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All rights including translation, reproduction by printing, copying or similar methods of this document, even of parts, are reserved. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of utility model or design, are reserved. Delivery subject to availability. Important note! The technical data enclosed is for general information. Please note the operating instructions and the references indicated on the products for installation, operation and maintenance. Product designations All product designations used are trademarks or product names of Chloride S.p.A. or other companies. This publication is issued to provide outline information and is not deemed to form any part of any offer and contract. The company has a policy, of continuous product development and improvement and we therefore reserve the right to vary any information quoted without prior notice. Right of technical modification reserved.
Chloride Via Fornace 30 40023 Castel Guelfo (BO) Tel. +39 0542 632111 Fax. +39 0542 632120 www.chloridepower.com
Preamble
Even the best device needs to be taken care of, if only for check-up or whether everything is within normal parameters. Due to working with dangerous voltages and high power, it is always possible, that there could happen any damage to the device. This 80-NET Technical Manual is thought for Service personal, which is trained by Chloride or Chloride authorised Trainers only. Please keep in mind that only qualified & authorized personnel is supposed to carry out any work on the UPS.
The 80-NET User Handbook/User Manual is a basis to this 80-NET Technical Manual. So please keep a copy of the 80-NET User Manual ready for any work on the UPS or other 80-NET concerning matters. Both manuals should be studied before commencing work. There are further documents to this Technical Manual 80-NET (10H52167TM01): the Technical Manual 80-NET Circuit Diagrams (10H52167TM01_CD), the Technical Manual 80-NET Checklists (10H52167TM01_CL), the Technical Manual 80-NET PPVIS & PPGraph (10H52167TM01_PP). All these documents belong together and where just separated for easier handling concerning updates and file-size.
As already mentioned Chloride is keen on constantly seeking to improve its products and, therefore figures and technical data can/will change without prior notice. These datas will not be AUTOMATICALLY updated by Chloride within this 80-NET Technical Manual and the additional documents. With every new released version of this 80-NET Technical Manual, Chloride will endeavour to update the information to the at that time current state. Every effort has been made to ensure that the information in this Technical Manual are correct. As a result, Chloride declines all responsibility for any errors, accidents or damage which may arise.
Dont be afraid of the high number of pages of this 80-NET Technical Manual as well as the additional documents (mentioned above). We tried to include all potentially required, relevant information about servicing the 80-NET. It is likely that some of these containing information will not be necessary for you to service your specific issue with the 80-NET. We even included procedures, checklists and their explanations for your convenience, which required a few pages in this manual.
2.0 1.0
2.0 1.0
2.0 1.0
2.0 1.0
2.0 1.0
TM
(Tech. Manual)
CD
PP
CL
(Checklists)
Date
Description
Rev.
Note: If you order the Technical Manual concerning updates with the order no. 10H52167TM01, you will receive all 4 documents. In case you want just one of these documents, please specify within your order.
Table of Content
1
1.1 1.2
1.2.1 1.2.2 1.2.3 1.2.4 1.2.5
Introduction ........................................................................................ 11
General .................................................................................................................. 11 Safety ..................................................................................................................... 12
General ............................................................................................................................. 12 Emergency........................................................................................................................ 12 Electric shock.................................................................................................................... 13 Precautions & Preparations .............................................................................................. 13 Access to electrically live UPS parts................................................................................. 14
1.3
1.3.1 1.3.2 1.3.3
1.4
1.4.1 1.4.2
1.4.2.1
Principle of operation........................................................................................... 21
General Overview ............................................................................................................. 21 Block diagram ................................................................................................................... 22
Operating Modes............................................................................................................................. 22
1.4.3
1.4.3.1 1.4.3.1.1 1.4.3.1.2 1.4.3.1.3 1.4.3.1.4 1.4.3.2 1.4.3.2.1 1.4.3.2.2 1.4.3.2.3 1.4.3.2.4 1.4.3.2.5 1.4.3.3 1.4.3.3.1 1.4.3.3.2
1.4.4
1.4.4.1 1.4.4.2 1.4.4.3
1.4.5
2
2.1 2.2
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.12
2.3
2.3.1
2.3.1.1 2.3.1.2
2.3.2 2.3.3
2.3.3.1
2.3.4
2.4
2.4.1 2.4.2 2.4.3 2.4.4 2.4.5
2.4.5.1 2.4.5.2
2.4.6 2.4.7 2.4.8 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 2.4.14 2.4.15
X8 Emergency Power Off (EPO) ................................................................................. 115 XT1 External Battery Temperature Connector ............................................................ 116 XT2 External Battery Switch Status............................................................................. 117 XT3 EPO activated ...................................................................................................... 117 XT4 Backfeed Protection activated.............................................................................. 118 AP10XT6 4 free programmable Input Contacts......................................................... 118 AP10XT5 2 free programmable Output Contacts...................................................... 119 AP10X4 Service Interface.......................................................................................... 120 Parameter Settings for Contacts in PPVIS ..................................................................... 121 Signal cables................................................................................................................... 129
2.5
2.5.1
2.5.1.1
2.5.2
2.5.2.1 2.5.2.2 2.5.2.3
2.5.3 2.5.4
Automatic Battery Test ................................................................................................... 145 Imminent Shutdown Curve ............................................................................................. 147
2.6 2.7
2.7.1 2.7.2 2.7.3 2.7.4
2.7.4.1 2.7.4.2 2.7.4.3
2.7.5
2.7.5.1
3
3.1 3.2 3.3
4
4.1
4.1.1
4.2 4.3
5
5.1 5.2 5.3 5.4
6
6.1 6.2
6.2.1 6.2.2 6.2.3
6.2.3.1 6.2.3.2 6.2.3.3 6.2.3.4
6.3
6.3.1 6.3.2 6.3.3
6.3.3.1 6.3.3.2
Capacitor Reforming ....................................................................................................... 209 Backfeed protection ........................................................................................................ 210 EPO in & out ................................................................................................................... 210 Automatic bypass test..................................................................................................... 210 Automatic transfer inverter to bypass and bypass to inverter ........................................ 211 Verify maintenance bypass switch QS3 and neutral switch QS14................................. 211 Temperature sensors...................................................................................................... 212 DC-Link Calibration......................................................................................................... 213 Incident Scenario Analysis Troubleshooting................................................................ 215
Case 1: Blown overvoltage protection on AP7 and AP33............................................................ 215 Case 2: Rectifier is not starting Frequency 60 Hz .................................................................... 218
6.4
6.4.1 6.4.2
7
7.1 7.2 7.3 7.4 7.5 7.6
8 9
9.1
9.1.1 9.1.2 9.1.3
9.2
9.2.1 9.2.2 9.2.3
9.3
9.3.1 9.3.2 9.3.3 9.3.4
9.3.4.1 9.3.4.2
Software............................................................................................................... 253
MopUPS Professional..................................................................................................... 256 MopUPS for Parallel/Redundant Systems (MopUPS P/R)............................................. 258 CIO (Critical Infrastructure Overseer) ............................................................................. 260 Remote Shutdown Clients .............................................................................................. 262
MopUPS Network Shutdown Agent (NSA) .................................................................................... 262 Remote Control Command (RCCMD) ........................................................................................... 263
9.3.5
9.3.5.1
9.4 9.5
9.5.1
9.6 9.7
9.7.1 9.7.2
External Battery Circuit Breaker ....................................................................... 269 MBSM External Synchronisation ...................................................................... 270
Connecting the MBSM.................................................................................................... 271 Configuration of the MBSM & UPS................................................................................. 274
9.8
9.8.1 9.8.2
9.9
9.9.1 9.9.2
9.10 9.11
10 11 12
12.1 12.2 12.3 12.4 12.5 12.6
List of Components ......................................................................... 285 Circuit Diagrams .............................................................................. 289 Appendices....................................................................................... 291
Checklists............................................................................................................ 291 List of Figures ..................................................................................................... 292 List of Parameters .............................................................................................. 295 List of Abbreviations .......................................................................................... 297 Glossary .............................................................................................................. 298 Index .................................................................................................................... 299
1
1.1
Introduction
General
Please keep in mind that only qualified & authorized personnel is supposed to carry out any work on the UPS. The safety instructions on the following pages have to be followed all the time.
For easier understanding and to highlight important remarks and notices we introduced the Whats important?-Box. In this blue box you will find basic information to understand the function of the UPS unit or any other important issue. Whats important? Description of Function
The grey Why? Additional Technical Information-Box whereas is for more detailed background information, which are not necessarily essential to handle the 80Net UPS, but which could be helpful in understanding the problem more clearly. Why? Additional Technical Information Detailed Description Of
BACKGROUND INFORMATION
Technical Details
Safety
General
Chloride puts personal safety before all other considerations. For this reason, before carrying out any work on the UPS units, you must carefully read all the safety procedures indicated in this manual as well as in the user manual and apply them.
Whats important? 80-Net contains dangerous voltages. As a result, any work which requires opening of the protective panels must only be carried out by technical personnel authorised by Chloride . Any maintenance work carried out in the UPS units must always be done with the machine in bypass state, as indicated in the user manual. Before starting to service the UPS, be sure to read this manual carefully for a correct and safe operation.
Warning:
The intermediate circuit contains voltages, even after the mains power supply voltage has been disconnected. Before operating inside the equipment, always disconnect the batteries using the disconnecting switch and make sure that the voltages in the intermediate circuit has dropped to 0V. The connections between the rectifier and the inverter remain live for a considerable time. Any work on the UPS including parameter changes should only be performed, if the reaction of the UPS is absolutely clear and not harming the UPS or its proper function. If you are not sure what the reaction will be, please contact the Chloride Service Support, before you act.
1.2.2
Emergency
In the event of an emergency, you can immediately cut the power supply to the machinery by simply opening all of the switches in the unit. Open output switch QS4 first, before opening the other switches. These switches are located behind the door on the front of the 80-NET. You can also cut the power by pressing the EPO emergency stop push button, if this option is installed.
Warning:
In case of using the EPO, be aware that the battery voltage is still present on the UPS!!
Do not touch the casualty with your hands until he or she has been isolated from all the live parts. After this seek immediately help.
1.2.4
Whats important?
Whats important? It must always be remembered that, once the second access panels are removed, live components are exposed. As a consequence, be careful managing tools and always remember that capacitor units and boards could be electrically live even if all the switches are off. Once maintenance is finished carefully replace the second access panel to avoid compromising the electrical isolation.
1.3.1
Product variations
The 80-NET product range includes the following three-phase input/output models: MODEL 80-NET/60 80-NET/80 80-NET/100 80-NET/120 80-NET/160 80-NET/200
(1) (2)
Order number (basic model) CH8006 0AA00 0AA0 (1)(2) CH8008 0AA00 0AA0 (1)(2) CH8010 0AA00 0AA0 (1)(2) CH8012 0AA00 0AA0 (1)(2) CH8016 0AA00 0AA0 (1)(2) CH8020 0AA00 0AA0 (1)(2)
For Siemens branded units there will be 6SU23 instead of the CH80 For Masterguard branded units there will be SU63 instead of the CH80 For non standard products, please refer to the catalogue for any other configuration (options).
Figure 1-1:
Picture 80-NET/80kVA
Figure 1-2:
Picture 80-NET/120kVA
There are several options available e.g. remote alarm unit, dust filters, LIFE.net. For more details please refer to the UPS catalogue 80-NET and chapter 9 of this manual.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.3 Product variations and specification
96,2 97
95,9 97
96,2 97
96,1 97
95,9 97
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.3 Product variations and specification
60
80
100
120
160
200
Permissible battery voltage range Recommended no. of cells: VRLA (5) WET NiCd VRLA float voltage @ 20C (6) VRLA end cell voltage VRLA float voltage temp. compensation DC ripple current in float mode for a 10 min. (5) autonomy as per VDE0510 Float voltage stability in steady state condition DC ripple voltage without battery Optimum battery temperature Battery recharge current setting range for 240 cells @ Vi/p = 400V Battery recharge current setting range: for 240 cells @ Vi/p = 340V Battery output power in discharge mode with nominal load End battery voltage for 240 cells End battery current for 240 cells with nominal load
390 to 700 240 240 375 2,27 1,65 -0,11% per C < 0,05C10 1 1 15 to 25 0-31 0-39 0-44 0-62 0-77 0-21 167,5 423
(V/cell) (V/cell)
0-6
0-8,5 0-10,5 0-10,5 0-17 67 169 83,7 211 100,5 396 254 134 338
127
Rating
(A)
60
94
80
125
100
156
120
185
160
250
200
312
Maximum primary input current @ ambient temperature within the range 0 - 40C AC/AC double conversion efficiency without (2) charging current @ nominal i/p conditions with (11) resistive load: (7) 25% load 50% load (7) (7) 75% load 100% load (7) (7) Digital interactive Heat dissipation at nominal input conditions and (11) output load: Float mode Recharge mode Digital i/p active mode Noise @ 1 meter as per ISO 3746 + range Protection degree with open doors Mechanical dimensions: Height Width Depth including front handle and vents Depth w/o front handle and vents No. of cabinets Frame color Weight Floor area Floor loading Cable entry Access Cooling (8)
(%)
82,8 90 92,7 93 98
86 92,5 93 94 98
87,1 92 93,4 94 98
88 92,5 93,8 94 98
88 92,3 93,4 94 98
87 92 93 94 98
(kW)
(dBA)
1780 845 1120 1245 858 830 1 7035 290 390 500 600 0,49 0,72 0,96 1,07 617 557 520 560 Bottom/Side Front Forced ventilation with fan redundancy 570
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.3 Product variations and specification
(kVA) 60 Nominal apparent power @ 40C ambient 80 100 120 160 200 (kW) 48 Nominal active power 64 80 96 128 160 (A) 87 Nominal output current 116 145 174 232 290 Maximum active power up to 100% of Conditions apply (10) nominal apparent power (11) (%) Overload at VOUT NOM. for 10 minutes 125 (%) Overload at VOUT NOM. for 1 minute 150 (%) Short circuit current for 10ms/<5s 200/150 (V) Nominal output voltage 400 (380/415 selectable, 3Ph + N) (Hz) Nominal output frequency 50 (60 selectable) Voltage stability in steady state condition for (%) input (AC & DC) variations and step load (0 to 1 100%) Voltage stability in dynamic condition for input (%) variation (AC & DC) and step load (0 to 100% Complies with IEC/EN 62040-3, Class 1 and vice versa) Voltage stability in steady state for 100% load (%) 3 imbalance (0, 0, 100) Output frequency stability: (%) synchronised with bypass mains 1 (2, 3, 4 selectable) synchronised with internal clock 0.1 (Hz/sec) Frequency slew rate <1 Output voltage distortion with 100% linear (%) <3 load Output voltage distortion @ reference non (%) <5 linear load as for IEC/EN 62040-3 (Ipk/Irms) Load crest factor without derating the UPS 3:1 (degrees) Phase angle accuracy with balanced loads 1 Phase angle accuracy with 100% unbalanced (degrees) <3 (11) loads Inverter efficiency @ nominal input conditions with resistive load: (%) Half load (7) 94,9 96,2 95,9 96,2 96,1 95,9 (7) 97 Full load 96,5 97 97 97 97 Neutral conductor sizing 1.7 nominal current Output power upgrading with ambient temperature: (%) At 25C 110 At 30C 105 At 40C 100
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.3 Product variations and specification
60
80
100
120
160
200
Nominal bypass voltage (1) Bypass voltage tolerance Nominal frequency Frequency range Maximum overload capacity: For 10 minutes For 1 minute For 600 milliseconds For 100 milliseconds SCR It @ Tvj=125C; 8.3-10ms ITSM @ Tvj=125C; 10ms Transfer time whit inverter synchronous to bypass: Inverter to Bypass Bypass to Inverter Default transfer delay time (inverter to bypass) with inverter not synchronous to bypass
400 (380/415 selectable, 3Ph + N) 10 50 (60 selectable) 1 (2, 3, 4 selectable) 125 150 700 1000 125000 5000
(%)
80000 4000
320000 8000
no break no break
(ms)
<20
Rating
60
80
100
120
160
200
(C)
0-40 35 40
humidity
20C
(non
(%) (m)
Up to 90 % 1000 (for higher altitudes 80-NET complies with IEC/EN 62040-3) Better than 3K2, see notes about installation site; check in accordance with IEC 68-2
Max altitude above sea level without derating Climate class according to IEC 721
(1)
In case of a split bypass configuration, the primary input and the bypass input must have a common earth. The neutral conductor could be part only to the bypass or primary mains but it must be present . (2) At nominal voltage and nominal frequency. (3) With input voltage at nominal value and with voltage distortion THDv 1%. (4) Imax input can be calculated using the maximum input power @ 400V in battery recharge mode. (5) Permitted number of cells = 240-300. Special battery cabinets needed for more then 240 cells. (6) There are several possible charging methods.. See chapter 2.5.2 for details. (7) For tolerances see IEC/EN 60146-1-1 or DIN VDE 0558; values ae referred to 80 and 120kVA ratings. (8) Redundant cooling system. With one fan OFF the UPS can supply continuously 70% of the nominal output power @ 25C ambient. (9) Including front handle; without handle 830mm (10) Nominal apparent power loads with PF > 0.8 can be supplied with marginal limitations to other performances. Please contact Chloride Technical Support for further details. (11) Top version only. SP version data: THDi < 25% (at nominal output load) and PF > 0.90; AC/AC double conversion efficiency at nominal output load: 92%; rectifier efficiency at full load: 95%; maximum output active power 80% of nominal apparent power; heat dissipations at nominal output load: +30%. (12) For output load >25% of nominal output power. General conditions for the Technical Data table: The data shown are typical and not definable in other ways; furthermore the data refer to 25C ambient temperature and PF= 1 where not specified. Not all the data shown apply simultaneously and may be changed without prior warning. Data apply to the standard version, if not otherwise specified. If the options described in chapter 9 are added, the data shown in the Technical Data Table may vary. For test conditions and measurement tolerances not specified in the table refer to the Witness Test Report procedure.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.3 Product variations and specification
In particular, there is NO fuse protection, as standard, on the input of the bypass line. To ensure protection for the UPS, the customer is asked to provide a External Protection for the bypass line, which complies to the following requirements: (for more details please refer to the user manual) 1) It must protect the bypass thyristors in case of short circuit downstream of the UPS; 2) It must be coordinated with the internal inverter fuses (selective release); in case of a short circuit upstream to the inverter, only the inverter output fuses should blow to disconnect the faulty inverter, but the load should be kept supplied by the bypass line.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.3 Product variations and specification
Principle of operation
General Overview
80-NET operates according to the online principle (double conversion operation). In online operation, the alternating voltage (AC) of the mains is converted into direct voltage (DC). This DC voltage is used simultaneously to charge the battery and supply the inverter. The inverter converts the direct voltage (DC) into interference-free alternating voltage (AC) at a fixed frequency and amplitude, from which are supplied the connected loads. This protects the load from mains supply disturbances and provides a secure supply for electrical loads (PCs, network servers, multi-console systems). In case of a mains failure, the batteries provides uninterrupted power to the loads for a given period, dependent on battery capacity and connected load.
The single line diagram of the UPS is shown in Figure 1-3. The systems operates on two DSP (digital signal processor) -driven IGBT converters (IGBT Rectifier and IGBT Inverter). The vector control technology will enhance the performance of these converters. In order to increase system redundancy, an independent electronic static bypass is integrated into the UPS. By adding system components, such as parallel kits, CROSS switches, safety and disconnecting devices, system bypass switches, in addition to software and communications solutions, it is possible to set up elaborate systems to ensure the complete protection of the loads. Operation and control of the UPS is provided through the use of microprocessorcontrolled logic. Indications, measurements and alarms, together with battery autonomy, is shown on an illuminated, 8 lines x 12 character liquid crystal display (LCD). 80-NET adopts intelligent double conversion technology which allows the UPS to operate in double conversion or digital interactive mode according to the selected priority. (For more details, please, see further down within these chapter.)
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
Figure 1-3:
1.4.2.1
Operating Modes
Online mode Normal UPS operating mode. The connected loads are supplied from the mains via the inverter. The batteries are charged as necessary. The inverter reliably filters mains disturbances and provides a stable, interference-free supply to the load. On the control panel, when the UPS is in online operation, the green OK LED is illuminated. Figure 1-4: Operating Mode Online In this operating mode, the UPS switches to battery operation if a mains failure occurs. If an overload or short circuit occurs at the UPS output, or if there is a fault in the inverter, the UPS switches to bypass operation.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
Bypass mode In this operating mode, the connected loads are supplied from the mains via the electronic bypass. The electronic bypass serves to further ensure power to the loads. If an overload or short-circuit at the UPS output occurs, it is automatically activated to ensure uninterrupted power supply to the loads.
Figure 1-6: Operating Mode - Bypass
The WARNING LED (yellow) on the control panel illuminates and every 30 seconds a acoustic signal is given. From this operating mode, the UPS automatically returns to online operation after the fault is corrected.
Maintenance bypass mode In this operating mode, the connected loads are supplied directly from the mains supply. The Mimic Panel (LCDisplay) is disabled. Maintenance bypass is used to supply the connected loads during maintenance work on the UPS.
Figure 1-7:
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
1.4.3.1.2 Overload (DCM) In the event of an inverter overload the static switch automatically transfers the critical load to the bypass line without interruption. And back to the inverter if selected in PPVIS. 1.4.3.1.3 Emergency (DCM) Upon failure or reduction of the commercial AC source (see the Technical Data Table for tolerances) the inverter supplies the critical load, drawing power from the associated battery through the battery charger/booster. There is no interruption to the critical load upon failure, reduction or restoration of the commercial AC source. While the UPS is powered by the batteries, indications show the actual autonomy time remaining (if the battery settings are done properly), as well as the duration of the mains failure . 1.4.3.1.4 Recharge (DCM) Upon restoration of the commercial AC source, even where batteries are completely discharged, the rectifier is restarting automatically, 'walk in' and gradually taking over both the inverter and battery charger. This function is fully automatic and causes no interruption to the critical load.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
567 Control of Overload Reaction CU2 This parameter defines the behaviour at overload.
Each individual bit of this parameter has a different meaning: Bit 0 = 1; Bypass will switch off when the kW-protection counter threshold is reached; Bit 1 = 1; Retransfer from bypass to inverter is blocked for a load above 95% (enabled only for single block) Bit 2 = 1; Transfer from inverter to bypass is done when kW-protection counter reaches a certain part of overload threshold; (only for single block; bit 1 must also be set;)
1.4.3.2.4 Emergency (due to mains supply failure or variance beyond tolerance limits, DIM) If 80-NET is supplying the load via bypass line and it varies beyond tolerance levels (adjustable using the software), the load will be transferred from bypass line to conditioned line. The load is powered from the mains via the rectifier and inverter, (provided the input mains remains within the tolerances). Should the input mains fall below the lower limit the battery is used to power the load via the inverter. The user is alerted to the battery discharge by visual and audio alarms and the remaining autonomy is displayed on the LCD. During this process, it is possible to extend the remaining autonomy by switching off non-essential loads. 1.4.3.2.5 Return to normal conditions (DIM) When the mains supply returns to within tolerance limits, 80-NET will continue to supply the load via the conditioned line for a period of time dependant on the bypass line failure rate (the conditioned line draws power from the mains not the battery). When the bypass line has stabilised, 80-NET returns to normal operation. The battery charger/booster automatically begins to recharge the battery, to guarantee a maximum autonomy in the shortest possible time.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
1.4.4.1
Vector control
To ensure the quick and flexible processing of measuring data, special arithmetic algorithms are implemented in DSP, rapidly generating controlled variables as a result. This will allow a real-time control of the inverter electronics, resulting in obvious advantages concerning the performance of the power components. These advantages will be: Improvement of short circuit behaviour, as individual phases can be controlled more quickly Synchronisation or phase angle precision between UPS output and bypass supply even in the case of a distorted mains voltage High flexibility in parallel operation parallel blocks may be housed in separate rooms. Several algorithms included in the Vector Control firmware are covered by patents owned by Chloride (95 P3875, 95 P3879 and 96 P3198).
