N_FS3079 for supply voltage of 115Vac or N_FS3080 for supply voltage of 230Vac). .
c)
The programming starts with all the jumpers (JP1÷JP12) open and proceed as indicated hereunder. 1)
PROGRAMMING IN CASE OF #4 FANS OF THE SAME TYPE
JP1) - Fan on M1
Close JP1 1-2;
JP2) - Fan on M2
Close JP2
JP3) - Fan on M3
Close JP3
JP4) - Fan on M4
Close JP4
JP5,6,7,8)
TAB.1 – Model of fan on M1 and /or M2 MODEL 4650N 7855 ES 148VK W2E200
First Issue 27/01/09
JP5 1-2 2-3
JUD411351
JP6 1-2 2-3 2-3
JP7 1-2 2-3
JP8 1-2 2-3
4 of 6
JP9,10,11,12) Setting necessary only if fans are connected on M3 and/or M4 TAB.2 – Model of fan on M3 and/or M4 MODEL 4650N 7855 ES 148VK W2E200
JP9 JP10 JP11 JP12 1-2 1-2 1-2 1-2 2-3 2-3 2-3 2-3 2-3
Note: “ - “ indicates “jumper open” 2)
PROGRAMMING IN CASE OF FANS OF TWO DIFFERENT MODELS
JP1) - Fan on M1
Close JP1 2-3;
JP2) - Fan on M2
Close JP2
JP3) - Fan on M3
Close JP3
JP4) - Fan on M4
Close JP4
JP5,6,7,8)
TAB.1 – Model of fan on M1 and /or M2 MODEL 4650N 7855 ES 148VK W2E200
JP5 1-2 2-3
JP6 1-2 2-3 2-3
JP7 1-2 2-3
JP8 1-2 2-3
JP9,10,11,12) Setting necessary only if fans are connected on M3 and/or M4 TAB.2 – Model of fan on M3 and/or M4 MODEL 4650N 7855 ES 148VK W2E200
JP9 JP10 JP11 JP12 1-2 1-2 1-2 1-2 2-3 2-3 2-3 2-3 2-3
Note: “ - “ indicates “jumper open”
First Issue 27/01/09
JUD411351
5 of 6
3)
PROGRAMMING IN CASE OF #3 FANS OF THE SAME MODEL AND #1 DIFFERENT
JP1) - Fan on M1
Close JP1 2-3;
JP2) - Fan on M2
Close JP2
JP3) - Fan on M3
Close JP3
JP4) - Fan on M4
Close JP4
JP5,6,7,8,9)
TAB.1 – Model of fan on M1 and /or M2 MODELLO 4650N 7855 ES 148VK W2E200
JP10,11,12)
JP5 1-2 2-3
JP6 1-2 2-3 2-3
JP7 1-2 2-3
JP8 1-2 2-3
JP9 1-2 2-3
TAB.2 – Model of fan on M4 MODELLO 4650N 7855 ES 148VK W2E200
JP10 JP11 JP12 1-2 1-2 1-2 2-3 2-3 2-3 2-3
Note: “ - “ indicates “jumper open”
First Issue 27/01/09
JUD411351
6 of 6
ISTRUZIONE OPERATIVA DI MONTAGGIO
MOUNTING OPERATING INSTRUCTION
Sonda termica su RTB_e con compensazione termica
Thermal probe on RTB_e with thermal compensation
Nei sistemi RTB_e con compensazione termica della tensione di tampone, collegare la FS1523, come riportato in figura 1, a M14 della scheda N_FS3004 con molex a 3 poli.
On RTB_e systems with thermal compensation of floating voltage, connect FS1523 (Picture 1) to M14 of N_FS3004 board with 3 poles molex.
Figura 1 – Picture 1
Rev.
/
Descrizione Description
First Issue
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
27.06.07
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
I/E
1
di Pag. of Pag.
1
Codice / Code
JRE409515
Rev.
/
ISTRUZIONE OPERATIVA
OPERATING INSTRUCTION
Montaggio scheda N_FS3011 CAN-LINK
Mounting board N_FS3011 CAN-LINK
1)
Montare la scheda N_FS3011 sulla scheda FS1420 come mostrato nella foto seguente.
1)
Mount the N_FS3011 board on the FS1420 as showed on the following picture.
2)
Collegare il Pin 1 di M1 della N_FS3011 al Pin2 del connettore DB9 femmina posto sul frontale del rack delle schede di controllo.
2)
Connect Pin 1 of M1 of N_FS3011 to Pin 2 of DB9 female connector placed on the front side of the control boards rack.
3)
Collegare il Pin 2 di M1 della N_FS3011 al Pin7 del connettore DB9 femmina posto sul frontale del rack delle schede di controllo.