1.4.4.2
1.4.4.3
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
5 Inverter ON push button 6 Inverter OFF push button 7 System Normal LED 8 Warning LED 9 Alarm LED 10 Reset push button 11 Command keyboard lock
Figure 1-8:
Mimic panel
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
LCDisplay menus description By using the appropriate push buttons it is possible to browse the following menus: Rectifier and Booster/Battery Charger converter menu displays - rectifier status - booster/charger status - alarms - voltage - total DC current - battery current with polarity - battery temperature When the inverter is supplied by the battery, the LCDisplay main page is showing the remaining autonomy time. A change in load shall cause the autonomy indicator to display the new autonomy time. Inverter menu displays - alarms - phase to neutral voltages - frequency measurements - inverter heat-sink temperature - cooling air temperature When the inverter is in overload condition, the remaining overload timeout time is displayed on the LCD main page. Bypass Supply menu displays - Alarms - phase to neutral voltages - frequency measurements Load/Bypass Static Switch menu displays - Alarms - current per phase - frequency measurements - load percentage capacity per phase - the peak factor Ipk/Irms for each phase of the load current It is possible to display the total time the load has been supplied by the inverter, and by bypass, the number of mains failures and the total duration of these failures.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 1 Introduction 1.4 Principle of Operation
Functional Description
For deeper understanding of the 80-NET and the interior of it, schematic drawings and descriptions of the boards functions can be found in this chapter. Furthermore a account of how the single power components are working will be given in the subchapter Power Components. For example the function of the rectifier will be described in detail. In addition to this, all kind of information about communication with the UPS, e.g. interfaces, Service Software PPVIS, Firmware and so on can be found here as well.
2.1
Overview
The UPS consists of the following major components: IGBT Rectifier: It is converting the mains AC voltage into a DC voltage, supplying the battery and inverter; IGBT Battery Charger / Booster: Keeps the battery charged; IGBT Inverter: It is converting the DC voltage (from rectifier or battery) into a regulated AC voltage to supply the load. (with Pulse-Width-Modulation); Dedicated DSP control systems for each IGBT converter: Through the vector control technology, the performance of the converter is enhanced; Electronic static switch and bypass supply: If the application requirements exceed the possibilities of the UPS, the load is automatically switched without break from inverter mode to bypass; Manual maintenance bypass switch: For service requirements;
Boards
Drawing 80-NET 60kVA/80kVA where to find the boards
Figure 2-1:
Function
V1 V2 V3 V4 V4 V5 V6 V7 V9 V10 V11
Board
U IGBT (VT2 400A 1200V) Mains input V IGBT (VT2 400A 1200V) Mains input W IGBT (VT2 400A 1200V) Mains input Booster/Charger IGBT (VT2 400A 1200V) Booster/Charger IGBT (VT2 400A 1200V) U1 SCR (V2 130A 1600V) Bypass input V1 SCR (V2 130A 1600V) Bypass input W1 SCR (V2 130A 1600V) Bypass input U2 IGBT (VT2 400A 1200V) UPS output V2 IGBT (VT2 400A 1200V) UPS output W2 IGBT (VT2 400A 1200V) UPS output
Item Code
10H44112P4312 10H44112P4312 10H44112P4312 10H44112P4312 10H44112P4312 00B44095PT016 00B44095PT016 00B44095PT016 10H44112P4312 10H44112P4312 10H44112P4312
Figure 2-2:
Function
AP5 AP6 AP7 AP19-AP26 QS14 FU1-FU3 FU4-FU6 TA4-TA6 TA9-TA11 KM1 KM3 C1-C3, C1-C3 C8-C10, C8-C10
Board
SMPS Board Supply Interface Board Bypass Control Board IGBT Interface Board Neutral Switch FU 200A 500V Extra Quick Blow FU 200A 500V Extra Quick Blow TA 200Adc TA 200Adc 230Vac 125A/80A 24Vdc 20A/9A C 100F 275Vdc
Item Code
15B10860G1 15B10848G1 15B10859G1 15B10857G1 10B46426P54C 00B46117PC200 00B46117PC200 10B48279P1 10B48279P12 10B48317P72 10B48317P71 10H42088P01
Figure 2-3:
Function
AP11-AP17 L1- L3 L6- L8
Board
IGBT Driver Board L1 250 H 120A L1 250 H 120A
Item Code
15B10851G1 10H48572P01 10H48572P01
Figure 2-4:
Function
AP1-AP2 AP3-AP4 AP27-AP28 L4
Board
CUX Board Interface Board Fan Speed Control Board L1 250 H 160A
Item Code
451909988311 15B10853G1 15B10855G1 10H48573P01
Figure 2-5:
Function
AP31-AP33
Board
Filter Board
Item Code
15B10861G1
Function
AP36-AP37 FU7-FU8 TA1-TA3 TA12-TA14 TA15-TA17
Board
Varistor Board Battery Fuses Mains Input TA 200A/200mA Output TA 200A/200mA Bypass Input TA 200A/200mA
Item Code
15B10671G5 00B46117PE250 00B48018P10 00B48018P10 00B48018P10
Figure 2-7:
Function
AP9 AP10 AP38
Board
Connectivity Board In/Out Board DC Modem LIFE.NET
Item Code
15B10849G1 15B10854G1 15B10840G1
Figure 2-8:
Figure 2-9:
Function
V1 / V1 V2 / V2 V3 / V3 V4 / V4/ V4 V5 V6 V7 V9 / V9 V10 / V10 V11 / V11
Board
U IGBT (VT2 300A 1200V) Mains input V IGBT (VT2 300A 1200V) Mains input W IGBT (VT2 300A 1200V) Mains input Booster/Charger IGBT (VT2 400A 1200V) U1 SCR (V2 160A 1600V) Bypass input V1 SCR (V2 160A 1600V) Bypass input W1 SCR (V2 160A 1600V) Bypass input U2 IGBT (VT2 300A 1200V) UPS output V2 IGBT (VT2 300A 1200V) UPS output W2 IGBT (VT2 300A 1200V) UPS output
Item Code
10H44112P3412 10H44112P3412 10H44112P3412 10B44112P4312 00B44095PT116 00B44095PT116 00B44095PT116 10H44112P3412 10H44112P3412 10H44112P3412
Function
AP5 AP6 AP7 AP19-AP26 AP40-AP46 QS14 FU1-FU3 FU4-FU6 TA4-TA6, TA9-TA11 KM1, KM1 KM3 C1-C3, C1-C3, C1-C3 C8-C10, C8-C10, C8-C10
Board
SMPS Board Supply Interface Board Bypass Control Board IGBT Interface Board IGBT Interface Board Neutral Switch FU 250A 500V Extra Quick Blow FU 250A 500V Extra Quick Blow TA 200Adc 230Vac 125A/80A 24Vdc 20A/9A 100F 275Vdc 100F 275Vdc
Item Code
15B10860G1 15B10848G1 15B10859G1 15B10857G1 15B10857G1 10B46426P54C 10H46741PC250 10H46741PC250 10B8279P12 10B48317P72 10B48317P71 10H42088P01 10H42088P01
Function
AP11-17 L1- L3 L6- L8
Board
IGBT Driver Board L1 170 H 180A L1 170 H 180A
Item Code
15B10851G1 10H48572P02 10H48572P02
Function
AP1-AP2 AP3- AP4 AP27-AP29 L4
Board
CU-Board Interface Board Fan Speed Control Board L1 170H 240A
Item Code
451909987710 15B10853G1 15B10855G1 10H48573P02
Backside of Switches.
Function
AP36-AP37 FU7-FU8 AP31-AP33 TA1-TA3 TA12-TA14 TA15-TA17
Board
Varistor Board Battery Fuses Filter Board Mains Input TA 600A/200mA Output TA 600A/200mA Bypass Input TA 600A/200mA
Item Code
15B10671G3 00B46117PE400 15B10861G1 00B48018P30 00B48018P30 00B48018P30
Function
AP9 AP10 AP38 Q8-Q10
Board
Connectivity Board In/Out board DC Modem LIFE.NET FU 2A 500V Slow Blow 6,3x32
Item Code
15B10849G1 15B10854G1 15B10840G1 10B46209P05R
Function
Board
Item Code
10H44112P4312 10H44112P4312 10H44112P4312 10B44112P3412 00B44095PT416 00B44095PT416 00B44095PT416 10H44112P4312 10H44112P4312 10H44112P4312
V1 / V1 U IGBT (VT2 400A 1200V) Mains input V2 / V2 V IGBT (VT2 400A 1200V) Mains input V3 / V3 W IGBT (VT2 400A 1200V) Mains input V4 / V4/ V4 / Booster/Charger IGBT (VT1 300A 1200V) V4 V5 U1 SCR (V2 250A 1600V) Bypass input V6 V1 SCR (V2 250A 1600V) Bypass input V7 W1 SCR (V2 250A 1600V) Bypass input V9 / V9 U2 IGBT (VT2 400A 1200V) UPS output V10 / V10 V2 IGBT (VT2 400A 1200V) UPS output V11 / V11 W2 IGBT (VT2 400A 1200V) UPS output
Function
AP5 AP6 AP7 AP19-AP26 AP40-AP47 QS14 FU1-FU3 FU4-FU6 TA4-TA6, TA9-TA11 KM1, KM1 C1-C3, C1-C3, C1-C3, C1-C3 C8-C10, C8-C10, C8-C10, C8-C10 Q1, Q1
Board
SMPS Board Supply Interface Board Bypass Control Board IGBT Interface Board IGBT Interface Board Neutral Switch FU 350A 500V Extra Quick Blow FU 350A 500V Extra Quick Blow TA 200Adc 230Vac 125A/80A 100F 275Vdc 100F 275Vdc FU 2A 500V Slow Blow 6,3x32
Item Code
15B10860G1 15B10848G1 15B10859G1 15B10857G1 15B10857G1 10B46426P54C 10H46117PC350 10H46117PC350 10B48279P4 10B48317P72 10H42088P01 10H42088P01 10B46209P05R
Function
AP11-17 L1-L3, L1-L3 L6- L8, L6-L8
Board
IGBT Driver Board L1 250H 120A L1 250H 120A
Item Code
15B10851G1 10H48572P01 10H48572P01
Function
AP1-AP2 AP3- AP4 AP27-AP30 KM3 R1, R2
Board
CUX Interface Board Fan Speed Control Board 24Vdc 20A/9A R 8R2 125W 10%
Item Code
451909988311 15B10853G1 15B10855G1 10B48317P71 10H40037P01
Function
AP31-AP33 AP36-AP37 FU7-FU8 TA1-TA3 TA12-TA14 TA15-TA17
Board
Filter Board Varistor Board Battery Fuses Mains Input TA 600A/200mA Output TA 600A/200mA Bypass Input TA 600A/200mA
Item Code
15B10861G1 15B10671G5 00B46117PE500 00B48018P30 00B48018P30 00B48018P30
Function
AP9 AP10 AP38 Q8-Q11
Board
Connectivity Board In/Out board DC Modem LIFE.NET FU 2A 500V Slow Blow 6,3x32
Item Code
15B10849G1 15B10854G1 15B10840G1 10B46209P05R
Function
V1 /V1 /V1 V2 /V2 /V2 V3 /V3 /V3 V4 /V4 /V4 /V4 V5 V6 V7 V9 /V9 /V9 V10 /V10 /V10 V11 /V11 /V11
Board
U IGBT (VT2 400A 1200V) Mains input V IGBT (VT2 400A 1200V) Mains input W IGBT (VT2 400A 1200V) Mains input Booster/Charger IGBT (VT2 400A 1200V) U1 SCR (V2 250A 1600V) Bypass input V1 SCR (V2 250A 1600V) Bypass input W1 SCR (V2 250A 1600V) Bypass input U2 IGBT (VT2 400A 1200V) UPS output V2 IGBT (VT2 400A 1200V) UPS output W2 IGBT (VT2 400A 1200V) UPS output
Item Code
10B44112P4312 10B44112P4312 10B44112P4312 10B44112P4312 00B44095PT416 00B44095PT416 00B44095PT416 10B44112P4312 10B44112P4312 10B44112P4312
Function
AP5 AP6 AP7 AP19-AP26, AP40-AP53 FU1-FU3 FU4-FU6 TA4-TA6, TA9-TA11 KM1, KM1, KM C1-C3, C1-C3, C1-C3, C1-C3, C1-C3 C8-C10, C8-C10, C8-C10, C8-C10, C8-C10 Q1, Q1, Q1
Board
SMPS Board Supply Interface Board Bypass Control Board IGBT Interface Board FU 500A 500V Extra Quick Blow FU 500A 500V Extra Quick Blow TA 400Adc 230Vac 125A/80A, 50-60Hz 100F 275Vdc 100F 275Vdc FU 2A 500V Slowblow 6,3x32
Item Code
15B10860G1 15B10848G1 15B10859G1 15B10857G1 00B46117PC500 00B46117PC500 10B48279P13 10B48317P72 10H42088P01 10H42088P01 10B46209P05R
Function
AP11-17 L1- L3, L1-L3 L6- L8, L6-L8
Board
IGBT Driver Board L1 170 H 180A L1 170 H 180A
Item Code
15B10851G1 10H48572P03 10H48572P03
Function
Board
Item Code
10H42088P01 00B42004P0219
C4, C4, C4, C4, C4, 100F 275Vac C5, C5, C5, C5, C5, C11 C13 30 F 470Vac
Function
AP1-AP2 AP3- AP4 AP27-AP30, AP54 KM3 R1-R2
Board
CUX Interface Board Fan Speed Control Board 24Vcc 20A/9A 50-60Hz 8R2 125W 10%
Item Code
451909988311 15B10853G1 15B10855G1 10B48317P71 10H40037P01
Function
AP31-AP33 AP36-AP37 FU7-FU8
Board
RFI Filter Board Varistor Board Battery Fuses
Item Code
15B10861G1 15B10671G5 00B46117PE800
Function
TA1-TA3 TA12-TA14 TA15-TA17 XS1-XS2 Q4-Q7
Board
TA 600A/200mA TA 600A/200mA TA 600A/200mA Socket 16A 250V FU 2A 500V slowblow 6,3x12
Item Code
00B48018P30 00B48018P30 00B48018P30 10B46521P01 10B46209P05R
Function
AP9 AP10 AP38 Q8-Q12
Board
Connectivity Board In/Out board DC Modem LIFE.NET FU 2A 500V Slowblow 6,3x12
Item Code
15B10849G1 15B10854G1 15B10840G1 10B46209P05R
The CU1 Rectifier CU-Board AP1 is connected with its own interfaces to other boards interfaces: AP1(CU1)_X109 AP3 (Rectifier Interface Board)_X109 AP1(CU1)_X110 AP3 (Rectifier Interface Board)_X110 AP1(CU1)_X120 AP10 (In/Out Board)_X2 AP1(CU1)_X130 AP2 (CU2 Inverter CU-Board)_X130 AP1(CU1)_X130 Aux. Contacts, Temp. Measurement
The hardware of the Rectifier CU-Board CU1 and the Inverter CU-Board CU2 is the same. The only difference between the two CU-Boards in the 80-NET is the different Firmware on CU1 and CU2. Whats important? The DIP switches on the CU-Board must be closed! Also the jumper settings are important! The interface X107 on the CU1 board is not used on 80-NET UPS. The X109 interface is a connection to the rectifier interface board, which is used for communication/exchange of certain values (for details please refer to the figure 2-17) The X110 interface is also a connection to the rectifier interface board, which is used for the signalling of the actual measured current and voltage values. X120 is responsible for the communication from and to the LCDisplay. E.g. to display the measured values, for signalling a start or stop command from the LCDisplay. The communication between the two CU-Boards is managed with the X130 (contacts 1-4 via RS485). Temperature measurement signal and the signal from the auxiliary contact QS1 are just two examples for signals, which are handled with X130. The CU1 board is detecting the temperatures of: - Rectifier (measuring channel ST-S-IN) - Booster/Charger (measuring channel ST-B) - Battery (measuring channel input contact XT1)
AP2 (451909987710)
451909987710
The CU2 Inverter CU-Board AP2 is connected with its own interfaces to other boards interfaces: AP2(CU2)_X109 AP4 (Inverter Interface Board)_X109 AP2(CU2)_X110 AP4 (Inverter Interface Board)_X110 AP2(CU2)_X120 AP10 (In/Out Board)_X1 AP2(CU2)_X120 AP8 (COM Display)_X1 AP2(CU2)_X130 AP1 (CU1) (Rectifier CU-Board)_X130 AP2(CU2)_X130 Aux. Contacts, Temp. Measurement AP2(CU2)_X130 Command keyboard lock The hardware of the Rectifier CU-Board CU1 and the Inverter CU-Board CU2 is the same. The only difference between the two CU-Boards in the 80-NET is the different Firmware on CU1 and CU2. Whats important? The DIP switches on the CU-Board must be closed! Also the jumper settings are important! The interface X107 on the CU2 board is only used for parallel connection with other 80-NET UPS of the same power-range. The X109 interface is a connection to the rectifier interface board, which is used for communication/exchange of certain values (for details please refer to the figure 2-17) The X110 interface is also a connection to the inverter interface board, which is used for the signalling of the actual measured current and voltage values. X120 is responsible for the communication from and to the LCDisplay. E.g. to display the measured values, for signalling a start or stop command from the LCDisplay. The communication between the two CU-Boards is managed with the X130 (contacts 1-4 via RS485). Temperature measurement signal and the signal from the auxiliary contact QS2 and QS3 are just three examples for signals, which are handled with X130. The CU2 board is detecting the temperatures of: - Inverter (measuring channel ST-S-OUT) - Ambient (measuring channel ST1) - Inverter/Neutral Stabiliser Converter (measuring channel ST-R-OUT) -optional-
The hardware of these two interface boards AP3 and AP4 is identically, only AP3 is used for measuring specific values for the rectifier and AP4 for specific values for the inverter. These boards are supplied by the SMPS board AP5. The power supply is than transformed to 5V, +/- 15V and 24V. These voltages are used to supply the board logic and to reform the input signals, bringing them to a level the CU-board is requiring them. With AC voltage reading circuits will be read the Input Voltage in case of AP3 and in case of AP4 the Output Voltage. With AC current reading circuits will be read the Input Current in case of AP3 and in case of AP4 the Output Current.
In case of board replacement the jumpers JP1-JP5 on the Interface Board need to be set either for AP3 or AP4 settings: (see also AIF 108) JP1 JP2 JP3 JP4 JP5 AP3 (Rectifier) OFF OFF OFF OFF ON AP4 (Inverter) ON OFF OFF OFF OFF
DC input voltage: 230V to 550V Output power: 500W maximum The SMPS supplies the following outputs: +8V 2,5A (isolated) for Inverter Drive Board +8V 0,3A (isolated) interface (RS232) +/- 17V 0,5A (isolated) for Inverter Driver Board
There are two distinct power stage converters: a Buck, to supply a regulated uninsulated voltage of 150V a Push-Pull, powered by 150V, to obtain the above mentioned insulated output supplies
The Push-Pull stage: The Push-Pull converter is controlled by a Siemens TDA4918 (IC2), a PWM controller operating in voltage mode, an internal overvoltage comparator with hysterisis is used to inhibit the output drivers of IC2 if the buck output goes over 190V, due to a buck failure. The operating frequency (about 50kHz) is set up by the value of C36 and R93, while the PWM ramp slope is determined by the value of C3. No feed forward actions is performed in this stage and the duty cycle is fixed at 50%, the dead time is generated inside the TDA4918 and can be externally modified. Resistors R73 and R74 sense the Push-Pull current and the ratio of R89 and R87 sets up the threshold level of the current limiter, a multiple RC network (R86, C41, R88 and C43) is used to clean up the current signal. A soft start action is present to limit the current when the output capacitors are charged, the duration of the soft start can be programmed by the size of the capacitor C35. A voltage reference of 2,5V is available at pin 11, it exhibits a highly constant
10H52167TM01 (IDSS/Andrea Weigert) Chapter: 2 Functional Description Rev. 2.0 10.May.2007 2.2 Boards Page 67/ 307 printed: 15.05.2007, 13:09
AP6 (15B10848G1)
15B10848G1 15H70837
This board is introduced to increase the possibilities of supporting important boards with power in the UPS. The AP6 is getting power (400Vac) from the bypass line (QS2 closed) and the mains line (QS1 closed), which is transformed to a DC voltage. A third power supply is coming from the DC Bus, supplied by mains input or battery. The DC voltage from this Supply Interface Board is supplied to the SMPS board. The SMPS board is reducing the voltage and is supplying it back to this Supply Interface Board. From here it is supplying AP3, AP9 and AP10 with power. It is also providing a additional isolation for the LCDisplay, due to the present transformer. (The supply back to the AP6 board from the SMPS board and than out to the other boards AP3, AP9 and AP10 is mainly done because of design reasons.)
AP7 (15B10859G1)
15B10859G1 15H70848
The duty of the Bypass Control Board is to forward the signal for switching to/from bypass line. This is either done because of a manual request to transfer or because of any fault situation causing the bypass to connect through. This board has its own power supply, it is powered by L1 and L2 of the bypass line, of course only as fare as QS2 is closed. The 400Vac are transformed to 24Vdc. The separate power supply is important in case the SMPS board is defective, because with its own power supply the bypass control board is still able to transfer the load from inverter to bypass line to ensure the uninterruptible power supply for the load. The output of this board is used for the thyristor gate drive. The task of the Bypass supply detector is to check if there are still 24V present from the bypass line. If this is not the case a fault message Error 50 Index 5 will be issued. This signal is sent out over Bypass Good (X3_3, X3_4) to the CU2.
AP8 (710-01970)
710-01970
On this board you can find the Jumper CN11, which is needed to speed up the communication between LCDisplay and CU-Board while flashing the CU2 Board. The DIP-switch SW1 is necessary to flash new firmware to the LCDisplay. Whats important? Freeze LCD function This function was established to speed up the serial communication between an external application, like PPVIS, and the CU2 (Inverter) through the LCD. To enable this function, simultaneously press the UP and DOWN key on the front panel for at least 2 seconds (only possible in the main synoptic window). While the function is active, the message LCD frozen will be displayed. When the function is activated, no diagnostics will be present on the LDC because communication with the CU has temporarily been suspended. If no request is sent through the Service serial port (X3) towards the LCD, the function disables after 10 minutes. (meaning e.g. the PPVIS cable is removed) This function also can be disabled by pressing the UP and DOWN keys again.
This board is the interface between the LCD and the EPO interface, the Plug-in LIFE.NET modem and other connectivity like a SNMP-Adapter.
This board contains 4 potential free digital input contacts (interface X6) and 2 potential free digital output contacts (interface X5), which can be parameterised with PPVIS. It also contains the X4 interface, which is only used for flashing the CU1 board.
AP11-AP17 (15B10851G1)
15B10851G1 15H70841
This board is used for rectifier, inverter, booster/charger and neutral booster IGBTs. The function of this board is to dress and decouple the signals from the CU-boards. This signals need to be of good quality to gate drive the IGBTs. The way through the UPS from the CU-board to the IGBT Driver Board is a long one, therefore the dressing and decoupling is necessary. These cleansed signals will be send to the IGBT Interface Boards, which are sitting directly beneath this IGBT Driver Board on top of the IGBT.
(15B10857G1)
This boards is used for rectifier, inverter, booster/charger and neutral booster IGBTs. The IGBT Interface Board is receiving dressed and decoupled signals from the IGBT Driver Board for the gate drive of the IGBTs. The temperature will be measured nearby the IGBT and forwarded to the Interface Board AP3/AP4. This signal is the base for the decision on which speed the fans are running and when to turn off/shut down the converter.
(15B10855G1)
The Fan Failure Detector is monitoring the current flowing towards the fans. If there is no current present or a current higher than normal, the fans are defective. There is a jumper on that board to check if an error message is displayed in case of faulty fans. Remove it and the error message 54 should appear on the LCDisplay. The signal on which the fan speed is decided is also implemented on this board by switching a relay. For 60Hz operation of the 80-NET, it is necessary to set the jumper JP1 accordingly. JP1 50Hz No 60Hz Yes
(15B10861G1)
2.2.20
Filter Board
AP35
15B10817G2 15H70816
(15B10817G2)
2.2.21
(15B10671G5)
Power Components
Rectifier
A rectifier can be composed of different types of semiconductors: I and V are not in-phase and the shape is not Diode very sinus-like Thyristor I and V are not in-phase and the shape is not very sinus-like
IGBT
The 80-NET pulse frequency of the IGBT is 6kHz; Advantages: - efficiency - acoustic noise - size and weight - voltage and current are in-phase - with the TOP version of the 80-NET there are just 3% circuit feedback Figure 2-49: - a diesel generator can be designed 1:1, Current IGBT Rectifier because of voltage and current being inphase and low circuit feedbacks (1:1 meaning for a 100kVA UPS a 100kVA diesel is needed; for other rectifier types a factor of 1:1,6 would be needed [100kVA UPS, 160kVA diesel])
How does the Rectifier work (Principal of operation)? The three-phase current taken from the commercial AC source is converted to a regulated DC voltage by the IGBT rectifier. In order to protect the power components within the system, each phase of the rectifier input is individually fitted with a fast-acting fuse. As shown in the block diagram (Figure 1-3), the IGBT rectifier is providing DC power to the DC/AC output converter (IGBT inverter) and to the DC/DC battery converter (booster/charger) when the latter is working in battery charger mode. The IGBT rectifier is a step up converter. It is controlling, through proper PWM, the output DC link stabilising the positive value with respect to Neutral at 365Vdc and the negative value with respect to the Neutral at -365Vdc and simultaneously it is controlling the three input AC currents to have the specified input current distortion (THDi).
Why? Additional Technical Information What is an IGBT? IGBT stands for Isolated Gate Bipolar Transistor and it is used simple spoken as a switch. It is a power switching device that can be easily driven as a FET and can carry current like a BJT (Bipolar Junction Transistor). Why is it used in a UPS? And not some other semiconductor e.g. thyristor? Because it is a fast switching and easy to control semiconductor, despite a higher VCEsat. The IGBT accepts a higher current as the rated value without any significant variation in its voltage capacity. Through the voltage control in the IGBT, the power to control the IGBT is low, at least concerning low switching frequencies. E.g. the control power for a bipolar transistor is more or less constant whatever the frequency is. The characteristic of the IGBT is like this because the input impedance is mainly capacitive with negligible leakage current.
Please be aware of ESD handling instructions (see chapter 6.3.4.2 Changing the IGBTs). The IGBT modules are devices sensitive to electrostatic discharge on the gates. The IGBT-MOS gate could become damaged.
Notice: Total Input Harmonic distortion (THD) and Power Factor (PF) The maximum voltage THD (THDV) permitted on the rectifier input (either from the utility or generator) is 15% (normal operation is guaranteed up to 8%). The maximum current THD injected into the mains (THDI) is less than 3% (Top version only) at maximum input power and input voltage THDV < 1% (nominal input voltage and current). Under these conditions the input power factor (PF) will be > 0.99 (Top version only). Under other input conditions and with other output load fractions the THDI will be < 5% (Top version only). This means that the 80-NET in double conversion mode is seen by the primary mains sources and distribution as a resistive load (i.e. it will absorb only active power and the current waveform will be practically sinusoidal), thus ensuring total compatibility with any power source. 80-NET includes all the performances offered by load active filtering devices as standard. Operation with diesel generator In order to obtain the required THD on input voltage, the coordination between diesel generator and UPS shall be based on the generators subtransient reactance, as opposed to its shortcircuit reactance.
3. Closing QS1 4. KM1 will be closed, when precharge is done 5. Rectifier start up
Parameter Number
1174
(150)
CU1
80 85 90
Page 82/ 307 printed: 15.05.2007, 13:09
2.3.1.1
Precharge
Why to precharge the DC-Link capacitors? Because in the first moment, when QS1 is closed and the capacitors are not charged, a very high input current is present, which could cause the fuses to blow. Therefore the capacitors will be precharged with resistor R1/R2. This limits the input current to Imax.
How is the precharge working? Before starting the precharge process, QS1, KM1 (mains contactor) and KM3 (precharge contactor) are open. Through closing QS1, the precharge process of the DC-link capacitors is started. The precharge contactor KM3 will be closed. As long as the minimal VDC is not reached (set with PNU 1159.2 +20V), the precharge process is continued. If VDCdelta per second is getting smaller than 10V, KM2A (on Rectifier interface) is closing and the KM1 contactor choke is caused to operate and therefore the mains contactor KM1 is closing, KM3 is opening. The precharge has stopped. The precharge threshold voltage VDC- /VDC+ is defined within parameter PNU1159.2 +20V (Half VDC link minimal voltage, rectifier mains contactor threshold), the factory setting is 250V, meaning 270V for the threshold of stopping precharge. The time frame for the precharge is defined through the hardware of resistor and capacitor, and therefore not changeable.
While the precharge is running, Warning 5 is displayed. When KM1 is closed warning 5 will disappear, because precharge is finished. If Warning 3 Index 2 and Warning 7 Index 2 appears, a wrong phase sequence is present at the input of the UPS. KM3 and KM1 are kept open by the CU1 board. Fault 142 Index 1 (Precharge short circuit) is displayed, when QS1 is closed and the VDC voltage (PNU 1159.1) is not reaching the predefined value within 1 seconds. (This time frame is hardwired in the Firmware can not be changed.) The CU1 opens the KM3. Fault 142 Index 2 (Precharge not finished) is displayed, if the DC voltage didnt reach the threshold value (PNU 1159.2 +20V) within a defined time frame (about 10 seconds). (This time frame is hardwired in the Firmware can not be changed.) Fault 142 Index 3 (Precharge contactor feedback) is displayed, if the auxiliary switch of KM1 is not giving a feedback within a defined time of 2 seconds after closing (when precharge is done). The CU1 board is receiving a signal form the QS1 auxiliary contact, that QS1 was closed. The various processes happening in the UPS will be controlled from the CU boards. The actual input currents will be measured via the TA1-TA3, the actual input voltage will be measured via the input voltage sense. The supply interface board (AP6) is supplied from the mains input (if not from one of the other possibilities see description of the board).
1159
(135)
CU1
i02:
250
Parameter Number
Factory setting 10
1158
(134)
CU1
Access Level 3: URL, IBS, PRU
Parameter Number
Factory setting 15
1166
(142)
Current-walk-in time
Time for the Rectifier walk-in from 0% to 100% nominal current limit
CU1
Access Level 3: URL, IBS, PRU, BYP, BTR
Buck Mode (Battery Charger Mode) There are several charger methods available to obtain optimum battery charge. All of them are selectable through PPVIS. Whats important? The recharge method depends on the battery type and battery manufacturer recommendation. 80-NET is operable with the following types of batteries: Lead Acid (VLA) Sealed Lead Acid (VRLA) Ni - Cd After setting certain parameters, the selection of the optimum charging method is completely managed by the microprocessor. The following shows the concept for Firmware Version 1.7 and higher:
Manual charging: PNU1424 (400) PNU1554 (530) PNU1626 (602) Automatic charging:
PNU1617(593), PNU1547(523), PNU1622(598), PNU1626(602), PNU1619(595), PNU1161(137), PNU1554(530), PNU1578(554), PNU1555(531), PNU1624(600), PNU1618(594), PNU1620(596), PNU1540(516), PNU1629(605)
U,I
Temperature correction PNU 1540 (516) PNU1424 (400) for manual PNU1555 (531) for autom.
For more details about these parameters and their functions and interactions, please refer to chapter 2.5 Battery.
Figure 2-55:
2. 1-Stage charging without charging pause (PNU 1617 = 1) This is also a gentle method to charge the batteries. After a mains failure, the cycle restarts always with the charging phase.
Figure 2-56:
3. 2-Stage charging with charging pause (PNU 1617 = 2) Charging with regeneration properties. The elevated voltage in charge stage 2 causes the battery to gas slightly, with the result that deposits are cleaned off the plates.
Figure 2-57:
Figure 2-58:
Factory setting 1
CU1
1-stage charging with charging pause 1-stage charging without charging pause 2-stage charging with charging pause 2-stage charging without charging pause
Functional description of Boost/Charge Mode There are two IGBT branches V4 and V4 in parallel for splitting the current in the Booster/Charger. To make it an ideal device for describing the function of the Booster/Charger, only one branch is used. The IGBT is shown here with its Diodes separately. Boost Mode
The Boost-Mode is for discharging the Batteries respectively to keep the VDC up while mains failure is present. (For this mode IGBT 1 is not needed.) To maintain VDC while mains failure, energy needs to be taken from the batteries and given to the DC-link respectively the capacitors C6 and C7. To do so IGBT 2 is switched through, causing a restoring of energy from battery to L4 (green line). This is caused due to UBatt impresses current into the choke L4, meaning the current ID is increasing.
To charge the batteries after a mains failure, the Buck-Mode is used. (For this mode IGBT 2 is not needed.) With IGBT 1 closed, a current is impressed into choke L4, meaning energy is stored in L4. Because it flows in the opposite direction like in the Boost-Mode, IL4 is negative. This is easy to understand, because energy has to be brought to the batteries, contrary to the boost mode were energy is taken from the batteries. While charging the batteries, the load still need to be supported. Meaning that only a part of the energy, coming from the rectifier, can be used to charge the batteries. This energy is limited to Pcharge = Pmax Ploadsupport with Pmax = Ilimit * Umax . If IGBT 1 would not open again, more than Pcharge would be used to charge the batteries, and therefore the load support is not ensured any more. (IGBT 1 = closed IL4 is increasing) But the batteries can still be charged while IGBT 1 is open (dashed line), because the energy, saved in L4, will now be transferred to the battery. IL4 is using D2. (IGBT 1 = open IL4 is decreasing) Again through the controlled PWM (50Hz) energy is keep nearly constant in C6 and C7 and therefore VDC stable.
Residual ripple filtering The battery charger output has a residual voltage ripple of <1% RMS. Capacity and charging characteristics When the mains input is not suitable to supply the rectifier, the DC/DC converter (booster mode) will provide the required power to the inverter. The rectifier is capable of supporting the inverter at nominal power and supplying the batteries with charging current. The following charging methods are an example of the methods available, giving the possibility of matching the different types of accumulators: Sealed, maintenance-free lead acid accumulators: Charging is at constant current up to the maximum floating voltage level. Thereafter the voltage is kept at a constant level within narrow limits (singlestep charging method). Sealed, low-maintenance lead acid accumulators or NiCd accumulators: Charging is at increased charging voltage and constant charging current (boost charge phase). When the charging current falls short of a lower threshold value the battery charger is automatically returning to floating voltage level (two-step charging method). Overvoltage protection The battery charger is automatically switching off if the DC battery voltage exceeds the maximum value associated with its operational status.
1426
(402)
CU1
1,6 1,7
1629
(605)
Cell Number
Amount of battery cells.
CU1
Access Level 3: URL, IBS
For more detailed about setting please refer to chapter 2.5 Battery and the additional document Technical Manual 80-NET Checklists (10H52167TM01_CL) where you can find a procedure for commissioning including checks for e.g. installation, parameters and so on.
Threshold for thermal protection: 180C Normally closed, when it opens the CU2 shuts down the inverter. Load is transferred to bypass. Output Filters for a nice sinus from the PWM (different for SP and C8-C10 TOP version) Temp. Sensor Chokes to filter out harmonics to provide a nice L6, L7, L8 sinus; Is switching on/off when a high temperature is reached TA9, TA10, Inverter output current measuring for controlling the inverter (DC CT) for I2T detection TA11 TA12, TA13, Output current measuring (AC current supplied to the load from the UPS) for showing on display (AC CT for overload detection) TA14 FU4, FU5, FU6 Output Fuses for phase L1, L2 and L3 Output switch QS4 Output voltage Measure the actual Inverter Output voltage; sense Used as feedback for the control of Inverter
Whats important? The inverter is not switching on, if the following is present: the DC input voltage for the inverter is lower than PNU101 VDC min the QS4 is not closed the QS3 is not open
Parameter Number
Factory setting 0
71 CU2
Line Voltage
Setting the rated voltage. Values: 0: 1: 2: 3: 4:
230V / 400V 220V / 380V 240V / 415V 120V / 208V 127V / 220V
72 CU2
Mains Frequency
Setting the rated frequency. Values: 0: 1: 2: 3: 4: 5: 6:
50 Hz 60 Hz Special frequency Auto default = 50 Hz Auto default = 60 Hz HU Contact on = 50 Hz / HU Contact off = 60 Hz HU Contact on = 60 Hz / HU Contact off = 50 Hz
Parameter Number
Factory setting 1
73 CU2
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Bypass installed
Bypass in place. Values: 0: No 1: Yes
Parameter Number
Factory setting 1
74 CU2
Access Level 4: URL
Separate lines
Separate lines for bypass and rectifier supply in place. Values: 0: No 1: Yes
Parameter Number
Factory setting 0
118 CU2
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V correction
Correction of the output voltage to compensate for line losses, for example.
Parameter Number
Factory setting 1
115 CU2
Access Level 3: URL, IBS, PRU, BYP
Asynchronous Transfer
Enable connection of the bypass after interrupt. Values: 0: No 1: Yes
Parameter Number
116 CU2
Access Level 3: URL, IBS
Bypass delay
Delay for connection of bypass after interrupt. (Only if the Asynchronous Transfer has been enabled PNU 115)
TA16,
Standard serial interface RS232 COM configured for use with PPVIS or external connectivity solutions - female X3 Serial Available, when the XS3 slot is empty or a MUN card is installed; Standard serial interface RS232 COM configured for data transfer protocol, modem or external connectivity solutions X6 Serial - male Not available, when a slot modem is installed; An AS400 compatible contact interface for signal exchange X7 Output - female An interface to provide emergency shut down of the bypass, X8 Input inverter and rectifier (EPO) XT1 External battery temperature sensor connection Input XT2 External battery switch status Input XT3 EPO activated Output XT4 Backfeed protection activated Output Optional I/O connection (behind cover): AP10-X4 Serial Service interface Optional I/O connection (behind cover): AP10-XT5 Output 2 free programmable output contact Optional I/O connection (behind cover): AP10-XT6 Input 4 free programmable input contact Slot available for use with a connectivity option, typically XS3 Serial ManageUPS Net SNMP adapter Slot for the LIFE.net slot modem, fitted as standard (user XS6 Serial removable) The serial interfaces are isolated and RS232 compatible. The inputs are opto-isolated and can be driven by external dry-contacts (e.g. relay contacts); the outputs are 1A, 24Vdc or 110Vac rated relay contacts.
2.4.2
Figure 2-68:
Slot XS3
Figure 2-69:
Slot XS6
X3 / RS232
Sub-D 9pin female
SIG GRD
USS-protocol is used for communication. This RS232 port X3 normally should not be used simultaneously with the corresponding slot bay XS3. You may use X3, while a SNMP adapter is built in the XS3 slot, but the service port is very slow.
It is no longer possible to communicate with the CU via the direct (blue/dark) way from X3. Because the ManageUPS in slot XS3 is now communicating with the CU (green/light). Meaning only one or the other communication is possible. BUT there is a hardwired connection between X3 and XS3 (orange), which is also closed by inserting a ManageUPS into XS3. This connection is necessary to configure the ManageUPS. And because of this existing connection it is still possible to communicate with the CU from interface X3. The information sent from X3 will follow the orange way to XS3, the ManageUPS is receiving the information and will forward it to the CU (via green way). Returned information follow the reverse way. NOTE: Every now and then, the ManageUPS wants to communicate with the CU itself, therefore there are breaks between the X3 XS3 CU communication, caused by the ManageUPS talking to the CU. This is slowing the communication down. It is NOT possible to operate a LIFE.net modem in slot XS3, because this slot is only able to communicate with USS protocol, not with the for LIFE.net necessary Lifenetprotocol. Which is only available on XS6.
X6 / RS232
Sub-D 9pin male
LIFE.net-protocol is used for communication. This RS232 port X6 cannot be used simultaneously with the corresponding slot bay XS6. If XS6 is not used with the LIFE.net modem, but with e.g. ManageUPS internal SNMP Adapter and therefore the protocol is changed from LIFE.net (standard in XS6) to USS protocol (needed for ManageUPS), than the same possibilities of use like X3/XS3 are possible (described under Interaction between interface X3 and Slot XS3 within the previous chapter).
The activated EPO electronically shuts down the rectifier, the inverter and opens the static bypass switch. The EPO activated feedback control command is associated with a dedicated contact output terminal XT3 (refer to the User Manual for further details). The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 . In accordance with the European Harmonized Document HD384-4-46 S1, an Emergency Switching Device (E.S.D.) has to be fitted into the installation, downstream of the UPS. As soon as the cause for the emergency, which triggered the switch, is removed, turn off all UPS switches (input, output, battery disconnector, and all external battery switches) and repeat the start-up.
Warning:
The battery voltage is still present on the UPS!! The rectifier is stopped as well as the Inverter and the Static Bypass Switch is open. This means there is still voltage present on the input terminals (mains and bypass) and on the DC-link (from battery).
To install an external sensor for measuring battery cabinet temperature, connect an optional temperature sensor to the Interface XT1. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .
The temperature sensor is a NTC Thermistor. (Chloride part no. 10H46738P02 incl. sensor (Chloride part no. 10H46738P01), cable (Chloride part no. 10H46739PCF) and plug (Chloride part no. 10H46739PF02V). A few important values of the NTC: - Nominal resistance at 25C = 2000 - Wire length 150mm - Temperature range: -40C to +125C
To monitor if an external battery breaker is open, connect an available auxiliary contact to the interface XT2. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .
2.4.9
If the EPO function is activated, the EPO status is forward to an input contact of an external alarm system, which is connect to the interface XT3. If the contact X8 is activated, a feedback signal is send to this XT3 contact. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .
To forward a status, if the backfeed protection is activated, connect the interface XT4 to an switch which isolates the UPS input side. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .
2.4.11
Signal Input contact XT6_1-2 Input contact XT6_3-4 Input contact XT6_5-6 Input contact XT6_7-8
Pin 1 2 3 4 5 6 7 8 9 10 11 12
Signal XT5-KM1 common Not used XT5-KM1 (NO) Not used XT5-KM1 (NC) Not used Not used XT5-KM2 common Not used XT5-KM2 (NO) Not used XT5-KM2 (NC)
This interface is used only for flashing the CU1 (CUX of the Rectifier) board.
58 CU2
Fast off
Quick stop. X8 This parameter is used to show whether quick stop (bypass and inverter of) via serial interface is allowed. Note: When a modem with external access is to be connected Quick stop should by all means be disabled for reasons of safety. value 0: 1:
No Yes
Parameter Number
Factory setting 1
80 CU2
Output contacts
Setting from the output contacts value 0: AS400 standard (would be PNU81 values: 0-3; with 0 = Inverter on) 1: Siemens (would be PNU81 values: 0-3; with 0 = Summary alarm) 2: Customized: Choose from the list of PNU 81 values.
This parameter is for setting ALL the contacts to a predefined state (either AS400 or Siemens) OR it is possible to set the Parameter 80 to customized what would be necessary to define/parameterise the contacts according to the wish/use of the customer.
81 Function of Output Contacts CU2 parameterised. The parameter is valid only in conjunction with
parameterisation output contacts = customer spec; Indices: i01: X7.3,8,5 i02: X7.1,6,5 i03: X7.2,7,5 i04: X7.4,9,5 i05: AP10_XT5.5,3,1 i06: AP10_XT5.12,10,8 i07: XT3.1,2 i08: XT4.1,2 value: 0: Inverter on/Summary alarm The required message for the output contact involved is
0 1 2 3 43 10 42 46
1: 2: 3: 4: 5: 6:
Active if: warning W10 is present; Active if: warning W2 AND W3 is present; Active if: inverter running;
Battery mode
not
7: 8:
Active if: Battery cell voltage > PNU 113 value [0,03V/cell hysteresis applied);
25: Battery 25
Active if: PNU566 Max. Output > 105%; (threshold 105% is temp. dependent)
34: Line
Active if: any warning OR any fault OR undelayed alarm of bypass failure OR undelayed alarm of mains failure is present;
Active if: bypass not available undelayed AND mains not available undelayed AND (batt. cell voltage < PNU113 value OR warning W3 present);
37: Power loss Alarm
Active if: Bypass fault during bypass operation OR (bypass not available AND inverter fault or overload);
38: Slope Up
Active if: Adjustable output voltage ramp is positive PNU59.103; Only if unit set as frequency converter;
39: Slope Down
Active if: Adjustable output voltage ramp is positive PNU59.103; Only if unit set as frequency converter;
40: Charger on command (for control of battery charger)
FALSE
Active if: ;
Indices: i01: Output contact X7.3,8,5 i02: Output contact X7.1,6,5 i03: Output contact X7.2,7,5 i04: Output contact X7.4,9,5 i05: Output contact AP10_XT5.5,3,1 i06: Output contact AP10_XT5.12,10,8 i07: Output contact XT3.1,2 i08: Output contact XT4.1,2
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0 0 0 0 0 0 0 0
value: 0: No 1: Yes
Factory setting
87 On delay of Output Contacts CU2 This parameter can be used for setting a delay between event
happened and event signalised. This can be done in 10-ms steps. Indices: i01: Output contact X7.3,8,5 i02: Output contact X7.1,6,5 i03: Output contact X7.2,7,5 i04: Output contact X7.4,9,5 i05: Output contact AP10_XT5.5,3,1 i06: Output contact AP10_XT5.12,10,8 i07: Output contact XT3.1,2 i08: Output contact XT4.1,2 Switch-on delay for contact output in 10-ms steps
88 Off delay of Output Contacts CU2 This parameter can be used for setting a delay between event
stopped and event stopped signalised. This can be done in 10ms steps. Indices: i01: Output contact X7.3,8,5 i02: Output contact X7.1,6,5 i03: Output contact X7.2,7,5 i04: Output contact X7.4,9,5 i05: Output contact AP10_XT5.5,3,1 i06: Output contact AP10_XT5.12,10,8 i07: Output contact XT3.1,2 i08: Output contact XT4.1,2 Switch-off delay for contact output in 10-ms steps
Factory setting
3 0 0 0 0
7: 8: 9: 10:
15:
24:
Indices: i01: Input contact X8.1,2 fast off EPO i02: Input contact AP10-XT6.1,2 i03: Input contact AP10-XT6.3,4 i04: Input contact AP10-XT6.5,6 i05: Input contact AP10-XT6.7,8
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0 0 0 0 0
value: 0: No 1: Yes
Factory setting
90 On delay Input Contacts CU2 This parameter can be used for setting a delay between event
signalised (from contact) and event happened (UPS reacting to the input). This can be done in 10-ms steps. Indices: i01: i02: i03: i04: i05: Switch-on delay for contact input in 10-ms steps
Input contact X8.1,2 fast off EPO Input contact AP10-XT6.1,2 Input contact AP10-XT6.3,4 Input contact AP10-XT6.5,6 Input contact AP10-XT6.7,8
Factory setting
91 Off delay Input Contacts CU2 This parameter can be used for setting a delay between event
stopped signalised (from contact) and event stopped (UPS reacting to the input). This can be done in 10-ms steps. Indices: i01: Input contact X8.1,2 fast off EPO i02: Input contact AP10-XT6.1,2 i03: Input contact AP10-XT6.3,4 i04: Input contact AP10-XT6.5,6 i05: Input contact AP10-XT6.7,8 Switch-off delay for contact input in 10-ms steps.