3)
Connect Pin 2 of M1 of N_FS3011 to Pin 7 of DB9 female connector placed on the front side of the control boards rack.
Descrizione Description
First Issue
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
27.06.07
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
I/E
1
di Pag. of Pag.
2
Codice / Code
JRE409517
Cavo di collegamento CAN_BUS RTB_e in parallelo ridondante
Connection cable CAN_BUS parallel redundant RTB_e
Materiale: 2 connettori DB9 maschio, cavo bipolare
Material: 2 DB9 male connectors, bipolar cable
1)
Collegare il Pin 2 di un connettore al Pin 2 dell’altro connettore.
1)
Connect Pin 2 of DB9 connector to Pin 2 of other DB9 connector.
2)
Collegare il Pin 7 di un connettore al Pin 7 dell’altro connettore.
2)
Connect Pin 7 of DB9 connector to Pin 7 of other DB9 connector.
JRE409517 ISSUE
2
ISTRUZIONE OPERATIVA DI MODIFICA Per utilizzo LEM ricarica batteria su raddrizzatori digitali in configurazione parallelo ridondante Questa istruzione si riferisce ad una configurazione generica composta da due RTB_e e una o due batterie. Si possono distinguere le seguenti configurazioni: 1.
Due RTB_e con diodo di blocco, connessi in parallelo su un’unica barra e una batteria collegata anch’essa in parallelo alla barra.
I due sensori di corrente di batteria devono essere collegati al connettore M7 della N_FS3004 di ciascun RTB_e. Sul connettore M18 della N_FS3004 di ciascun RTB_e, si devono cortocircuitare con un jumper i pin 17-18.
Rev.
/
Descrizione Description
Emissione
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
27/06/07
P. Conti
E. Simoni
E. Simoni
Lingua Language
Pagina Page
I/E
1
di Pag. of Pag.
4
Codice / Code
JRE409518
2.
Due RTB_e con diodo di blocco, connessi in parallelo su un’unica barra e due batterie collegate anch’esse in parallelo alla barra e congiuntore fra i due sistemi.
Ogni batteria deve avere un sensore di corrente (Hall effect ammeter) per ciascun RTB_e. La tabella sotto riportata evidenzia la logica di collegamento dei sensori di corrente sulla N_FS3004. BATTERIA 1 BATTERIA 2 RTB_e1
M7
M13
RTB_e2
M13
M7
Sulla scheda FS1420 dovranno essere implementate le seguenti modifiche in base alla corrente di ricarica di batteria degli RTB_e. R122 = 10 k ¼ w R129 = in accordo alla seguente tabella Rapporto di trasformazione del sensore ad effetto Hall di batteria 2000/1 4000/1 5000/1
Massima corrente di ricarica della batteria
R 129 [kOhm] 1W
151A 230A 305A 300A 760A
33 22 33 // 33 33 33 // 33
Il contatto ausiliario del congiuntore dovrà essere portato ad entrambi gli RTB_e. Nel caso in cui il congiuntore non fosse previsto, si dovrà provvedere a cortocircuitare con un jumper, in ogni RTB_e, i pin 17-18 del connettore M18 della N_FS3004. JRE409518 ISSUE
2
MODIFICATION OPERATING INSTRUCTION To use battery recharge LEM on parallel redundant digital rectifiers This instruction is related to a generic configuration of two RTB_e and one or two batteries. We can have the following configurations: 1.
Two RTB_e with blocking diode, connected in parallel in one sinlge bar and one battery aswell connected in parallel to the bar.
The two battery current sensors have to be connected to M7 connector of N_FS3004 of each RTB_e. On M18 connector of N_FS3004 of each RTB_e, the pin 17-18 have to be short circuit with a jumper.
JRE409518 ISSUE
3
2.
Two RTB_e with blocking diode, connected in parallel on one single bar and two batteries aswell connect in parallel to the bar and coupling switch between the two system.
Each battery must have a current sensor (Hall effect ammeter) for each RTB_e The following table show the connection logic of current sensories on N_FS3004. BATTERY 1
BATTERY 2
RTB_e1
M7
M13
RTB_e2
M13
M7
On the FS1420 board will have to be implemented following modifications according to the battery recharge current of RTB_e. R122 = 10 k ¼ w R129 = as according of following table Battery Hall effect ammeter ratio 2000/1 4000/1 5000/1
Maximum Battery recharge current 151A 230A 305A 300A 760A
R 129 [kOhm] 1W 33 22 33 // 33 33 33 // 33
The auxiliary contact of coupling switch will have to be carried on each RTB_e. If there is not coupling switch, we will have to short circuit pin 17-18 of M18 connector of N_FS3004 with a jumper, on each RTB_e.
JRE409518 ISSUE
4
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