110 Mains Failure Warning Delay CU2 This parameter is setting the duration between a mains failure and
Access level 2: URL, IBS,PRU, BYP, BTR
a subsequent warning signal. When the set time is over and the warning signal is issued, the contact X7.4,9,5 is caused to operate (meaning Pin 5 and 9 are than closed).
113 Battery Pre-warning Voltage Level CU2 If the battery charging voltage is falling under this set voltage a
warning is issued. PNU 81 (Function of output contacts) value 24 (U Batt/C)
If the remaining battery time falls below this limit an warning signal Concerning the output contacts, the relay is caused to operate, when the warning is issued respectively when the set time is under-run.
Factory setting
CU1 Min. and max. battery temperature. When one of this limits is
reached, warning 19 will be issued. Indices: i01: Minimal battery temperature i02: Maximal battery temperature
0 30
2.4.15
Signal cables
A detailed description (incl. drawings) of how the cables are routed through the UPS can be found in the user manual in the according chapter. Notice: The interface cables must be shielded and located away from the power cables (min. 20 cm). The shield must be connected at both ends. Control and power cables must cross at a 90 angle.
Indicates if the charge voltage and the charge current limitation can
0: 1:
2.5 Battery
2.5 Battery
Active Power Rating Output + Full load losses = Total DC-Power Full Load With
Active Power Rating Output [kW] = Nominal Inv. Output Power [kVA] * Power Factor (cos phi) E.g. 200kVA UPS; Power Factor (cos phi) = 0,8; Active Power Rating Output = 200kVA * 0,8 = 160kW Total DC-Power Full Load = 160kW + 12,6kW = 172,6kW Provide the following data: - No. of strings? _____ e.g. 2 - No. of blocks per string? _____ e.g. 40 - Total no. of blocks? _____ (=No.of strings * No.of blocks/string) e.g. 80 - No. of cells/block? _____ e.g. 6 To calculate the necessary W/cells respectively W/block for each of the following loads in the table, use the formulas: W/Cells = Total DC Power Full load [W] Total no. of blocks * No. of cells/block Total DC Power Full load [W] Total no. of blocks W/Cells [W] W/Block [W] * load%
2.
3.
* load% W/Block [W] e.g. 2157,50 e.g. 1618,13 e.g. 1078,75 e.g. 539,38 e.g. 107,88
E.g. for Total no. of blocks = 80 blocks and No. of cells/block = 6 W/Block (100%) = ( 172600 W / 80 ) * 100% = 2157,50 W/block W/Block (75%) = ( 172600 W / 80 ) * 0,75 = 1618,13 W/block W/Block (50%) = ( 172600 W / 80 ) * 0,50 = 1078,75 W/block W/Block (25%) = ( 172600 W / 80 ) * 0,25 = 539,38 W/block W/Block (5%) = ( 172600 W / 80 ) * 0,05 = 107,88 W/block
2.5 Battery
5.
Figure 2-82:
Battery Calculation Constant Power Discharge Table of Battery Manufacturer Data Sheet
How to find the values for the parameters? The target for finding parameter values is to align the Constant Power Discharge table values as close as possible to the calculated values for W/block. To do so, the combination of V/cell (VpC), discharge time and W/Block is crucial. The problem will be finding exact values. Which V/cell line should be taken, is based on the discharge time of the according W/block value. As a guideline, the following table can be used: Time V/cell < 1 hour 1,65 >1 hour and < 3 hours 1,70 > 3 hours 1,75 Whats important? For choosing the value V/cell it is important to know, what is the treatment philosophy of the planner/customer for the battery. The more values V/cell are aligned with 1,65V, the longer the backup time BUT the battery life duration will be shorter (due to deep discharge). (Or the other way around: the higher V/cell, the shorter the backup time BUT the battery life duration will be longer.) This first value (100% load) must be chosen in that way, that the related time value is not smaller than 5 minutes. The value for 5% load (last value) must be chosen in that way, that the related time is not larger than 600 minutes. This is due to the fact, that the UPS firmware is designed to act within these values. Other values can not be handled by the UPS correctly. The calculated value for 100% in the example is 2157 W/block. It is unlikely to find an exact value, therefore the next larger value can be taken in this case 2255 W/block. Why? With a look to the table, it can be seen, that there are some values for
10H52167TM01 (IDSS/Andrea Weigert) Chapter: 2 Functional Description Rev. 2.0 10.May.2007 Page 133/ 307 printed: 15.05.2007, 13:09
2.5 Battery
W/Block [W] (calculated) e.g. 2157,50 e.g. 1618,13 e.g. 1078,75 e.g. 539,38 e.g. 107,88
W/Block [W] e.g. 2255 e.g. 1573 e.g. 972 e.g. 513 e.g. 108
V min. [V/cell] e.g. 1,65 e.g. 1,65 e.g. 1,65 e.g. 1,65 e.g. 1,80
6.
To find the values for the other load values, deal with them in the same way like 100% load. The values taken from the data sheet need to be transformed to the parameter values. The values for Discharge Time and V min. remain unchanged and become PNU 511 and PNU 513. The values for W/Block must be transformed to become PNU 510. W/block [W] Power/Block = * No. of strings No. of cells/block e.g. Power/Block = 2157/ 6 *2 = 360 PNU 1534 Power/Block [W/cell] e.g. 360 e.g. 270 e.g. 180 e.g. 90 e.g. 18 PNU 510.5 = 360 PNU 511/1535 Discharge Time [min.] e.g. 5 e.g. 10 e.g. 20 e.g. 45 e.g. 300 PNU 513 V min. [V/cell] e.g. 1,65 e.g. 1,65 e.g. 1,65 e.g. 1,65 e.g. 1,80
Index 5 4 3 2 1
Values for PNU 1536 can be taken from the already calculated Total DC Power Full load and from the Discharge Time at 100% load. = Total DC Power Full load KW PNU 1536.1 = Discharge Time at 100% load Min. PNU 1536.2 PNU 626.2 10% of Capacity in Ah A Batt. Current Limit There is a Excel-Sheet to help calculating the battery parameter values. Which is also displaying the discharge curve as a diagram. Please ask your Chloride Service Center for it.
2.5 Battery
Parameter Number
1629
(605)
Cell Number
Amount of battery cells.
CU1
Access Level 3: URL, IBS
Factory setting
511/1535
600 60 30 10 5
2.5 Battery
1536
(512)
CU1
64 60
2.5.1.1
Each time the following conditions are fulfilled, the 80-NET is recalculating the battery calculation values by itself: The battery capacity is > 95% The load remains > 40% during the battery discharging and must stay within a 5% window The Minimal battery voltage (PNU 1426.2 [402.2]) is reached This can also be done manually by the trained service technician during e.g. maintenance. The battery test needs to be done until the end of the discharging of the battery to measure the time.
2.5 Battery
This parameter contains the time values in [min] from the battery
600 60 30 10 5
2.5 Battery
Whats important? This value is also present on the CU2 board (PNU 511). Meaning that if the values of PNU 1535 will be changed also the values of PNU 511 MUST be changed manually.
The time-depending end of discharge can also be selected with PNU 590 Message Configuration. If this possibility is chosen, discharging is stopped when Battery hold-up time PNU22 < PNU 117 Battery stored energy time. (More details under chapter 6.2 Warnings and Faults)
2.5 Battery
CU1
Access Level 3: URL, IBS
Defines the used charging algorithm. 0: 1-stage charging with charging pause 1: 1-stage charging without charging pause 2: 2-stage charging with charging pause 3: 2-stage charging without charging pause
Charge Principle (0) 1-stage with pause: After mains failure Charging mode is entered. If the Charge Current is almost not present any more, the Post-Charging phase is entered for a defined period (PNU 1578). Afterwards the Pause is entered, again for a defined period (PNU 1547). The battery is charged with Float Charge voltage (PNU1555).
Charge Principle (1) 1-stage without pause: Charging is done at constant current (PNU 1554) up to the maximum Float charge voltage level (PNU 1555). Thereafter the voltage is kept at this constant level within narrow limits. Used for sealed, maintenance-free lead acid accumulators:
Figure 2-86:
2.5 Battery
Charge Principle (3) 2-stage without pause: If a mains failure occurs, the battery is recharged afterwards with boost charge voltage (PNU1622), as long as the battery current is higher than Current V2 V1 (PNU1625) OR until the defined Max. stage 2 time (PNU1626) is expired. After one of the previous mentioned terms is fulfilled, the DC level will change to Float Voltage (PNU1555) for further charging of the battery. Before actually entering Charge Stage 2 after mains failure, a test will be performed. The Charge Current must stay constant on Max. charge current level (PNU 1554) for a defined period (PNU 1624). If this is not the case, Charge Stage 1 is entered right away.
The Float Charge voltage will be set with PNU1555 and the Boost Charge voltage with PNU1622.
2.5 Battery
CU1
Access Level 3: URL, IBS
Defines the amount of hours after which Charge Battery has to be initiated; requires also that Charge Battery is enabled.
CU1 Limit).
Factory setting 40
Time, which specifies how long the battery is recharged after end
CU1 charging.
Factory setting 60
CU1 to switch to the boost charge level. Only active for 2 step charging
without charge pause.
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Time for which the battery current limitation must be active in order
2.5 Battery
1625 Current V2
(601)
V1
Current under which the system switch from charge stage 2 to CU1 charge stage 1, if the PNU1626 time was not reached.
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Factory setting 10
CU1
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Parameter Number
1629
(605)
CU1
Access Level 3: URL, IBS
2.5 Battery
Whats important? Please be aware, that some battery manufacturer do NOT recommend a initial charging of their batteries. In any case, check the data sheet of the chosen battery type.
Parameter Parameter name Number Description value range Factory Dimension setting 01 0
CU1 YES (1). For the initial charge, the battery is charged with the initial
If a initial battery charging is wanted, this PNU needs to be set to end-of-charge voltage (PNU1620) during the reselected time (PNU1619). After this period, this parameter will automatically be return to no. 0: no 1: Yes (initial charge)
Factory setting 12
CU1 charging voltage. During initial charging, the initial charging time is
counted downwards.
Time during which the battery is charged with the initial end-of-
CU1
Access Level 3: URL, IBS
2.5 Battery
Factory setting 1
CU1
Enabling or disabling the battery temperature channel. When disabled, the displayed temperature will always be 20C! value 0: 1:
Disabled Enabled
The charging voltage is temperature-depending. The correction is based on the temperature factor, defined with PNU1540 (516), and proportional to a deviation from the default temperature (20C).
2.5 Battery
CU1
Access Level 3: URL, IBS, PRU, BYP,BTR
Automatic battery test function settings. i01: Automatic Battery Test Enable i02: Battery Test duration (s) i03: Battery Test Interval Time (h) i04: Battery Test Inhibit Time (h)
2.5 Battery
1426
(402)
CU1
1,6 1,7
If Fault 183 appears, then the battery voltage has fallen under the value of PNU1426.i02 during the Battery test.
2.5 Battery
2.5 Battery
511 Time discharge characteristic CU2 discharge characteristic. The values are given by the battery
manufacturer. Indices: i01: Time discharge point 1 (highest time) i02: Time discharge point 2 i03: Time discharge point 3 i04: Time discharge point 4 i05: Time discharge point 5 This parameter contains time values in [min] from the battery
600 60 30 10 5
Whats important? This value is also present on the CU1 board (PNU 1535). Meaning that if the values of PNU 511 will be changed also the values of PNU 1535 MUST be changed manually.
Parameter Parameter name Number Description value range Factory Dimension setting 0 2,9 [0,01V] 1,8 1,7 1,67 1,65 1,65 value range Factory Dimension setting 03
513 Shutdown Voltage Table CU2 describing a interpolation of the discharge time dependent deep
discharge voltage. i01: Shutdown Voltage Discharge Point 1 (largest time) i02: Shutdown Voltage Discharge Point 2 i03: Shutdown Voltage Discharge Point 3 i04: Shutdown Voltage Discharge Point 4 i05: Shutdown Voltage Discharge Point 5 Together with PNU 511 Time Discharge Characteristic, this values
591 Delta Shutdown Imminent CU2 voltage curve for defining the pre-warning (W10i2).
Access Level 3: URL, IBS, PRU, BYP,BTR
2.5 Battery
PPVIS is a program for costumer and service purposes to show the UPS's state and to change configuration data. PPVIS communicates with the UPS by serial RS232 communication (interface X3), using the USS protocol. (Cable length should not extend 15 meters.) Together with a converter (RS485 to RS232) also an RS485 can be used, which has the advantage, that several units could be address with different slave addresses. (Cable length up to 1200 meters.) The functionality of the program embodies: Visual UPS control panel Status display Battery Display Oscilloscope for diagnostic purposes Event memory Parameter reading and writing Data storage functions for visualisation with PPGraph Life.net
PPVIS
RS232/RS485
Only used: for parallel operation Actual value Acquisition (analog) Analog outputs CUdSMC, CUX Digital input/output (e.g. IGBT firing)
display control
Panel
Power circuits
Whats important? To operate PPVIS with 80-NET one of the following versions or higher is necessary!!! 1.8.087 (Chloride version) 1.8.113 (Masterguard version)
2.7.2
CU2 Inverter
This firmware is responsible for the control of the inverter, booster/charger, bypass detection and overload measuring. The firmware number is: 10H01360 The firmware code and version can be found in PPVIS on the set [1][CU2] Equipment Information: PNU 720.1 SW Version (board slot 1 - CU) Version e.g. 1.8 PNU 721.1 Software issue date (Year) generating year e.g. 2005 PNU 721.2 Software issue date (Month) generating month e.g. 10 PNU 721.3 Software issue date (Day) generating day e.g. 28 PNU 724.0 CU1 Firmware Code 10H01360
6 Status menu
4 7 Main menu UPS Settings menu UPS Settings windows UPS Settings choose new value UPS Settings result 14 15 16
2 Warning/Fault Diagnostics
17
LIFE menu
18
19
20
21
11 About... menu
With the About menu page it is possible to get the following system information: UPS name (80-NET or Series D) UPS rating (in kVA) [CU2-PNU 75.42] Manufacturer [PNU 952] LCD Firmware code, release and date CU1 Firmware code, release and date [CU1-PNU 1748, 1744.1 and 1745.1-1745.3] CU2 Firmware code, release and date [CU2-PNU 724, 720.1 and 721.1-721.3] CU1 DSP Firmware code and date [CU1-PNU 1749.1 and 1749.2] CU2 DSP Firmware code and date [CU2-PNU 725.1 and 725.2]
Whats important? Freeze LCD function This function was established to speed up the serial communication between an external application, like PPVIS, and the CU2 (Inverter) through the LCD. To enable this function, simultaneously press the UP and DOWN key on the front panel for at least 2 seconds (only possible in the main synoptic window). While the function is active, the message LCD frozen will be displayed. When the function is activated, no diagnostics will be present on the LDC because communication with the CU has temporarily been suspended. If no request is sent through the service serial port (X3) towards the LCD, the function disables after 10 minutes. This function also can be disabled by simultaneously pressing the UP and DOWN keys again. The following values are measured: Mains input [PNU 1030] V mains L1 (V) [PNU 1031] V mains L2 (V) [PNU 1032] V mains L3 (V) [PNU 1042] Frequency mains (Hz) [PNU 26.2] T inlet air (C) Bypass input V bypass L1 (V) V bypass L2 (V) V bypass L3 (V) DC-Link Vdc (V) DC current (A)
Mains failure no. Mains fail time: d (days) Mains fail time: h (hours) Mains fail time: m (minutes) Mains fail time: s (seconds)
[PNU 1584.1] [PNU 1585.1] [PNU 1585.2] [PNU 1585.3] [PNU 1585.4]
[PNU 18]
UPS output V output L1 (V) V output L2 (V) V output L3 (V) Frequency output (Hz) I output L1 (A) I output L2 (A) I output L3 (A) Time on inv.: d (days) Time on inv.: h (hours) Time on inv.: s (seconds) Battery V Batt. Per cell (V/Cell) T Batt. (C) Batt. Current (A)
[PNU 9] [PNU 10] [PNU 11] [PNU 17] [PNU 14] [PNU 15] [PNU 16] [PNU 13.1] [PNU 13.2] [PNU 13.3]
Out app power (kVA) Out app power L1 (kVA) Out app power L2 (kVA) Out app power L3 (kVA) Out real power (kW) Out real power L1 (kW) Out real power L2 (kW) Out real power L3 (kW) Overload threshold (%) Load (%)
[PNU 20.4] [PNU 20.1] [PNU 20.2] [PNU 20.3] [PNU 19.4] [PNU 19.1] [PNU 19.2] [PNU 19.3] [PNU 565] [PNU 566]
Batt. disconnected
Inv. Turning on
2.7.4.1
2.7.4.2
2.
3.
2.7
Firmware
In case you are connected directly with the X120 of the CU-Board (cable connection 2.c) the jumpers on the LCDisplay board do not have to be changed. The CU-Board is also equipped with jumpers X160, next to the interface X120. According to the jumper settings, the board is either in - Standard Operation (normal running firmware), - Flashing Operation (upload of the firmware into the flash memory), - or Reset Operation (microprocessor reset) In standard operation the two jumpers are set to 7-8 and 9-10; to set the flash mode, the two jumpers have to be set to 3-4 (responsible for starting the flashing operation after switching on the power supply) and 5-6 (responsible for a modified chip selection).
Figure 2-93:
10-9
8-7
6-5
4-3
2-1
Change the jumpers X160 of the CU2 Board to 3-4 and 5-6.
10H52167TM01 (IDSS/Andrea Weigert) Chapter: 3 Installation Rev. 2.0 10.May.2007 Page 156/ 307 printed: 15.05.2007, 13:09
2.7
Firmware
5.
Install the C16Xflasher (if not already existing on your notebook) Start the Setup.exe and follow the instructions on your screen. After finishing the installation, start the program and click on Settings.
Figure 2-94:
C16X Flasher
Enter the following settings: - System clock - Baud rate - Fix sector 1 erasure - Sector erase
Figure 2-95:
Confirm with OK. Remove the plug X1 on AP7 Bypass Control Board, to make sure that the thyristors on the bypass do not fire. 6. Close QS2 (Before closing QS2, make sure the cable is properly set on both sides, the jumpers are changed and that you selected the correct file for flashing.) Select the file Back on the main screen C16Xflasher you have to select the file you wish to flash into the CU-Board by clicking on Select Image File and choosing the appropriate file, e.g. cu01D.H86.
7.
2.7
Firmware
9.
2.7
Firmware
2.
3.
4.
5.
6.
7.
8.
9.
10. Press the Program device button Start the flashing program. Wait till it is successfully done. 11. Open switch QS2 again Wait till the UPS is voltage free.
2.7
Firmware
2.7.4.4
2.7
Firmware
Figure 2-98: Pin connection for the direct connecting cable from PC to X120 in CU-Board
Please pay attention to the correct wiring of the pins. Otherwise the cable will not work correctly. Whats important? Please be aware, that: - Not all PCs /Notebooks can be used with this cable, because the RS232 interface is not providing the necessary nominal level. - There is no galvanic isolation between the signal common of the PC/Notebook and the electronic of the UPS, meaning that in case of special failure the PC/Notebook could get damaged.
2.7
Firmware
2.7.5.1
2.
3.
4.
Figure 2-99:
Uncheck the other boxes, ONLY H8 should be checked. Then keep following the instructions on your screen for further installation again.
10H52167TM01 (IDSS/Andrea Weigert) Chapter: 3 Installation Rev. 2.0 10.May.2007 Page 162/ 307 printed: 15.05.2007, 13:09
2.7
Firmware
Figure 2-100:
Figure 2-101:
After entering a Name, choosing a Location and pressing the OK button you will receive a message: You have created a new workspace. Would you like to run the Project Wizard to add a Project to the Workspace?. Confirm with YES. Enter a Project Name:
Figure 2-102:
10H52167TM01 (IDSS/Andrea Weigert) Chapter: 3 Installation
2.7
Firmware
Figure 2-103:
Figure 2-104:
2.7
Firmware
Figure 2-105:
Check if the selected Connection is Boot Mode, the selected interface is Direct Connection and the box Kernel already resident is NOT checked:
Figure 2-106:
2.7
Firmware
Figure 2-107:
Figure 2-108:
2.7
Firmware
Figure 2-109:
Figure 2-110:
Choose under Tool Customise folder General the dropdown Would you like to perform a read-back verification after programming; change it to YES. Open the .mot file you would like to flash into the LCDisplay with a double click.
Figure 2-111:
2.7
Firmware
Figure 2-112:
After successfully connecting, choose Image operation will take about 2 minutes.
Figure 2-113:
6.
Reset the DIP switches Set the SW1.2 and SW1.3 DIP switch back to OFF and move the SW1.1 first to ON and than back to OFF again. The program should start now. Check With the menu on the display you can check if your chosen software was flashed to the display all right. Go to the submenu About, there you can find all firmware and software versions. Verify if the your one is listed there.
7.
2.7
Firmware
3
3.1
Installation
General
For a detailed description of how to install the UPS and batteries, please refer to the User Manual. You will find the following information among other things in the User Manual: Safety concerning Batteries and UPS Preparation for use of the UPS incl. transport, delivery and storage, unpacking/re-packaging and so on How to install the UPS External protection devices Current and suggested cable sizes Operation temperature and altitude Cable entry is from the bottom or bottom-side of the cabinet.
Whats important? Please be aware, that the 80-NET does have two supplies, the mains supply and the bypass supply. In case the customer has only one supply for the UPS, it is necessary to bridge the two supplies of the UPS. If this is not done, warning 2 appears and the display may stay dark. It is important to make sure that the mains, bypass and load connections are done as a correct phase rotation (right-handed field). If this is not done, warning 2 or/and warning 3 will appear. The 80-NET needs a NEUTRAL!!!! Make sure it is connected. (Not only in the UPS, but also on site in the customers distribution.)
3.2
3.1
General
Again, for information about this topic respectively for further details, refer to the user manual. E.g. questions concerning cable sizes, currents
This device is equipped with manual switches intended only for service bypass and internal service operations. It is, therefore, essential that the customer install external protection devices at the installation site. These must be installed near the unit and labelled as the mains separation device for the UPS. Batteries are a potential source of danger due to their electrical charge and chemical composition. Therefore observe the battery handling instructions of the manufacturer. These usually can be found in the material which accompanies the shipment. Make sure the correct polarity is present!
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 3 Installation 3.3 Connecting the UPS & Battery
4
4.1
Whats important? If the UPS device has not been used for a period of more than one year, the intermediate circuit capacitors must be reformed. If the UPS devices are commissioned within one year after delivery (check nameplate), this action is not necessary. Check chapter 6.3 Trouble Locating & Testing for details on how to reform the capacitors. A adequate checklists for commissioning of the 80-NET could be found in the additional documentation to this Technical Manual 80-NET: Technical Manual 80-NET Checklists (10H52167TM01_CL)
Whats important? Please be aware, that the 80-NET does have two supplies, the mains supply and the bypass supply. In case the customer has only one supply for the UPS, it is necessary to bridge the two supplies of the UPS. If this is not done, warning 2 appears and the display may stay dark. It is important to make sure that the mains, bypass and load connections are done as correct phase rotation (right-handed field). If this is not done, warning 2 or/and warning 3 will appear. The 80-NET needs a NEUTRAL!!!! Make sure it is connected. (Not only in the UPS, but also on site in the customers distribution.)
Warning! If the battery is connected to the intermediate circuit while the circuit is deenergised, the intermediate circuit capacitors could explode or the battery fuses may trip or become damaged. In this case, exchange the battery fuses as a precaution. Any work on the UPS including parameter changes should only be performed, if the reaction of the UPS is absolutely clear and not harming the UPS or its proper function. If you are not sure what the reaction will be, please contact the Chloride Service Support, before you act.
Figure 4-1:
To indicate that a action must be performed, - there are flashing switches in the diagram to indicate that the according switch must be opened/closed; - there are two symbols for starting/stopping the inverter; these symbols are flashing, if the action is suggested;
Figure 4-2:
In the event of a fault, a warning message is displayed, exit the procedure, correct the fault condition and reset before proceeding. To exit the procedure, press the Exit button at any time.
4. 5. 6. 7. 8.
4.3
Shut-down Procedure
To shutdown the unit completely, follow this procedure: 1. Stop the inverter by pressing the inverter stop button for at least 5 seconds; 2. Open QS9; 3. Open QS4; 4. Open QS2; 5. Open QS1;
To transfer the load to maintenance bypass and to shutdown the unit, follow this procedure: Normal mode (electronic 1. Press inverter OFF on LCDisplay for 5 seconds bypass); 2. Close QS3; Service mode 3. Open QS4; Maintenance bypass mode 4. Open QS1 and QS2; 5. Open QS9 (Disconnect the batteries) and any other external battery switch; 6. BEFORE continuing work, measure the voltage at the battery terminal, the DC-link and at the mains input and wait until it has dropped to 0V. (This is to avoid electrical shocks.);
5
5.1
Maintenance
General
Although there is no need to substitute UPS internal components regularly as a preventative measure at any point during its design life, depending on environmental conditions, specific components, more subject to aging (e.g. electrolytic capacitors, backup batteries, fans etc.), may require replacement on an occasional basis. Therefore, CHLORIDE recommends that regular maintenance checks be carried out on site by an authorised customer service. The UPS indicates when the end of a fans lifetime has expired. A replacement fan is recommended. For maintenance or repair the UPS is equipped with a maintenance bypass switch (QS3), which enables transfer of the load to a bypass mains supply without any interruption in the supply to the load.
Whats important? The transfer/retransfer of the load is achieved by synchronising the UPS automatically to the bypass mains supply, paralleling it with the inverter, then opening or closing the maintenance bypass switch. The switch configuration during maintenance bypass is as follows: QS1 = OPEN QS2 = OPEN QS3 = CLOSED QS4 = OPEN QS9 = OPEN Any work on the UPS including parameter changes should only be performed, if the reaction of the UPS is absolutely clear and not harming the UPS or its proper function. If you are not sure what the reaction will be, please contact the Chloride Service Support, before you act.
Warning! During parallel operation of UPS units, the load switching function of the built-in service bypass must be carried out by an external switching device. All internal subassemblies are accessible for typical and most frequent maintenance from the front of the unit via hinged doors.
All checklists for maintenance of the 80-NET could be found in the additional documentation to this Technical Manual 80-NET: Technical Manual 80-NET Checklists (10H52167TM01_CL)
To bring the UPS into a service state (transfer from online to maintenance bypass operation): Normal mode (electronic 1. Press inverter OFF on LCDisplay for 5 seconds bypass); 2. Close QS3; Service mode 3. Open QS4; Maintenance bypass mode 4. Open QS1 and QS2; 5. Open QS9 (Disconnect the batteries) and any other external battery switch; 6. BEFORE continuing work, measure the voltage at the battery terminal, the DC-link and at the mains input and wait until it has dropped to 0V. (This is to avoid electrical shocks.); Qualified personal may now carry out maintenance work while observing the corresponding safety measures. If there is a external mains separation device for the UPS and the loads no longer need power, you may open that one too.
Parameter Parameter name Number Description value range Dimension 0 65535 Factory setting 0
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 5 Maintenance 5.4 Battery maintenance
0 0 0
Factory setting
0 0 0 0
5.3
Extended maintenance
Which parts in the 80-NET should be changed in regular intervals: Fans: The UPS indicates when the end of the lifetime is reached. Replacing the fans is recommended. Batteries: Batteries in no proper state are highly recommended for replacement. Capacitors: DC as well as AC capacitors should be exchanged in defined intervals, depending on individual environmental conditions e.g. temperature, load, room air-conditioned and so on.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 5 Maintenance 5.4 Battery maintenance
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 5 Maintenance 5.4 Battery maintenance
6
6.1
Whats important? Trained Engineers ONLY!!! Remember, only trained, Chloride authorised personal is allowed to carry out any work on the UPS!!! Any work on the UPS including parameter changes should only be performed, if the reaction of the UPS is absolutely clear and not harming the UPS or its proper function. If you are not sure what the reaction will be, please contact the Chloride Service Support, before you act.
Before starting any work in the UPS (e.g. changing boards), make sure that you shutdown the UPS respectively that you transferred the load to maintenance bypass and that the 80-NET is voltage free.
Buzzer The buzzer has different patterns, which indicate the active warning or fault. Pattern 1: long intervals This event is less serious. It is not essential that the cause must be corrected immediately, unless otherwise specified in table Warning indicators. Pattern 2: short intervals This a serious event. The cause should be rectified straight away to avoid a fault condition. Pattern 3: continuous tone This a serious event. The affected UPS component is always switched off and the UPS automatically switches to the best possible operating mode for supplying the loads. The buzzer is silenced automatically as soon as the cause of the event is corrected. It can also be silenced manually by pressing the button TEST/RESET. If a warning appears, the UPS continues to operate. The yellow LED ALARM illuminates on the LCDisplay and a warning number is indicated. If a fault occurs, the red FAULT LED illuminates on the control panel. A number between 33 and 99 or between 133 and 199 appears in the diagnosis page of the display indicating the fault.
Fault reset If a fault occurs: - Firstly stop the buzzer by pressing the TEST/RESET button. - Secondly correct the fault. - Thirdly reset the fault by pressing the TEST/RESET button again.
6.2
Description
Notes / Action
Inverter over-temperature
CU2
W1i2
Temp. above warning threshold defined by PNU152.2; Check if fans are running correctly? Air supply/ventilation ok? Room temperature ok? Check actual value of temperature and verify with PPVIS value (Sensor ok?) Verify, if the measuring channel ST-S-OUT is ok? Cable ok? Contact to Interface Board AP4 X83_1-3 ok? Reduce Load; Heavy non-linear load with DC content present; Temp. above warning threshold defined by PNU153.2; Like above (only measuring channel = ST-R; contacts AP3 X83_4-6);
CU2
W2i2
W2i3
Bypass input breaker QS2 closed? If yes, measure if auxiliary contact is switching: on CU2 board X130_17-18 ; Appears, when bypass voltage or frequency is out of tolerance for a time period longer than defined in PNU110; Voltage tolerance: PNU106 (related to value of PNU71) Frequency tolerance: PNU104 (related to value of PNU72) For the detection of this warning a average value of all three phases is used (no single phase consideration); Measure if the actual values are within tolerance If yes, check AP4; If there is just one power supply for mains and bypass of the UPS, than they are probably not connected; Bypass line connection was not done as right-handed field; Bypass failure signal from POB; Can only appear if UPS is in Distributed Parallel System configuration; Appears if one of the other UPSs is having W2i1 or W2i2 or F50; Verify on which UPS of the parallel system is showing W2i1/ i2 and correct it; Check connection between POB boards; Check POB boards (of the UPS with W2i1 or W2i2 first); Check AP4 boards (of the UPS with W2i1 or W2i2 first);
6.2
Description
Notes / Action
CU1
W3i2
W3i3
W3i4 W3i5
PK Out of Synchronisation
Mains input switch QS1 closed? If yes, measure if auxiliary contact is switching: on CU1 board X130_13-14; Rectifier is not working; Set when AC voltage outside PNU1130 [106] i01 and i03 window (Factory setting V< -20% OR V> +15<%); Set when Frequency outside PNU1128 [104] value (Factory setting Hz<0 -6% OR Hz < +6%); Appears, when mains voltage or frequency is out of tolerance for a time period longer than defined in PNU1134 [110]; Rectifier is turning off automatically; UPS is running on batteries; Measure if the actual values are within tolerance If yes, check AP3; If there is just one power supply for mains and bypass of the UPS, than they are probably not connected; Mains connection was not done as right-handed field; Set when AC voltage is inside a window defined with PNU1130 [106] i02-i03 (Factory setting -20% < Vac < -15% ); Mains voltage to low to charge the batteries; Battery charger is switched off; Check mains voltage;
4 Inverter I2T
W4i1
Inverter I2T
CU2
I2T over current detected on inverter output with DC CT TA9-TA11; Check the inverter output DC CTs TA9-TA11; Check the output AC CTs TA12-TA14; Check the output fuses FU4-FU6;
DC-link voltage under threshold defined by PNU1159.2 (CU2) and by PNU101 (CU1); If Booster is not working properly any more; If UPS is in Battery mode, than It appears when Battery is not ok any more; Precharge active Wait until precharge is done; Set while DC voltage < PNU101 Contactor KM3 is broken; Resistor R1/R2 is broken; Bypass disable for DC voltage low Active during precharge; Because there is no output contactor in this UPS, it is necessary to inhibited the Static Bypass Switch to switching through, while the DC capacitors are not charged; If this is not done, the DC capacitors would be charged backwards from the output over the bypass line, what is not allowed; ((threshold 2 * RMS - 30V), delay 0,4sec);
6.2
Description
Notes / Action
6 Overload warning
W6i1
CU2
W6i2
Current limit
W6i3
Overload
Inverter overload time counter has reached 90% of time-out threshold; Load transferred to bypass if PNU567 Bit 2 = 1 is set (singe block only); Overload based on current value only; Temp. and time are taken in account for this overload warning; Overload monitored with AC CT TA12-TA14; For more details, please refer to the according subchapter of 6.2.3 Additional Explanations for Warnings and Faults; Inverter current limitation active; In case of peak currents (detected by TA9-TA11) on the inverter output, the bypass line will be used in parallel with the mains line, to reduce the current in the mains line; This is called dynamic line support; Load % is above threshold defined by ambient temperature; Start of KW protection counter; Output overload incl. recovery time;
Appears only when UPS is powered up, not while running; Check and if necessary change to a right-hand rotation; Maybe a one phase bypass mains failure is present; Appears only when UPS is powered up, not while running; Check and if necessary change to a right-hand rotation; Maybe a one phase mains failure is present;
CU2
W8i2
Maintenance bypass switch closed Maintenance bypass QS3 is closed; Could it be opened? If yes, open; QS3 open? If yes, measure if auxiliary contact is switching: on CU2 board X130_13-14; SBS bypass switch closed External SBS QS5 is closed (Input Function PNU93 i01=4); Check if the SBS could be opened; If yes, open; Is QS5 of the SBS already open? If yes, check the connection between X8 on the UPS and the SBS and the auxiliary contact on the SBS;
CU2
Set by CU2 when W3i2 "primary mains power failure" AND "inverter running"; Reset when mains power returns (rectifier ON) OR "inverter stop"; Also present, when rectifier has a problem; The battery is supplying the load;
6.2
Description
Notes / Action
Set when battery voltage PNU24 < PNU511&PNU513 interpolation curve (End of Discharge curve); Inverter stopped; Reset after [W5=0 AND inverter restart delay (PNU588) expired] Check the battery; Check the calculation settings; For more details, please refer to the according subchapter of 6.2.3 Additional Explanations for Warnings and Faults; Set when battery voltage PNU1048 < PNU1426.1 CU1 Battery under voltage limit: (default value 1.6 V/cell). Booster stopped; Check the battery; Check the calculation settings;
Reserved Rectifier H/W Init, Commissioning PNU1076 (52) = 2; Boost-charger test mode Control source is not CU2
PNU1078 (54) is not = 2;
CU1
Battery switch QS9 closed? If yes, measure if auxiliary contact is switching: on AP3 board X94_1-2; Battery not available; Battery fuses ok? Battery ok? Check if battery loop is closed; XT2 closed? For a external battery it must be closed; Connector closed? External battery switch closed?
CU2
Appears when PNU109 = 0. This parameter is counting down; Change the fans; For short term solution until the spare fans are available: Reloading the PNU109 manually with a new fan life time. BUT make sure that the fans are able to endure the new set time. Otherwise the UPS could get damaged!
15 CU1 CU2
16 CPU time slice override (normally masked) CU2 time slice skipped; CU1 W16i1 Inverter CU board time slice overrun CU2
W16i2 Rectifier CU board time slice overrun CU1 time slice skipped;
6.2
Description
Notes / Action
17 Reserved
UPS is in battery mode; (Rectifier is signalising mains failure and the inverter is running;) Set by CU1 if W3i2 Primary mains power failure and Booster on; Batteries will not be charged; Command by CU2 when PNU93=1 or 18 active (Input function);
CU1
Battery temp. sensor fault: Batt. temp T< -10C or T>50C; Verify if temp. probe is working; measure the actual temp.; Temp. probe connected? Room temp. ok? Battery will not be charged; Battery temp. 10C<T<PNU1557.i01 [533] or 40C<T<50C; Check air supply of batteries; Temp. probe working ok? Battery temp. user alarm: Batt. temp. P1557.i02<T<40C; Check air supply of batteries; cooling ventilation must be implemented; Batteries ok? Batt. temp. value can be verified with PNU1050.2 (SET Actual Values CU1)
20 System warnings 1
W20i1 Inverter remotely stopped Set when PNU93.1 =19 (Input function) active Neutral switch QS14 closed? If yes, measure if auxiliary contact is switching: on CU1 board X130_6-8; If not, shut down UPS before managing the QS14; While warning is set, the closing of precharge contactor KM3 is inhibited and the rectifier stays off (CU1); Start of the input inverter is inhibited (CU2); Temp. T< -10C or T>50C Verify, if the measuring channel ST-1 is ok? Cable ok? Contact to Interface Board AP4 X82_3-4 ok? Should show 15C in PPVIS; Check actual temperature; Check if sensor is defective; Temp. 10C<T<PNU133.i01 or 40C<T<50C Air supply ok? Room temperature ok? Check actual value of temperature and verify with PPVIS value (Sensor ok?) Temp. PNU133i02 <T<40C Check air supply; cooling ventilation must be implemented; QS6 PNU93.i1 Input function X8 = 22;
W20i5 Input air high temperature CU2 W20i6 SBS output switch open CU2
Load not supplied through the secure bus; Inverter off; Load supplied by bypass; Inverter start inhibited; DC voltage < PNU135.i3 UDC link min. voltage;
6.2
Description
Notes / Action
23 Reserved
25 Reserved
26 Pending command
W26i1 Inverter stop pending command
Set in parallel operation when local command present but not global; Set in parallel operation when local command present but not global;
Due to overload the transfer to inverter is inhibited (PNU567) BUT inverter is running and is waiting to take over; Reduce load;
CU1 CU1 W30i2 Do not close output switch CU2 CU2 31 Reserved
Closure of QS9 battery switch disabled due to DC bus voltage low; (Set when W5 and W13 active; Reset when W5=0); Closure of QS4 output switch disabled due to DC bus voltage low;
6.2
Description
CU2
34 CU microcontroller error
F34
Inverter fault
Flash newest firmware onto the CU2 board; Exchange CU2; Inverter stopped;
Other fault
Power class not initialised; Select the correct power class;
Inverter Fault
Only, when a optional output contactor is installed; Check contactor coil; Check if the contactor is supplied with 24Vdc; Inverter contactor is off (feedback) AND inverter is in state inverter operation AND test-mode not selected AND output contactor present (PNU651 =1);
CU2
Inverter Fault
Appears if inverter start failed after 4-consecutive attempts within 96s interval time because VDC < PNU101; Check if under-voltage is present in the DC-link; Check the battery; Check the load; Check if rectifier and/or booster (Batt. mode) is working properly;
38 Reserved
6.2
Description
39 Inverter DC overvoltage
F39
CU2
40 E.P.O.
F40
E.P.O.
Inverter Fault
If you have a newly flashed CU-Board, try a parameter reset; Exchange CU2 board; Like above ; Like above ; Like above ;
CU2 F40i2 Wrong state of DSP state-machine F40i3 Impermissible Interrupt F40i4 Wrong initialisation of data in DSP
43 Inverter desaturation
F43i1 DC/AC desaturation phase U
Inverter Fault
Short circuit in the IGBT? IGBT Driver Board AP15 defective? Inverter stopped; CU2 X109_B23; Short circuit in the IGBT? IGBT Driver Board AP16 defective? Inverter stopped; CU2 X109_A24; Short circuit in the IGBT? IGBT Driver Board AP17 defective? Inverter stopped; CU2 X109_B24;
CU2
F43i2 DC/AC desaturation phase V
Inverter Fault
Before F44 appears, W6 was already present; Set after 5 attempts within 1 min. of dynamic line support; Verify load; Verify output filter L6-L8; Dynamic line support is active, when current limit is lasting more than 3 ms.; The bypass static switch will be turned on for 800 ms.;
CU2
45 Power supply feedback failure CU2 F45i1 Power supply feedback failure
6.2
Description
CU2
F46i3 Output frequency out of limits F46i4 Output short-circuit F46i5 DC component phase U F46i6 DC component phase V F46i7 DC component phase W
Inverter Fault
I2T fault on phase U; Reduce load; Check the output current sense AC CT TA12-TA14; I2T fault on phase V; Reduce load; Check the output current sense AC CT TA12-TA14; I2T fault on phase W; Reduce load; Check the output current sense AC CT TA12-TA14; Maximum of inverter output power exceeded (overload time counter has reached threshold); Load transferred to bypass if PNU567 Bit 2 = 1 is set (single block only); Overload based on current value only; Temp. and time are taken in account for this overload fault; Overload monitored with AC CT TA12-TA14;
CU2
F47i2 Inverter I2T phase V
Inverter Fault
Backfeed fault detected by TA15-TA17 (bypass current sense); given to AP4 X61_1-6 and than to CU2 X109_B9 (output contact XT4 will get a signal from CU2 X109_B13 to signal a detected backfeed); SW enabled by PNU142; Check bypass static switch; Check bypass current sense TA15-TA17;
CU2
50 Bypass HW fault
F50i1 CU2 F50i2 F50i3 F50i4 F50i5
Reserved Reserved Reserved Reserved Electronic fault ready acknowledge is missing despite power supply OK F50i6 Incorrect state in bypass state- machine
Check electronic components; Bypass static switch failure (X110 pin 3-4 "STS_GOOD" = OFF AND bypass input OK); Software fault;
6.2
Description
Bypass fault
Bypass on AND overload time out counter reached; Verify load; Check the output current sense AC CT TA12-TA14; In PARALLEL system: check the bypass current distribution;
CU2
Other Fault
PNU93 (X8) input function = 24;
Other Fault
The signal for the fan test is sent from AP27/AP28 over AP4 X2_3-4 to CU2 X109_B10 ONLY when fans are running on high speed; For the automatic fan test, the fans will be speed up to high speed; If the fans are running on high speed due to high temp. in the UPS, the fans are constantly monitored; Check fans, and replace if necessary;
CU2
Other Fault
fault in write-operation - write verify not OK. fault in write-operation - no ack. after slave address fault in write-operation - no ack. after storage address fault in write-operation - no ack after value address fault in read-operation - no ack. after slave address fault in read-operation - no ack. after storage address fault in read-operation - no ack. after value address no end of data signal after value read invalid address at EEPROM - order invalid data type at EEPROM - order
Other Fault
CU2
Other Fault
Re-flash the CU2 board with the corresponding firmware release;
Other Fault
Output voltage fault despite bypass input ok; Measure the actual bypass output voltage; Check output voltage sense (AP4 X4_1,3,5); Check bypass static switch; Check bypass control board AP7;
Other Fault
CU2
CU2 fault accessing dual port RAM Fault set by "ready signal" missing coming from optional device connected to DPR;
6.2
Description
CU2
Other Fault
Check cable and cable connection of POB; Change the POB;
Other Fault
Should show 15C in PPVIS; Check temperatures sensor connection and cable; Check actual temperature; Check if sensor is defective;
CU2
Other Fault
Other Fault
Inductance over-temperature; Verify, if the measuring channel from choke to CU2 is ok? Cable and contact ok? Booster stopped; F73i2 Neutral booster over-temperature Temp. above fault threshold defined by PNU153.3; Booster stopped; Fans running? Air supply ok? Room temperature ok? Measure actual temp. value and verify with PPVIS value; Sensor ok? Verify, if the measuring channel is ok? Cable and contact on AP4 X83_4-6 ok? F73i3 Neutral booster desaturation Desaturation (input X109_B8); Check IGBT; Check neutral booster CT; F73i4 Neutral booster temperature Booster stopped; sensor fault Verify, if the measuring channel ST-R-OUT is ok? Cable and contact on AP4 X83_4-6 ok? Measure actual temp. value and verify with PPVIS value; Sensor ok?
74 Reserved 82
6.2
Description
83 Battery faults
F83i1 Battery fuse blown
CU2
F83i2 Battery insulation failure
Rectifier Fault
Special fault; Generated when rectifier and battery booster fault are present simultaneous (because faults are mapped by the CU2, in the rectifier group, and therefore can not be handled independently.);
CU1
Rectifier Fault
Appears after W24 (W24 disappears when F133 appears); Rectifier turned off! Temp. above fault threshold defined by PNU1174.3; Fans running? Air supply ok? Room temperature ok? Measure actual temp. value and verify with PPVIS value; Sensor ok? Verify, if the measuring channel ST-S-IN is ok? Cable ok? Contact to AP3 X83_1-3 ok? Overload present? Reduce load; Over temperature in choke L1-L3; Rectifier turned off! Verify, if the measuring channel to CU2 X130_15-16 is ok? Cable ok? Contact CU2 X130_15-16 ok? More see above Rectifier turned off! Verify, if the measuring channel ST-S-IN is ok? Cable ok? Contact to Interface Board AP3 X83_1-3 ok? More see above
CU1
Rectifier Fault
DC overvoltage > 450Vdc; Check SCR in bypass line and the Bypass Control Board AP7; Check the load; Backfeed/regeneration present? Is output contactor (if present) opening? Input transients present?
DC Over voltage
CU1
140 E.P.O.
F140
Rectifier Fault
PNU93 (X8) input function 3. (Info transmitted over CU2 to CU1 PZD 1 bit 7);
E.P.O.
CU1
6.2
Description
Rectifier Fault
Precharge short circuit, because threshold PNU1159.1 [135.1] was not reached within 1 sec.; Precharge did not reach safe voltage despite mains OK; (PNU1159.2 [135.2] +20V) Precharge resistor R1/R2 and capacitor C1-C3 ok? Precharge contactor KM3 ok? Fuses FU1-FU3 ok? KM1 ok? HW defective; Timeout for the feedback from the rectifier mains contactor KM1; KM1 ok? Not allowed precharge state;
CU1
Rectifier Fault
Short circuit in the IGBT? IGBT Driver Board AP11 defective? Rectifier stopped; Phase U (CU1 X109_B23); Short circuit in the IGBT? IGBT Driver Board AP12 defective? Rectifier stopped; Phase V (CU1 X109_A24); Short circuit in the IGBT? IGBT Driver Board AP13 defective? Rectifier stopped; Phase W (CU1 X109_B24);
CU1
F143i2 Rectifier desaturation phase V
Other Fault
6.2
Description
Other Fault
Re-flash CU1 board with the corresponding firmware release;
CU1
CU1 fault accessing dual port RAM Fault set by "ready signal" missing coming from optional device connected to DPR;
160 Reserved -161 162 Battery temperature sensor fault CU1 F162 163 Reserved -172 173 Booster Charger protection
F173i1 Booster-Charger filter overtemperature CU1
Other Fault
Rectifier Fault
Inductance over-temperature Verify, if the measuring channel from choke to CU1 X130_17-18 is ok? Cable ok? Contact on CU1 X130_17-18 ok? Check the choke L4; Booster/Charger stopped; F173i2 Booster-Charger over temperature Booster/Charger stopped; Temp. above fault threshold defined by PNU1175.i3; Fans / air supply / room temperature ok? Measure actual temp. value and verify with PPVIS value; Sensor ok? Verify, if the measuring channel ST-B is ok? Cable ok? Contact on AP3 X83_5-6 ok? F173i3 Booster-Charger Desaturation Desaturation (input X109_B8) F173i4 Booster-Charger temperature Booster/Charger stopped; Verify, if the measuring channel ST-B is ok? Cable ok? Contact on AP3 sensor fault X83_5-6 ok?
174 Reserved -181 182 Rectifier DC closed loop fault CU1 F182i1 Rectifier DC closed loop fault 183 Battery test fault
F183
Rectifier Fault
Check rectifier;
Other Fault
Fault detected during a manual or automatic battery test. Set during battery test when Battery voltage < PNU1426.i2 Min. Battery voltage;
6.2
6.2.3.2
6.2
Figure 6-1:
Overload capacity
6.2.3.3
6.2
Figure 6-2:
More details for explaining this Warning 10 Index 1 and 2 in connection with Warning 11 Index 1 can be found in chapter 2.5.4 Imminent Shutdown Curve.
6.2.3.4
6.2
Please keep in mind that, after troubleshooting, due to wrong connection of components, when the UPS is turned ON, it is possible that damages could occur to the UPS. To avoid any risk of damages a preliminary visual check is strongly required before the unit is supplied. As a start, find the main points in the list below: Input transient suppressor. In case of wrong connection the varistors may explode; Hall effect sensor current transformer (HCT). On the system schematics TA4, TA5, TA6, TA9, TA10, TA11. They must be correctly wired and with the right polarity; AC current transformer (CT). On the system schematics TA1, TA2, TA3, TA12, TA13, TA14. They must be correctly wired and with the right polarity; DC bus electrolytic capacitors. Check for the correct polarity; Battery connector wired correctly; KM1 coil connections. The driver signal of KM1 must be wired correctly to avoid any possible wrong start up of the UPS;
Possible cause
Action
Battery calculation disabled or Check and/or enable the battery not correctly set; calculation
Possible damage of the IGBT, Check IGBT and boards and IGBT Driver Board or IGBT exchange if necessary. Interface Board present. Is a MUN II adapter connected to Update the LCD firmware to 2.00 X3 of the UPS? or higher. If yes, is the LCD firmware version lower than 2.00?
6.3.2
Figure 6-3:
The PNU 125.0 UPS operat. in manual byp. needs to be set to Yes, only then the inverter will start by pressing the Inverter start button. PNU 783 Test Operation needs to be set to On to start the power circuit test. PNU 786.0 Test voltage stands for the nominal output voltage (which complies to the value 71.0 Line voltage), while a value of 16384 means 400Vac and 1638 means 40Vac. 9. Make sure that the switches are in the following positions: a. QS1 = closed b. QS2 = open c. QS4 = open d. QS9 = open 10. Press the Inverter ON button on the UPS; 11. In addition to the shown values of the PPVIS status display, measure the output voltage L1/L2/L3 to neutral with a DVM and compare the result .
Figure 6-4:
13. Now you can perform your tests. E.g. slowly increase the value of parameter 786.0 1638 2638 or 3000 and so on. While you do so, please monitor the values on the Status Display and on your DVM. The three phases need to be symmetric (within tolerance of course). 14. After being done with your tests, turn off the inverter on the LCDisplay and additionally by setting the PNU125 back to No. Also set the PNU 783 Test Operation to OFF Dont forget to exit the Testmode, to reset all PNU, to change the Target back to EEPROM and to built-in the POB again, if present.
Figure 6-5:
Note: Any appearing warning or fault message are normal, because the system is in an abnormal state.
6.3.3.1
Figure 6-6:
Figure 6-7:
The values given below may vary slightly from the values measured while testing an IGBT. 1. Ensure that the UPS is shut down and the battery is disconnected 2. Wait until the DC-Link capacitors discharged: verify that the bus voltage is zero before proceeding 3. Disconnect the cables from the IGBT to be tested 4. With reference to the below table, carry out a check of the impedances across the IGBT terminals using a DVM set to the Diode range 5. If the indicated values are different to those shown, or if the device fails to switch ON/OFF then it must be regarded as unserviceable and needs to be replaced.
What to do Checking IGBT1 Connect DVM across the Emitter-Collector junction Reverse the DVM connector to check internal diode Reconnect DVM to original polarity Connect the +ve DVM connector to the gate Recheck the EmitterCollector junction
E2 C1
C1 E2
0L 0,388
E2 G1 E2
C1 E1 C1
0L The device should turn ON 0,64 This low reading indicates that the device is turned on (Note it will remain ON under the present circumstances due to its internal Cge capacitance High resistance indicates that the device is OFF IGBT switched off in a serviceable condition Diode Forward Resistance
Turn the device OFF by shorting G1 and E1 Checking IGBT2 Connect DVM across the Emitter-Collector junction Reverse the DVM connector to check internal diode Reconnect DVM to original polarity Connect the +ve DVM connector to the gate Recheck the EmitterCollector junction
E2
C1
0L
C2 E1 E2
E2 C2 E1
0L 0,322
C2 E1 G2 C2 E1
E2 E2 E2
0L The device should turn ON 0,445 This low reading indicates that the device is turned on (Note it will remain ON under the present circumstances due to its internal Cge capacitance High resistance indicates that the device is OFF
C2 E1
E2
0L
6.3.4
Capacitor Reforming
If the UPS was not used for more than a year, it is necessary to reform the intermediate circuit capacitors. To reform the capacitors on the 80-NET there are two possible ways described hereafter, which could be used: A 1. 2. 3. 4. 5. 6. 7.
8.
9. 10. B 1. 2. 3. 4. 5. 6. 7.
The unit is connected to the distribution and is still off; Remove all 6 fuses of the Supply Interface Board AP6; Remove/open Q1; Insert a DVM on the inputs of fuse FU5 and FU6; Close QS1 and reopen QS1 without any delay; This should be done as quickly as possible; Wait until the capacitors are discharged again (until the voltage dropped to 0V again); Repeat step 5 and 6 about 10 times per year of not use of the UPS; E.g. the UPS was standing 1,5 years on stock procedure should be repeated about 15 times Again repeat steps 5 and 6 for the same amount of times; BUT this time, after closing QS1, wait a little bit until reopening QS1 again; Suggested time is about 2 sec., the voltage on the DVM should not rise above 600V; Also wait until the voltage dropped to 0V between each closing of QS1; Insert the fuses on AP6 again and Q1; A normal commissioning procedure can now be done;
The unit is connected to the distribution and is still off; Remove all 6 fuses of the Supply Interface Board AP6; Remove/open Q1; Insert a megohmmeter on the inputs of fuse FU5 and FU6; This should be set to 500V Close QS1 and slowly increase the voltage due to the megohmmeter; Open QS1 again and wait till the voltage dropped to 0V; Insert the fuses on AP6 again and Q1; A normal commissioning procedure can now be done;
Please keep in mind that this procedure of reforming the capacitors is no guarantee, that the capacitors will be ok. After such a long period of not using the unit, there is still a possibility that the capacitors could get respectively are damaged.
Whats important? This function is required by the UPS safety standard. A proper test must be done. With the UPS in normal mode supplying some load (i.e.75%) and the bypass input switch open, short circuit each thyristor on the bypass line (one at a time) and verify that the status of XT4 changes to the active position.
6.3.6
6.3.7
Whats important? This test must only be carried out with the DC-bus capacitors fully charged. Suggested load 20% - 30% of the nominal resistive load. With the main input switch QS1 already closed, close the bypass input switch QS2. After a delay of a few seconds the UPS supplies the load through the bypass line SCR. To verify that the bypass is working correctly and there is not any phase rotation inside the UPS, using a DVM, measure the input and output voltage of each phase vs. neutral and verify that: U1-U2 = 0V + 1V V1-V2 = 0V + 1V W1-W2 = 0V + 1V. Input AC bypass voltage: compare the three input voltages, measured with a DVM, with the PPVIS/LCD readings (CU2). The differences between the DVM and the PPVIS/LCD measures must be within a range of + 1%. Output AC voltage: compare the three input voltages, measured with a DVM, with the PPVIS/LCD readings (CU2). The differences between the DVM and the PPVIS/LCD measures must be within a range of + 1%.
6.3.9
Figure 6-8:
Overview Temperature Ranges for Ambient, Battery, Rectifier, Booster/Charger, Inverter and Neutral Booster
A) Procedure scaling of measured and shown DC-Link voltage (CU1): 1. Starting point should be a UPS, which was running in online-mode for about 15 minutes with a test load of about 50%; (if test load is not available, do it in opencircuit operation) 2. Connect PPVIS and select SET CU1 DC-Calibration. (With this, the rectifier will be calibrated in booster mode.) 3. Set PNU 1075 Access Level to Expert and PNU 1823 Superservice to Superservice 4. 4. Measure the neg. DC-Link voltage and align the DVM reading with the value of PNU1100.19 (VDC Link ) to 365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about 1V should be adhered. 5. Measure the pos. DC-Link voltage and align the DVM reading with the value of PNU1100.20(VDC Link + ) to +365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about 1V should be adhered. 6. Go back to Superservice = SF 0 and Access Level = Normal Operation B) Procedure scaling of measured and shown DC-Link voltage (CU2): 1. Starting point like CU1. 2. Connect PPVIS and select SET CU2 DC-Calibration. 3. Set PNU 51 Access Level to Expert and PNU 799 Superservice to Superservice 4. 4. Measure the neg. DC-Link voltage using PPVIS PNU38.1 and align that PPVIS reading with the value of PNU76.19 (VDC Link ) to 365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about 1V should be adhered. 5. Measure the pos. DC-Link voltage using PPVIS PNU38.2 and align that PPVIS reading with the value of PNU76.20 (VDC Link + ) to +365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about 1V should be adhered. 6. Go back to Superservice = SF 0 and Access Level = Normal Operation
If the input THD is not like specified, it is possible to try to calibrate the offset of the rectifier input current. (Only if absolutely necessary!) D) Calibration of the rectifier input current offset 1. Turn off the rectifier by transferring the load on maintenance bypass and setting Function selection CU (PNU 52) on CU2 to H/W_Init URL. 2. Connect PPVIS directly to the CU1 board via the X4 interface on the AP10 (access on the UPS roof). 3. Verify the rectifier input currents per phase with the PPVIS oscilloscope. (Measured with TA4-TA6 to verify the DC-Offset.) (Settings: Trace Mode: Medium, Trigger Control: Single Shot) With the Numerical View it is possible to calculate the average of the deviation (e.g. L1= -150, L2= -16, L3= -78) 4. Connect PPVIS on the X3 interface again and select the SET CU1 DCCalibration. 5. Set PNU 1075 Access Level to Expert and PNU 1823 Superservice to SF 4. 6. Insert the calculated average deviation values into the corresponding PNU 1100.24, 1100.25 and 1100.26 VEC_I_INV_OFFSET_L1, L2 and L3 7. Go back to Superservice = SF 0 and Access Level = Normal Operation. 8. Turn on the rectifier: Return the Function selection CU (PNU 52) to Return. 9. These value correction will be used for the rectifier control only. It is not possible to measure the corrections, because you can not change the mains. You can only vary how the rectifier control is changing the mains. (A direct improvement can only be seen by the current harmonic distortion and it is fluctuating quite a bit.)
Figure 6-10: Bypass Control Board with a damaged overvoltage protection on line 2
Figure 6-12: Output chokes with removed side cover and visible damage on the second choke
List of AIF for 80-NET (Version 10.05.2007): AIF no. Description 108 15B10853G1 Interface Board
If the old CU-Board is dead, you have to replace the board without downloading the parameters before. After building in the new CU-Board the UPS needs to be adjusted again, for this you might take the downloaded parameter sets from the commissioning or a later service assignment of the UPS.
Replacement procedure: 1.) To replace the fans, please remove the screws of the fan grid
Figure 6-14:
Fan replacement 1
Figure 6-15:
Fan replacement 2
3.) Slowly lift up the fan grid and fan, disconnect the supply connector and remove fan. (The cable connections of the fan are not very long, therefore be careful not to rip or break the cable plugs.) Fan can now be replaced.
Figure 6-16:
Fan replacement 3
6.5.1
6.
7.
0 0
Parameter Number
1554
6.5.2
2.
3. 4. 5. 6.
Parameter Number
605
Access Level 3: URL, IBS
7
7.1
Parallel Systems
General
The 80-NET is connectable in parallel for multi-module systems (up to 8 units with same rating). The parallel connection improves reliability and/or the total output power. For the mentioned configuration a Parallel-Kit is needed, which is available as option, that could be added on at a later time. The option consists among other parts of one subassembly POB (Parallel Operation Board) and a shielded 25 conductor communication cables to the neighbouring UPS modules (closed loop ring bus). A parallel system is controlled and monitored automatically via the controller of the individual UPS blocks. These control is shared among the units (no master/slave architecture). The distribution of the load is divided equally between the individual UPS systems. This is achieved with a tolerance of less than 5% at any system load fraction (0 - 100%). The loop ring bus allow the parallel configuration to share the system load also with an interruption in the data cable (first failure proof system). When planning the system and during installation, power cables, having the same length, are to be used between the input distribution and the input terminals for the bypass and rectifier (U, V, W, - U1, V1, W1, N), as well as from the UPS outputs (U2, V2, W2, N) to the parallel connection point on the load side. Differences of 20% are allowed for power cable lengths of up to 20 m. For larger distances, cable lengths may not vary by more than 10%. Each UPS in the parallel system must have an input and output disconnector, to deenergise the UPS for maintenance work. Equally important is installation of a external manual bypass to switch off the UPSs without interrupting the mains supply for the load. It is advisable to include in planning, a connection for a test load, so that the system can be tested under (test) load. It is possible to increase the power of the system using a non-redundant parallel configuration. In this case all connected UPS units deliver the rated power and, in the event of a unit failure or overload, the system transfer the load to bypass. There are two types of parallel configuration: Distributed (n-times UPS + S.B.S. or just n-times UPS) mostly to increase power output; Centralized (n-times UPS + C.O.C.) mostly to enhance reliability not used on 80-NET!!!;
Figure 7-1:
Parallel UPS - Start Inverter To switch ON the inverters of the UPS in a parallel system, press and hold the inverter start button on each UPS control panel, one by one. With starting the last inverter, all the inverters in the system will switch ON and the load is supplied from the inverters. Until all the inverters have switched to ON, the process of turning on can be stopped by pressing and holding the inverter stop button on the control panel for a minimum of five seconds.
Parallel UPS - Normal operation - Stop inverter To switch off the inverters of the UPS in a parallel system, press, and hold, the inverter stop button on each UPS control panel, one by one. The inverter continues to supply the load until the last inverter stop button has been pressed for five seconds, then all the inverters in the system switch off and the load is transferred to the bypass supply. Until all the inverters have switched off and the load is transferred to the bypass, the process of turning off may be reset on any, or all, of the UPS, by pressing the inverter start button on the control panel for a minimum of five seconds.
And than connect also the interface X130 (POB) with the interface X140 (POB) of the NEXT unit. e.g. block 1 POB X130 block 2 POB X130 block n POB X130
Check if the PNU 95 is still set to value 0; this is done under Parameter Input Set Optional Modules.
Parameter Parameter name Number Description value range Factory Dimension setting 0-1 0
CU2 value
Access: Level 3 URL
0: 1:
No optional board or POB CB1 or CBP (Communication board via Profibus DP)
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 7 Parallel System 7.2 POB Connection
Figure 7-2:
A contact from the SBS needs to be connected to the EPO contact X8 of each UPS in the parallel configuration. In addition the parameter 93.1 Input Function Contact on the CU2 board of each UPS needs to be set to value 4 Manual bypass switch report and a second input contact PNU93.2 needs to be set to value 22 System output switch open. This must be done because the UPSs necessarily need to know if the QS5 is still closed, otherwise the inverters will not start if this would be the fact. The S.B.S. is available with the following data: Rating: Height (mm) Width (mm) Depth (mm) 1780 620 858 400A 1780 620 858 800A 1780 1020 858 1600A 1780 1020 858 2500A Depth including front door handle; without handle 830 mm;
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 7 Parallel System 7.3 S.B.S. (System Bypass Switch)
value 0: 1:
2. Close the external mains switches for each UPS. Close QS1 of each UPS. Load is still supplied via the SBS. Rectifiers are now running.
3. Verify if each UPS is recognising the POB; (PNU 129 value must be set to YES) If not check if the POB is fitted correctly, check cable connections; 4. Measure the DC-link voltage of each UPS respectively check the values in the display menu under Actual Values. Is it within tolerance? (nominal should be +/- 365Vdc)
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 7 Parallel System 7.5 Commissioning
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 7 Parallel System 7.5 Commissioning
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 7 Parallel System 7.5 Commissioning
11. Measure the output currents again. (per phase, per UPS) Current splitting should be equal for each UPS. 12. Turn ON the inverters again. Measure the output currents again. (per phase and UPS)
13. Check if the battery voltage on the UPS side of the battery switch QS9 is the same polarity as the battery voltage on the battery side of the switch QS9. (For each UPS) If ok, close QS9 of each UPS (Warning 13 disappears.) If a external battery switch is present: Close QS9 first! Measure the battery voltage polarity before and after the still open external battery switch. If ok, than close the external battery switch.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 7 Parallel System 7.5 Commissioning
132 Inverter Forced ON/OFF CU2 Inverter Stop or Inverter Start button, when this parameter is set
Access: Level 3 URL, IBS, PRU, BYP, BTR
This parameter allows the inverter to be switched on/off by the to 1. value 0: Forced switch ON/OFF not possible 1: Forced switch ON/OFF possible
1. 2. 3.
129 Parallel Operation CU2 parallel operation are satisfied (POB and connection cables in
place). value 0: No 1: Yes This parameter is used to determine whether the requirements for
Shutdown of the whole parallel distributed system 1. Press the inverter stop button on each UPS for at least 5 seconds; after the last button, all the inverters should shutdown; 2. Close QS5 (SBS); 3. Open QS6 (SBS); 4. Shutdown each UPS like a single unit; 5. Open all external switches, if not already done;
Frequency Converter
80-NET may be programmed for use as a frequency converter (50Hz in -60Hz out or 60Hz in -50Hz out), with or without a battery connected. The bypass input will be disabled and the warnings and faults, which are not appropriate for use of 80-NET as a Frequency Converter will be masked. The LCD cancels the bypass and battery symbol. In this operational mode, the data shown in the Technical Data Table may vary (e.g. output overload capability). Please contact Chloride Technical Support for details.
If the UPS will run on 60Hz, it is necessary to set the jumper JP1 on the Fan Speed Control Board (AP27, AP28, AP29) accordingly. JP1 50Hz No 60Hz Yes
Optional Equipment
Some of the options listed in this section may modify the data in the standard technical data tables (see chapter Specification). It may not be possible to use certain options simultaneously on the same UPS.
9.1
LIFE
In order to increase the overall reliability of the system, 80-NET will be delivered with the LIFE.net communication kit, providing connection to Chlorides LIFE.net monitoring service. LIFE.net allows the remote monitoring of the UPS through telephone lines or GSM link in order to ensure maximum reliability of the UPS throughout its operational life. The monitoring is a real 24-hour, 365 day service. The UPS is automatically dialling up the service center at defined intervals (by the customer) to provide detailed information that are analysed from the service center in order to predict near term problems. In addition, it is possible to control the UPS remotely, if this is selected. The communication of UPS data to the Chloride LIFE command center is transmitted via the integrated modem. There are 4 different kinds of UPS CALLs to the LIFE center (the received UPS information will be collected in a database and allocated to the corresponding UPS. And if needed acted upon. The database includes all information about the UPS and end-user data, e.g. like address, contact person and so on.): Routine Call: The UPS calls the LIFE center at predefined intervals and is transmitting the Event Storage. Manual Call: By pressing a combination of LCDisplay keys, a manual call is activated. This possibility allows the end-user to check a valid communication with the LIFE center and also to send UPS information whenever he likes to the LIFE center. Buffer Full Call: In case the Event Storage is full with not yet (to the LIFE center) delivered events, and new space is needed for more events, the UPS can call the LIFE center to drop these information of. Alarm Call: In case the events indicate a immediate attention of service staff, the UPS will call the LIFE center. LIFE center staff can log into the UPS and undertake necessary analysis as well as appropriate actions to correct the anomalous UPS function. During the call the command center shall: Identify the UPS connected Request the data stored in the UPS memory since the last connection Request real-time information from the UPS (selectable)
9.1 LIFE
Security is obeyed due to restrictions which allow only a user with valid PC hardware key, USER-ID and password to access data of the LIFE.net center respectively to send remote control commands to the UPS. It is also possible to parameterise the UPS, so that no remote control commands can be send to the UPS respectively will be accepted by the UPS. In case the end-user wishes to execute commands only on the LCDisplay of the UPS.
9.1.1
Whats important? A connection to the UPS via PPVIS (version > 1.7) is needed for a check of the LIFE settings and further detailed UPS information. The XS6 slot is internally connected with the X6 interface, due to this, no extra connection/cable is needed. The LIFE.net adapter is powered through the XS6 slot. A connection (telephone cable with RJ11 plug terminal) from the LIFE.net adapter to the telephone socket must be set up.
9.1 LIFE
Figure 9-1:
To check any LIFE settings, connect the notebook to service port X3 and start PPVIS. Check if the communication setup is correct: Menu SETUP COMMUNICATION; They should be Baud Rate = 9600, Parity = None and Port = COM1; press ok. Check the clock settings: Menu SETUP OPTIONS; On the tab General the question UPS Clock check? should be answered YES and the Maximum tolerable time should be set to 5 min. Switch on the UPS. Close and restart PPVIS. Open the Control Panel of the UPS and check if a message Correct the UPS clock? appears, confirm with YES. Check if COM1 is setup for LIFE.net via the parameter menu Parameter Input Service Commissioning (SET field) Look for the parameters: a) Baud rate X6 Modem/Multi RS232 684.1 9600 Baud b) Ser. Protocol X6 Modem/Multi RS232 688 LIFE c) Bus address X6 Modem/Multi RS232 683.1 0 (for single UPS) d) Parity Settings X6 Modem/Multi RS232 690 No Parity (For parallel UPSs, the bus address of the 1. UPS is 0, of the 2. UPS is 1, of the 3. UPS is 2 and so on) If necessary change the parameters to the mentioned values and switch the UPS OFF and then ON again. (While changing the parameters, UPS must be in bypass mode; return to normal operation after switching the UPS on again.) Disable the serial communication between LCD and CU-Board; (PNU 53 Enable parameterisation on CU2 and PNU 1077 on CU1; set to serial 1 + serial 2) Because both, LCD and PPVIS, access the same LIFE data, it is necessary to disable the serial communication between LCD and CU-Board to avoid unexpected LIFE settings throughout LIFE configuration and monitoring. (Note: - Do not switch off the UPS while the LCD communication with the CU-Board is disabled. - The message CU communication lost will appear on the LCD.)
10H52167TM01 (IDSS/Andrea Weigert) Chapter: 9 Optional Equipment Rev. 2.0 10.May.2007 Page 240/ 307 printed: 15.05.2007, 13:09
9.1 LIFE
9.1 LIFE
Figure 9-2:
9.1 LIFE
Figure 9-3:
General notes: The CAT5 cable may be up to 100m long On a MUX board, the yellow LED illuminates ONLY if there is a valid INPUT signal from another MUX board The CAT5 cable also carries the power supply; this means, as long as one UPS is still ON (in parallel systems) this MUX board is able to communicate with the LIFE center. The UPS clock is handled by the LIFE center server and therefore the UPS date and time will be synchronised with the LIFE center server and can hence be different from the PC clock were PPVIS is started. The execution of several actions can take several seconds. E.g. modifying the next call date, reset delayed call
9.1 LIFE
Malfunction
No calls initiated by The number of the LIFE Call the LIFE center with a analogue telephone the UPS center is unavailable via the same line the UPS should use. Is the number correct? Is a prefix needed? Are dialling pauses needed (use comma for each 2 second pause)? Modem is switched off Switch the modem on Incorrect LIFE center Check whether the correct prefix and telephone number inserted number including dialling pauses (commas) is inserted in the LIFE.net configuration of PPVIS. The UPS calls the The LIFE center does not Check if the serial number of the UPS and the LIFE center but recognise the UPS one registered at the LIFE center is the same. does not transfer The LIFE.net data (in Set the timekeeper ahead by one second in data PPVIS) memorised by the order to reset the LIFE.net events; the UPS should switch to service mode automatically; UPS are corrupt Deactivate the service mode and repeat the data transfer test. Interference on the To decrease interference, coil the telephone telephone line connecting cable in a toroid with at least 10 turns. The UPS does not LIFE.net time is not To resynchronise the LIFE.net clock with the initiate routine calls synchronised with the time timekeeper it is necessary to reset LIFE.net completely; press the Reset LIFE.net button in of the timekeeper the LIFE.net configuration and than reconfigure LIFE.net. The UPS does not The UPS is not configured Ensure that the UPS is configured to receive respond to calls to receive calls calls; (PPVIS LIFE.net configuration: Answer initiated by the LIFE enabled) center The telephone line is shared Ensure that other user, which may be connected with other users in parallel with the UPS telephone line, do not respond to calls from the LIFE center. The UPS may be busy Wait 10 seconds, then repeat the call from the programming the modem LIFE center. The UPS may be in some Wait 2 minutes, then repeat the call from the other not connected state LIFE center. communication Make sure the parameter 53 Enable The LIFE settings The displayed on PPVIS between LCD and CU-Board Parameterisation (included in set Service Commissioning) is set to 3. do not match the has not been disabled operator input OR the LIFE settings reading in PPVIS are extremely slow
9.1 LIFE
CU2 Value:
i01: i03: i04: i05: Interface 1 (X3, X5) Interface 2 (X2) Interface to the rectifier (RS485) CAN interface
300 bauds 600 bauds 1200 bauds 2400 bauds 4800 bauds 9600 bauds 19200 bauds 38400 bauds value range Factory Dimension setting 0-2 2
CU2 2);
Caution: Re-parameterisation requires resetting the CU-board! *Switching between these two protocols is possible during normal UPS operation. Starting point is the protocol in the EEPROM. A change is possible for RAM only or RAM and EEPROM. Value: 0: 1: 2:
9.1
53 Enabling Parameterisation
Authorises the source from where parameterisation can be carried
CU2 out.
value i0: i1: i2: i3: i33: i34: i35: i129: i130: i131: i161: i162: i163: Non Serial 1 (X3+X5) Serial 2 (X2) Serial 1 (X3+X5) + serial 2 (X2) Serial 1 (X3+X5) + Profibus Serial 2 (X2) + Profibus Serial 1 (X3+X5) + serial 2 (X2) + Profibus Serial 1 (X3+X5) + CAN Serial 2 (X2) + CAN Serial 1 (X3+X5) + serial 2 (X2) + CAN Serial 1 (X3+X5) + Profibus + CAN Serial 2 (X2) + Profibus + CAN Serial 1 (X3+X5) + serial 2 (X2) + Profibus + CAN
CU1 out.
value Bit 0: Bit 1: Bit 2: Bit 3: Bit 4: Bit 5: Bit 6: Bit 7: Serial 1 (X3+X5) Serial 2 (X2) Reserved (PMU) Reserved (SCB) Reserved (PTX) Profibus Serial 3 (Inverter CU2) CAN
9.1
9.2.1
Hardware installation internal MUN: 1. Put the internal adapter into XS3 or alternatively into XS6, but remember to change the protocol language to USS. Install screws to secure ManageUPS ESD grounding (earth shielding) connection to UPS chassis. Configuration: A. Connect the network with a shielded cable (Cat 5) to the 10/100Base-T connector of the MUN adapter. Two flashing lights can be seen (orange = connection; green = data-flow) (if not, check cabling and power supply) B. Configuring Network settings: If your network does not have a BootP server, use the serial configuration cable (CA-2A00S-02) to connect a PC/terminal (9600,8,N,1 send Line Ends with Line Feed), to ManageUPS Terminal Port (TERM) to configure network and other settings. Type CONSOLE to access the configuration menu. See your ManageUPS user documentation for further details . Default username = admin Default password = admin OR A. Connect the network with a shielded cable (Cat. 5) to the 10/100Base-T connector of the MUN adapter. Two flashing lights can be seen (orange = connection; green = data-flow) (if not, check cabling and power supply) B. Install the included DCU software either from the CD or download it from the Chloride connectivity webpage for a comfortable configuration over the network. C. Start the DCU software and configure the new found MUN adapters via that software. See also the following chapter. More details can be found in the installation manual, application note or user manual. Note: external MUN If your are using both MopUPS shutdown software and ManageUPS NET Adapter II, connect the ManageUPS UPS Port to RS232 port on the UPS. Connect the MopUPS computer serial port to the Terminal Port on ManageUPS for serial communication. For network communications choose MOPNET communications option when installing MopUPS. Note: internal MUN For network communications choose MOPNET communications option when installing MopUPS.
Figure 9-4:
2.
The serial number of the MUN adapter can also be seen. This helps to identify the correct adapter, while installing more than one adapter. (Serial number can also be found on a sticker on the adapter.) Click on the adapter you want to configure. Normally you should receive the following picture:
Figure 9-5:
DCU is trying to access the DHCP assigned IP address of the MUN adapter. The IP address can be seen in the left bottom corner. The default username and password are both admin.
Figure 9-6:
3.
As the access you have from your local computer is limited due to TCP/IP regulations, there might be the need of changing the address of your computer for initial setup. - Please make a click with the right mouse button onto the Network Surroundings symbol on your desktop and got to properties - Please make a click with the right mouse button on the LAN Connection and go to properties - Please click on the Internet Protocol (TCP/IP) and than on the button Properties - Please click on Use the following IP address and type in a free IP address from range that can be accessed by the adapter - Press OK, OK, OK you should be back at the beginning Please change back to DCU and try to access the adapter again. Enter admin / admin for login and password. The first access over the adapter to the UPS may need some time. The following screen must appear.
Figure 9-7:
4.
The MUN adapter can be configured now. Details can be found in the user manual.
9.2.3
Environmental Sensor
The environment sensor can be purchased together with a ManageUPS NET Adapter II. This bundle ManageUPS II + E includes a ManageUPS NET Adapter II, a auxiliary BLUE BUS connector, 1 environment sensor module and 5 meter BLUE BUS cable.
Figure 9-8:
Environmental Sensor
Environment monitoring sensor provides: Temperature Humidity 3 input signals (volt free relay contacts) 1 output signal control relay (30V / 1A) Environment Monitoring - benefits Early Warning System: Detection of environment conditions that can lead to equipment failure and downtime if left uncorrected; Sending of notifications via email and/or SNMP trap to the appropriate destination; Flexibility: Three (3) input contact sensors provide for monitoring of volt-free contact status indicators provided on 3rd party devices. (Example, room or enclosure door sensors, IR sensors, water sensors, process control sensors etc. ) One (1) output relay can be used to switch warning lights, audible horns or other signal control functions. The environment sensor can be extended by connecting up to 15 further sensors in serial. To add more sensor modules or other BLUE BUS accessories, connect the BLUE BUS OUT to the BLUE BUS IN of the next module. Set a BLUE BUS address between 32-47 using dip switches 2-5 on the side of the sensor. Dip 1 is Terminator for last module on the bus.
9.3
Software
There are different versions of software tools available for shutdown, messaging, monitoring and configuration: MopUPS Professional MopUPS P/R for Parallel/Redundant System MopUPS NSA (Network Shutdown Agent) RCCMD (Network Shutdown Agent) ManageUPS CIO ManageUPS DCU
Figure 9-9:
Definitions: A system is normally composed of one or more UPS, whom act in the same way (together) upon events. According to this, if e.g. two single units on site are instructed to react differently in case of the same event or e.g. supply different sections of the customer load, they would count as two systems, because they do not work together.
A server (host) is a computer system that provides services to other computing systems called clientsover a network. In our application it is used to operate the main software for monitoring, messaging and shutdown. (That would be MopUPS Professional and MopUPS P/R.) A client is a computer system that accesses other (remote) services on another computer (server) over the network. In our application, this will be the computers on which MopUPS NSA or RCCMD will be installed. These two software tools will shutdown the computers whom they are installed on, on request of the server.
For installation and setup of MopUPS Professional and MopUPS P/R, please refer to the Users Guide and Reference.
Before starting to install MopUPS, you should prepare some data among others: License Key shipped with the CD or sent via email. IP address of each ManageUPS NET Adapter on your network each UPS module monitored by MopUPS will be represented by a ManageUPS NET Adapter. Name of the SMTP server on your network - for email alert messaging functions. Email address who should receive an email alert. Phone number and PIN number of the intended pager recipients for pager alert. Correct spelling of the network names of the computers targeted for remote shutdown and also when to shutdown for enabling network shutdown functions. UPS information (output power, battery autonomy, redundancy, and so on)
Messaging Management Shutdown Local Shutdown Remote Shutdown via MopNSA Remote Shutdown via RCCMD Parallel UPS / multiple UPSs Single UPS Serial Connection Network Connection Windows Unix Linux Novell
MopUPS Professional Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes
MopUPS ManageU ManageUPS MopNSA P/R PS CIO II /II+E Yes Yes Yes Yes Yes Yes Yes No Yes Yes No Yes Yes Yes Yes No Yes Yes Yes Yes No No No Yes Yes No Yes Yes No No No Yes Yes No Yes No Yes No No No No Yes Yes Yes Yes
All events are logged in the event log file and messaged to the host administrator. Any event can become a Trigger for an event response. The event response controller manages default and user-determined event response actions. Event response settings can be viewed and configured from the Event Settings tab (System Level View).
ManageUPS CIO: Monitors all agents Displays all current alarms (client) Network navigation to all agents Central event archive & report HLM (higher lever manager) integration module
Infrastructure Management Tool Monitor UPS and related premise infrastructure devices via TCP/IP network Centralize alarm management for many devices many buildings many sites Streamline asset management tasks with standard reports of current status and activity history Simplify integration with higher-order management systems via Open protocols Software Application Windows 2000/XP Monitors all Chloride UPS over ethernet via Chloride protocol Monitors other devices via SNMP Auto-discover and network search functions simplify configuration and set-up tasks Easy organization of UPS inventory via drag and drop folders & smart folders Display UPS inventory via list-tree view (folders) and Map view custom maps / blueprints / floor plan drawings / photos - imported as JPG files
Rev. 2.0 10.May.2007 Page 260/ 307 printed: 15.05.2007, 13:09
9.3.4
9.3.4.1
A
XS3
B
XS3
C
XS6 not available
D
XS3 and XS6 not available
X3 Application on (also available when Serial Interface 1 ManageUPS Card (e.g. MopUPS) fitted in XS3) X6 Application on (not available when Serial Interface 2 Slot Modem/MUX (e.g. MopUPS) fitted in XS6) Profibus AS400 CU-Board Box X7
USS
available
available
available
available
available
available
available
yes yes
yes yes
yes yes
Legend
1 2 3 4 5 6 7 LED for System normal LED for UPS alarm LED for Shutdown imminent LED for Mains failure LED for Load on bypass Free Button for LED test 8 9 Button Alarm mute LED indication of: ON OFF Acoustic alarm off Brand name
10
Remote alarm unit indication Indication LED Single system colour System normal Green Load supplied by inverter UPS alarm Red Alarm status Shutdown Red Battery at end of autonomy imminent Mains failure Red Primary mains failure or outside limits
Parallel system Load supplied by the UPS Alarm status At least one UPS has battery at end of autonomy At least one UPS has primary mains failed or outside limits, or the UPS stopped Load supplied by bypass
Load on bypass
Red
9.7.1
Fuses Fuses
Figure 9-22:
Factory setting
Offset compensation tuning The parameter PNU 67.1 has been designed to compensate the phase error between the bypass input and the inverter output signal. The value to be inserted to compensate the error is calculated applying one of the following formula: HEX input: PNU 67.1 [hex] = phase-error [] * 0x10000 / 360 (0x10000 is 10000 in Hex format.) Decimal input: PNU 67.1 [dec] = phase-error [] * 65536 / 360 To carry out the procedure it is necessary to use an oscilloscope between bypass input and inverter output.
For a trouble-free communication it is necessary to carry out the following: cable must be twisted and shielded (e.g. 24AWG wire); transmission line must be terminated with a 120 Ohm resistance; the terminations should be located at the two extremes, or most distant points, of the line; shield shall be connected to the connector chassis at one end of cable only;
9.8 JBUS
The JBUS protocol enables the master unit to communicate with the slave units (connected in the network). Communication is always initiated by the master, he is sending a request frame to which only the addressed slave will reply. The master can read or write one or more bits or words within the address range of the devices. (JBUS is supporting only N-word commands (command 3) and RTU (Remote Terminal Unit) mode but no ASCII mode. Characteristics:
Baud rate 9600 (settable) Data length 8 Parity None Terminal emulation VT-100 Start bit Stop bit Flow control 1 1 None
On the MULTICOM JBUS adapter you will find 4 interfaces, COM1, COM2, COM3 and COM4 with the following signals: Pin Signal Explanation
1 2 3 4 5 6 7 8 9 DCD RX TX DTR GND DSR RTS CTS RI Carrier detect Receive data Transmit data Data terminal Digital ground Data set ready Request to send Clear to send Ring indicator
The serial cable connected to each serial port should not be longer than 10 meters.
9.8 JBUS
Connect the power supply cable and switch the adapter ON using the switch present at the rear panel. Connect a PC with a serial RS232 cable to COM4 of the adapter. Use HYPERTERMINAL on your PC to configure the F5 serial parameters of the adapter: UPS type UPS address (must match the address set in the UPS) JBUS address (must match the JBUS slave address assigned by the JBUS master) UPS * COM1 baud rate (must match the baud rate set in the UPS normally 9600) UPS * COM2 baud rate (must match the baud rate defined by the JBUS master normally 9600) Connect the RS232/RS485 converter via the serial cable to the COM2 of the adapter. Connect the COM1 of the JBUS adapter via serial cable to COM port X3 of the UPS. Verify if the UPS is turned ON. Verify with PPVIS if X3 is using the USS protocol. Verify if the BUS address of the USS protocol is available at X3. Verify if the same BUS address is entered into the JBUS adapter. Verify with the terminal emulation software if the JBUS adapter and the UPS are regularly communicating.
9.8 JBUS
9.8 JBUS
9.9.1
Installation
Please be aware of the safety instruction given in this manual before installing the Profibus. The Profibus is only communicating with the CU2-Board (inverter), therefore it must be installed in that electronic box. The 80-NET must be switched off. Open the front cover to access the electronic box. Put the smaller Profibus CBP2 card onto the adapter card. (The position of the card upper or lower mounting place has no preference.) There are 3 slots in the electronic box of the CU2-Board (inverter): SLOT1 is the LEFT slot and is reserved for the CU-board. SLOT2 is the RIGHT slot and can be used for the POB or Profibus interface card CBP2. SLOT3 is the MIDDLE slot and is only used for the Profibus interface card CBP2 when slot2 is used for POB. (If not already installed, the inverter electronic box must be equipped with the included back plane to allow communication between the installed optional boards. for details please refer to the installation manual of the Profibus.) Connect your notebook to the service port X3 and start PPVIS. It is necessary to set parameters to make the CU-board recognize the Profibus card. Select the SET Optional Module under Parameter Input. Switch to access level Experts and function selection H/W init Depending on the slot where you installed the Profibus card, change the settings of Module on Place 2 or Module on Place 3 from no module [or POB] (0) to CB1 or CBP (1). With the fields Profibus PZD5 PDZ9 content you can change/choose customer specified settings. Switch to access level Return and function selection Normal operation Make a power reset. The three LED on the front of the Profibus interface card CBP2 indicate the status of the board.
9.9 Profibus
Whats important? During normal operation, all 3 LEDs repeatedly flash at the same time for the same length of time. If this is not the case, there is an exceptional condition. Please refer to the troubleshooting section of this chapter. When the UPS is parameterised correctly, then the red and yellow LED are blinking simultaneously. If only the Red is blinking, then the UPS is not correctly configured.
Parameter Parameter name Number Description value range Factory Dimension setting 0 - 23
1 2 3 4 5
NO Value V Mains L1 [V] V Mains L2 [V] V Mains L3 [V] V intermediate circuit [V] V Output L1 [V] V Output L2 [V] V Output L3 [V] I Output L1 [0,1 A] I Output L2 [0,1 A] I Output L3 [0,1 A] Frequency Output [0,1 Hz] Frequency Mains [0,1 Hz] Output real power L1 [0,1 kW] Output real power L2 [0,1 kW] Output real power L3 [0,1 kW] Output real power total [0,1 kW] Output apparent power L1 [0,1 kVA] Output apparent power L2 [0,1 kVA] Output apparent power L3 [0,1 kVA] Output apparent power total [0,1 kVA] Batt. Hold-up time [s] Batt. Current [0,1 A] V Batt./Cell [0,01 V]
9.9 Profibus
Check/Action
correctly Parameterise the UPS; Go back to the installation chapter and change the set Optional Module from Parameter Input accordingly; Red LED is Off or No voltage supply for CBP Replace the CBP or back plane board On present; Yellow LED is Off or Data exchange with the Check the parameterisation; On UPS is not possible; Replace the CBP or back plane board Green LED is Off or Transfer of useful data via Profibus cable not connected; On Profibus is not possible; Profibus master is not initialised; Nothing happens Change the slot; Wrong slot If you do not use a POB board, the slot for the Profibus must be SLOT2 (right one);
9.9 Profibus
9.11
Dust filters
This option improves the air inlet protection level from IP20 to IP40 for specific applications such as dusty environments. The filter is housed in the UPS cubicle (IP20).
10
List of Components
This list will not be updated!!! Please check the partner web site for the newest version.
Material description
Function
kVA rating
Drawing number
Item code
451909988311
200
1 1 1 1 1 1 1 1 1 1 3 1 3
RE CU-Board (CUX) IN RE Interface board IN SMPS board Supply Interface board Bypass Control board LCDisplay Connectivity board In/Out board RE CB IGBT Driver board IN RE CB IN RE CB IN RE IGBT Interface board CB IN RE CB IN
AP1, AP2 AP3, AP4 AP5 AP6 AP7 AP8 AP9 AP10 AP11-AP13, AP14, AP15-AP17
60/80:
AP19-21, AP22-23, AP24-26 100/120: AP19-21, AP40-42 AP22-23, AP43 AP24-26, AP44-46 160: AP19-21, AP40-42 15H70842 AP22-23, AP43,47 AP24-26, AP44-46 200: AP19-21, AP40-42, AP48-50 AP22-23, AP43,47, AP24-26, AP44-46, AP51-53
60/80: 100/120: 160: 200:
15B10857G1
6 4 6 9 4 9 2
Fan Speed Control board I B Filter board RFI O I Varistor board B DC Modem LIFE.NET RE IN VT1 CB RE CB IN CB RE IN VT2 RE CB IN BY V2 BY V2 BY V2 130A 1600V SCR 160A 1600V SCR 250A 1600V SCR 300A 1200V IGBT
15H70845
15B10855G1 1 1 1 1 1 1
3 4 5 1 1 1 1 1 1 6 6 4 3 2 3 3 1 1 1 1 1 1 1 1 1 1 1 1
15H70849 15B70681
10B44112P3412
V1-V3, V4, V4', V9-V11, 100/120: V4, V4', V4'' 160: V1-V3, V1'-V3', V9-11, V9'-V11' 200: V1-V3, V1'-V3', V1V3 V4,V4 V4,V4 V9-11, V9'-V11', V9-V11 V5, V6, V7 V5, V6, V7 V5, V6, V7
10B44112P4312
6 6 9 4 9
3 3 3 3
This list will not be updated!!! Please check the partner web site for the newest version.
Material description
Function
KVA rating
Drawing number
Item code
10B42052P04
200
22
C6,C7 C1-C3, C1-C3,, C4-C5, C4-C5, C8-C10, C8-C10 100/120: C1-C3,C1-C3,C1C3, C4-C5,C4-C5,C4C5, C8-C10,C8-C10, C8-C10 160: C1-C3,C1-C3, C1C3, C1-C3, C4-C5,C4-C5, C4C5,C4-C5, C8-C10, C8-C10, C8-C10,C8C10 200: C1-C3, C1-C3, C1-C3, C1-C3, C1-C3, C4-C5, C4-C5, C4-C5, C4-C5, C4-C5, C8-C10, C8-C10, C8-C10, C8C10, C8-C10
60/80:
10H42088P01 12 15 10 15
C11,C12,C13 C21-C23, C24-C26, C27-C29, C32 C30, C31 100/120: C27, C30, C31 160: C27, C30,C31,C40-C41 C20,C33-C35 C36-C39 200: C27, C30,C31,C40-C41 C20,C33-C35 C36-C39
60/80:
00B42004P0219
3 3 3 4 2
2000Vdc
C 330nF 1200Vdc polypropyl. QS3 125A QS1, QS2, QS3, QS4 QS1, QS2, QS3, QS4 QS1, QS2, QS3, QS4 QS9, QS14 100/120: QS14 160: QS14
60/80: 100/120: QS9 200: QS14
10B46426P13C
10B46426P07C
10B46426P59C
10B46426P54C
Y QS4 Y QS4
160A 200A
QS9
This list will not be updated!!! Please check the partner web site for the newest version.
Material description
Cont. Aux (NO)
Function
KVA rating
Drawing number
Item code
10B48317P66
200
3 1
I I
KM5 KM3
KM3
60/80: 100/120: 160: 200: 60/80: 100/120: 160: 200:
10B48317P71 KM1 KM1, KM1' KM1, KM1' KM1,KM1',KM1 EV1,EV2 EV1-EV3 EV1-EV4 EV1-EV5 10B48317P72
EV1
230V 200W 1520R 50-60Hz 200A 500V Extra Quick Blow 250A 500V Extra Quick Blow 350A 500V Extra Quick Blow 500A 500V Extra Quick Blow 250A 700V Extra Quick Blow 400A 700V Extra Quick Blow 500A 700V Extra Quick Blow 800A 700V Extra Quick Blow 2A 500V Slow Blow 6.3x32
10B48250P2 3 3
3 4 5
I FU O I FU O I FU O I FU O B B B B FU FU FU FU
FU1-FU3 FU4-FU6 FU1-FU3 FU4-FU6 FU1-FU3 FU4-FU6 FU1-FU3 FU4-FU6 FU7, FU8 FU7, FU8 FU7, FU8 FU7, FU8
60/80: 100/120: 160: 200: 60/80: 100/120: 160: 200:
3 3 3 3 3 3 2 2 2 2 7 9
FU
Q1, Q4-Q9 Q1, Q1', Q4-Q10 Q1, Q1', Q4-Q11 Q1, Q1', Q1, Q4-Q12 for Q8, Q9, Q1 for Q8-Q10 for Q8-Q11 for Q8-Q11
10B46209P05R
10 3 9 3
Fuse Holder 6.3x32 switchable Fuse Holder 6.3x32 tube plug I O TA B I O TA B I TA Y O I TA Y O I Y TA O 200A/200mA
5 6 8 4 4 4
for Q4-Q7 TA1-TA3, TA12-TA14, TA15-TA17 TA1-TA3, TA12-TA14, TA15-TA17 TA4-TA6 TA7, TA9-TA11 100/120: TA4-TA6, TA7, TA9-TA11
60/80:
600A/200mA 200Adc
3 3 3
3 3 3
3 3 3
200Adc
3 1 3 3 1 3 3 1 3
400Adc
10B48279P13
This list will not be updated!!! Please check the partner web site for the newest version.
Material description
Function
KVA rating 60/80:
Drawing number
Item code
I O L1 I O I L1 O DC L1 DC L1 DC L1 DC L1 I
250H
120A
160:
10H48572P01
L1-L3, L6-L8
60/80: 160:
10H48572P02 L4 L4, L4 10H48573P01 10H48573P02 10H48572P03 10H48573P03 10H46738P02 10H40037 10H40037P01 10H46746PC1 10H48581P9008 10H48581P9012 451909987000
L4 L1-L3, L1-L3 L6-L8, L6-L8 L4, L4 ST1 R1, R2 OPTION dust filter OPTION input choke OPTION input choke OPTION parallel system
ST 2k NTC R 8R2 125W 10% Mat. Filt. General Filter A30 L3 ca. 0,3mH 125A L3 ca. 0,2mH 180A POB
I = Mains Input B = Bypass Input O = Output (after Inverter and Bypass) Y = Battery (between DC-Link and battery input contacts
11
Circuit Diagrams
All relevant circuit diagrams were put into a separate document for easier handling concerning updates and file-size. The document is called Technical Manual 80-NET Circuit Diagrams and the document number is 10H52167TM01_CD.
You will find the following schematic diagrams in that separate manual: (drawing no. 10H72802) Interconnection of Boards Precharge Circuit / Input Filter Battery Converter and Output Inverter Fan Control Circuit Signals Precharge Circuit / Input Filter (120kVA only) Rectifier (120kVA only) Battery Converter (120kVA only) Inverter (120kVA only) Output Filter (120kVA only) Fan Control Circuit (120kVA only) Details X and Y Precharge Circuit / Input Filter (160kVA only) Rectifier (160kVA only) Battery Converter (160kVA and 200kVA) Inverter (160kVA only) Output Filter (160kVA only) Fan Control Circuit (160kVA only) Precharge Circuit / Input Filter (200kVA only) Rectifier (200kVA only) Inverter (200kVA only) Output Filter (200kVA only) Fan Control Circuit (200kVA only) For schematic diagram variations because of options, please refer to: Input Choke Option Parallel Option
12
12.1
Appendices
Checklists
The different mentioned checklists and their explanation within this manual were collected and put into a separate document for easier handling concerning updates and file-size. The document is called Technical Manual 80-NET Checklists and the document number is 10H52167TM01_CL.
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 12 Appendices 12.3 List of Parameters
10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Chapter: 12 Appendices 12.4 List of Abbreviations
Electronic Bypass
Qualified Personal
PLL
DHCP
2
2-Stage Charging With Charging Pause ...................... 88, 139 2-Stage Charging Without Charging Pause ................. 89, 139
A
AC CT..................................................... 82, 99, 184, 196, 199 AC Reading Circuits Current ................................................ 64 AC Reading Circuits Voltage ................................................ 64 Accumulators NiCd......................................................................... 93, 140 Sealed, Low-maintenance Lead Acid ...................... 93, 140 Sealed, Maintenance-free Lead Acid ...................... 93, 139 Adaptor RS232/RS485 ....................................................... 275 Advanced Battery Care ................................................ 94, 297 AIF 219 108 15B10853G1 Interface Board........................ 65, 219 Air Inlet Protection Level..................................................... 282 Ambient Temperature Channel ............................................ 62 AP1 CU1 Rectifier .. 36, 42, 48, 54, 60, 62, 79, 84, 120, 159, 285 AP10 In/Out Board . 38, 44, 50, 56, 60, 62, 69, 73, 107, 118, 119, 120, 122, 125, 126, 128, 159, 285 AP11-AP17 IGBT Driver Board .. 35, 41, 47, 53, 74, 79, 189, 194, 285 AP19-AP26 IGBT Interface Board..... 34, 40, 46, 75, 79, 285 AP19-AP26, AP40-AP53 IGBT Interface Board................ 52 AP2 CU2 Inverter ................ 36, 42, 48, 54, 60, 62, 155, 285 AP27-AP28 (AP29) Fan Speed Control Board..... 36, 42, 48, 54, 76, 191, 285 AP3 Interface Board Rectifier . 36, 42, 48, 54, 60, 64, 65, 69, 75, 79, 82, 173, 182, 183, 185, 187, 193, 285 AP31-AP33 Filter Board .......................... 37, 43, 49, 77, 285 AP31-AP33 RFI Filter Board ............................................. 55 AP35 Filter Board .............................................................. 77 AP36-AP37 Varistor Board................ 37, 43, 49, 55, 77, 285 AP38 DC Modem LIFE.NET.................... 38, 44, 50, 56, 285 AP4 Interface Board Inverter .. 36, 42, 48, 54, 62, 64, 65, 75, 173, 182, 186, 187, 188, 190, 191, 192, 195, 285 AP40-AP46 IGBT Interface Board............................... 40, 46 AP5 SMPS................................... 34, 40, 46, 52, 64, 66, 285 AP6 Supply Interface Board ........ 34, 40, 46, 52, 69, 84, 285 AP7 Bypass Control Board....... 34, 40, 46, 52, 70, 106, 174, 189, 191, 285 AP8 LCDisplay .................................................... 62, 71, 285 AP9 Connectivity Board .............. 38, 44, 50, 56, 69, 72, 285 AS400................................................. 107, 112, 114, 121, 265 Asynchronous Transfer (PNU 0115) .................................. 104 Automatic Battery Test (PNU 1438) ............................. 94, 145 Automatic Battery Test (PNU 1438.2) ................................ 145
B
Backfeed............................................... 65, 104, 106, 124, 189 Current Detector .............................................................. 65 Load Capacitor .............................................................. 106 Protection ...................................... 104, 107, 118, 190, 210
C
C.O.C.................................................................................. 226 C16X Flasher...................................................................... 157 C1-C3 Input Filter Capacitors .................................... 82, 194 Cell Number (PNU 1629) ............................................. 95, 135 Charge Mode (Buck Mode) ............................................ 87, 92 Charge Principle ................................................................. 139 Charger/Booster .............................................. see Booster/Charger Charging Method (PNU 1617) ...................................... 89, 139 Charging Pause Duration (PNU 1547) ............................... 141 Circuit Diagrams ................................................................. 289 Client .................................................................................. 253 Commands Disabled ............................................................ 30 Commissioning ................................................................... 171 Communicate with CU........................................................ 110 Connectivity Board AP9 .....................see AP9 Connectivity Board Control of Overload Reaction (PNU 567) ............................. 26 Converter Temperature Threshold (PNU 1174) ................... 82 Crystal Oscillator ................................................................ 270 CU Board.............................................. 36, 42, 48, 54, 58, 285 CU1 Rectifier AP1 ..................................see AP1 CU1 Rectifier CU2 Inverter AP2 ................................... see AP2 CU2 Inverter Current V2 V1 (PNU 1625) ............................................ 142 Current-Walk-In .................................................................... 86 Current-Walk-In Time (PNU 1166) ....................................... 86
D
DC CT..................................................................... 82, 99, 183 DC Modem LIFE.NET AP38....... see AP38 DC Modem LIFE.NET DC-Link Calibration ..................................................................... 213 Voltage .......................................................................... 213 DC-Offset............................................................................ 214 DCU Software.............................................. see ManageUPS DCU Delta Shutdown Imminent (PNU 0591) .............................. 148 DHCP Network Configuration............................................. 247 Diesel Generator .................................................................. 80 Digital Interactive Mode (DIM) ................................ 21, 25, 103 Battery ............................................................................. 26 Emergency ...................................................................... 26 Inverter Stop .................................................................... 25 Overload .......................................................................... 25 Digital Signal Processor ........................................... 28, 58, 96 Diode .................................................................................... 78 DIP Switch SW1................................................................................. 71 SW1.1.................................................................... 162, 168 SW1.2.................................................................... 162, 168 SW1.3.................................................................... 162, 168 Disabled Battery Calculation .............................................. 131 Discovery and Configuration Utility .................................... 264 Display................................................................................ 298 Not Present.................................................................... 200 Double Conversion Mode (DCM) ................................... 21, 24 Emergency ...................................................................... 24 Overload .......................................................................... 24 Recharge ......................................................................... 24 Dynamic Line Support ........................................................ 298 Rev. 2.0 10.May.2007 Page 300/ 307 printed: 15.05.2007, 13:09
F
Fan Control........................................................................... 65 Fan Replacement ............................................................... 221 Fan Speed Control Board AP27-AP28 (AP29)..... see AP27-AP28 (AP29) Fan Speed Control Board Fans (High Speed) ............................................................. 130 Fast off (PNU 0058)............................................................ 121 Fault.......................................................... 22, 29, 31, 150, 181 033................................................................................. 188 034................................................................................. 188 035................................................................................. 188 036................................................................................. 188 037................................................................................. 188 039................................................................................. 189 040................................................................................. 189 041................................................................................. 189 042................................................................................. 189 043................................................................................. 189 044................................................................................. 189 045................................................................................. 189 046................................................................................. 190 047......................................................................... 190, 196 048................................................................................. 190 049................................................................................. 190 050................................................................................. 190 051................................................................................. 191 052........................................................................... 25, 191 053................................................................................. 191 054................................................................................. 191 055................................................................................. 191 056................................................................................. 191 057................................................................................. 191 058................................................................................. 191 059................................................................................. 191 060................................................................................. 192 061................................................................. 192, 235, 236 062................................................................................. 192 072................................................................................. 192
G
GSM Link............................................................................ 238 GUI ............................................................................. 254, 258 Guided Procedure .............................................................. 172
H
Half UDC Link Minimal Voltage (PNU 1159) ........................ 85 Heat-Conductive Paste ...................................................... 208 Hitachi Flash Development Toolkit..................................... 163 Hold-off Delay Rectifier Start ................................................ 86 HYPERTERMINAL (JBUS) ................................................ 277
I
IGBT ............................................................... 78, 79, 206, 208 Changing ....................................................................... 208 Converter......................................................................... 21 ESD Handling Instructions ............................................ 208 Examination................................................................... 206 IGBT Driver Board AP11-AP17 see AP11-AP17 IGBT Driver Board IGBT Interface Board AP19-AP26...................... see AP19-AP26 IGBT Interface Board AP19-AP26, AP40-AP53 .....see AP19-AP26, AP40-AP46 IGBT Interface Board AP40-AP46 see AP40-AP46 IGBT Interface Board, see AP40-AP46 IGBT Interface Board Imminent Shutdown.................................................... 147, 197 In/Out Board AP10 .................................. see AP10 In/Out Board Initial Charging.................................................................... 143 Input Contacts .................................................................... 118
M
Mains Contactor KM1 ...........................see KM1 Mains Contactor Mains Failure Statistics (PNU 1584) .................................. 178 Mains Failure Warning Delay (PNU 0110) ......................... 129 Mains Frequency (PNU 0072) ............................................ 100 Maintenance ......................................................... 27, 176, 177 Bypass Mode................................................................... 23 Bypass Switch QS3 ............ see QS3 - Maintenance Bypass Switch ManageUPS ............................................................... 107, 110 CIO ................................................................ 253, 255, 260 DCU............................................................... 248, 253, 264 NET Adapter II............... 247, 252, 255, 257, 258, 262, 264 ManageUPS NET Adapter II .............................................. 265 Max. Charge Current (PNU 1554) ..................................... 141 Max. Charge Current (PNU 1554) ...................................... 224 Max. Stage 2 Time (PNU 1626) ......................................... 142 MBSM................................................................................. 270 AP1 (SSC Board) .......................................................... 271 Offset Compensation..................................................... 274 RJ45 .............................................................................. 271 XT1 ................................................................................ 271 XT2 ................................................................................ 271 Message Configuration (PNU 0590) .................................. 148 Microcontroller ...................................................................... 58 Minimal Battery Voltage (PNU 1426) .......................... 94, 146 MopNSA ...........................................................See MopUPS NSA MopUPS ............................................................................. 107 Event Response ............................................................ 259 GUI ................................................................................ 254 NSA ....................................................... 247, 253, 255, 262 P/R......................................... 247, 253, 254, 255, 258, 262 Professional................................... 247, 253, 254, 255, 256 UPS Diagnostic ............................................................. 256 Multi Bus Synchronisation Module ..................................... 270 Multi-Module Systems ........................................................ 226 Multiple Network Access Methods ..................................... 247 MUN ............................................. See ManageUPS NET Adapter II MUX............................................................................ 240, 265
J
JBUS .................................................................................. 275 Jumper CN11 ....................................................................... 71, 156 X160 ...................................................................... 156, 159
K
KM1 Mains Contactor34, 40, 46, 52, 65, 79, 82, 83, 84, 119, 194, 199 KM2 .............................................................................. 65, 119 KM2A Aux. Contact AP3 ............................................. 82, 83 KM3 Precharge Contactor .... 34, 40, 48, 79, 82, 83, 84, 183, 186, 194
L
L1-L3 Filter Chokes ..................... 35, 41, 47, 53, 79, 82, 193 L4 36, 42, 195
O
Online Mode ......................................................................... 22 Optional I/O connection ...................................................... 107 Optional Modules Slot 2 (PNU 0095) ................................. 228 Output Contacts.......................................................... 119, 129 (PNU 0080).................................................................... 121 Function (PNU 0081)..................................................... 122 Negated (PNU 0082) ..................................................... 125 OFF Delay (PNU 0088) ................................................. 126 ON Delay (PNU 0087) ................................................... 125 Output Switch QS4 ................................see QS4 Output Switch Over Current Protection........................................................ 13 Overheating ........................................................................ 200 Overload ............................................................................. 196 Ambient Temperature.................................................... 196 Amount .......................................................................... 197 Bypass................................................................... 103, 191 Bypass (DCM) ................................................................. 24 Period ............................................................................ 197
P
Pager .................................................................. 254, 256, 258 Parallel Operation (PNU 0129)........................................... 236 Parallel Operation Board ............................................... see POB Parallel System Inverter OFF .................................................................. 227 Inverter ON .................................................................... 227 Parameters ....................................................................see PNU Parity settings X2 (PNU 0690)............................................ 246 Personal safety..................................................................... 12 PFC ...................................................................................... 16 PLL ..................................................................................... 298 PNU 0006 U Bypass Mains 1.............................................. 153 0007 U Bypass Mains 2.............................................. 153 0008 U Bypass Mains 3.............................................. 153 0009 U Output 1 ......................................................... 153 0010 U Output 2 ......................................................... 153 0011 U Output 3 ......................................................... 153 0013 Operating Hours ................................................ 153 0014 I Output L1......................................................... 153 0015 I Output L2......................................................... 153 0016 I Output L3......................................................... 153 0017 Output Frequency.............................................. 153 0018 Bypass Mains Frequency .................................. 153 0019 Output Real Power ............................................ 153 0020 Output Apparent Power ..................................... 153 0022 Battery Hold-up Time......................... 147, 184, 197 0023 Battery Current .................................................. 153 0024 U Batt./Cell ........................................ 153, 184, 185 0026.2 Temperature, external .................................... 153 0031.12 Operating Hours ........................................... 153 0031.8 Rectifier PZD RxD .......................................... 153 0051 Access Level ............................. 202, 213, 214, 220 0052 Function Selection .... 158, 174, 175, 185, 214, 220, 235 0053 Enabling parameterisation......................... 240, 246
Q
QS1 Mains Input Switch . 79, 82, 83, 84, 173, 183, 203, 210, 211, 231, 235, 236 QS14 Neutral Switch ............. 34, 40, 46, 186, 211, 235, 236 QS2 Bypass Supply Switch .... 106, 157, 174, 182, 203, 210, 211, 232, 235, 236 QS3 Maintenance Bypass Switch .. 27, 32, 62, 99, 176, 184, 211, 235, 286, 298 QS4 Output Switch ..... 12, 99, 174, 187, 203, 211, 232, 235, 236, 286 QS5 SBS Bypass Switch................................. 231, 234, 236 QS6 SBS Output Switch.................................. 186, 234, 236 QS9 Battery Switch .... 27, 91, 174, 175, 177, 179, 185, 187, 200, 203, 223, 234, 235, 236 Qualified Personal .............................................................. 298 Quartz Crystal Oscillator .................................................... 270 Quick Stop .......................................................................... 121
R
R.A.U. (Remote Alarm Unit) ............................................... 266 Acoustic Alarm............................................................... 266 Connecting .................................................................... 268 Panel ............................................................................. 267 RCCMD ...................................................... 247, 253, 255, 263 Rectifier .......................................................................... 32, 78 Hold-off Delay (PNU 1158).............................................. 86 Main Components ........................................................... 79 Principal of Operation ...................................................... 78 Start Hold-off Delay (PNU 1158) ..................................... 86 Temperature Channel...................................................... 60 Remote Control Command................................................. 263 Remote Management ......................................................... 256 Remote Messaging..................................................... 256, 258 Remote Monitoring (LIFE) .................................................. 238 Removing one Battery Block .............................................. 225 Resistor R1/R2 ............................................... 48, 83, 183, 194
S
S.B.S. ......................................................... 226, 229, 231, 232 Safety procedures ................................................................ 12 Scalability ........................................................................... 258 SCR (Bypass)..................................................... 33, 39, 45, 51 Second Access Panels......................................................... 13 Security............................................................................... 247 Separate lines (PNU 0074) ................................................ 100 Serial Cable ........................................................................ 155 Serial Interface 1 ................................................................ 265 Serial Interface 2 ................................................................ 265 Serial protocol X2 (PNU 688) ............................................. 245 Server ................................................................................. 253 Service................................................................................ 254 Service Bypass........................see QS3 Maintenance Bypass Switch Service Interface...................................... see X3 Service Interface Service Software PPVIS..................................................... 149 Serviceability ...................................................................... 248 Shutdown Local .............................................................................. 256 Network ......................................................................... 256 Shutdown Voltage Table (PNU 0513) ............................... 148 Shutdown Voltage Table (PNU 513) ................................. 136 Single-Line Diagram ............................................................. 29 SMPS Board AP5 ............................................... see AP5 SMPS SMS Notification (LIFE) ...................................................... 239 SNMP ................................................................................. 257 Summary Alarm.................................................................. 113 Supply Interface Board AP6 ..........see AP6 Supply Interface Board Synchronisation .................................................................. 270 Automatic......................................................................... 27 Synchronisation Fault ......................................................... 270 System................................................................................ 253 Security.......................................................................... 258 Shutdown....................................................................... 256 System Bypass Switch installed (PNU 578) ....................... 230
U
UPS ON.............................................................................. 114 UPS Operation in Manual Bypass (PNU 0125).................. 205 UPS Status Information ...................................................... 247 USS Protocol .............................................................. 149, 265
V
V Correction (PNU 1158) ................................................... 100 Varistor Board AP36-AP37............ see AP36-AP37 Varistor Board Vector Control....................................................................... 28 Vector Control Technology................................................... 21 Voltage Dependent Battery Warning.......................... 197, 198 Voltage-free contacts ......................................................... 112
W
Warning ............................................ 23, 29, 30, 147, 181, 197 001......................................................................... 182, 188 002................................................. 169, 171, 173, 174, 182 003........................................................... 84, 169, 171, 183 004................................................................................. 183 005........................................................................... 84, 183 006................................................................. 184, 189, 196 007........................................................................... 84, 184 008......................................................................... 184, 232 009................................................................................. 184 010......................................................... 147, 184, 197, 198 011......................................................... 146, 147, 185, 198 012................................................................................. 185 013................................. 173, 174, 185, 223, 232, 234, 236 014................................................................................. 185 015................................................................................. 185 016................................................................................. 185 017................................................................................. 186 018........................................................................... 23, 186 019................................................................................. 186 020................................................................................. 186 021......................................................................... 186, 187 022......................................... 173, 174, 186, 232, 235, 236 024......................................................................... 187, 193 025................................................................................. 187 026................................................................................. 187 027................................................................................. 187 028................................................................................. 187 029......................................................................... 187, 270 030................................................................................. 187 031................................................................................. 187 032......................................... 173, 174, 187, 232, 235, 236
T
TA12-TA14 ... 37, 43, 49, 55, 99, 183, 184, 190, 191, 196, 199 TA15-TA17 ......................................... 37, 43, 49, 55, 106, 190 TA1-TA3 ......................................... 37, 43, 49, 55, 82, 84, 199 TA4-TA6 ....................................... 34, 40, 46, 52, 82, 199, 214 TA7 ....................................................................................... 91 TA9-TA11 ..................... 34, 40, 46, 52, 99, 183, 184, 190, 199 Technical Data Table............................................................ 16 Battery ............................................................................. 17 Environmental.................................................................. 19 Inverter output ................................................................. 18 Primary input ................................................................... 16 Static bypass ................................................................... 19 System data..................................................................... 17 Temperature Detection Circuit ............................................. 65 Temperature Factor (Battery charging) (PNU 1540) .......... 144 Temperature Measurement ............................................ 60, 62 Temperature Sensors................................................. 116, 212 Temperature Thresholds .................................................... 212 Test auto. transfer Inv. to Bypass.................................... 211 Test Operation (PNU 0783)................................................ 205
X
X107 CU1 ................................................................................. 60 CU2 ................................................................................. 62 X109 CU1 ........................................................................... 60, 62 CU2 ................................................................................. 62 X110 ................................................................................... 228