Astrid UPS HALLEY/E Series User manual

UPS HALLEY/E 20÷80KVA
PRODUCT MANUAL

Rev. Descrizione
Description Data Date Emesso Issued Controllato Checked Approvato Approved Lingua Language Pagina Page di Pag. of Pag.
A First issue 01/02/06 G. Senesi V. Gremoli V. Gremoli E 1 55
B General revision 05/05/08 G. Senesi V. Gremoli V. Gremoli
C Added battery fuse box informations 02/12/09 E.Biancucci R. Berti V. Gremoli
Codice / Code
OM226142
English
PRODUCT MANUAL
UNINTERRUPTIBLE POWER SUPPLIES
•HALLEY/E 20kVA (3Ph / 3Ph)
•HALLEY/E 30kVA (3Ph / 3Ph)
•HALLEY/E 40kVA (3Ph / 3Ph)
•HALLEY/E 60kVA (3Ph / 3Ph)
•HALLEY/E 80kVA (3Ph / 3Ph)
The present manual is an integrant part of the products technical back-up documentation. Read the warnings with
attention as they give important instructions concerning safety.
This equipment must be used only for its appointed operation. Any other use is to be considered incorrect and
therefore dangerous. The manufacturer cannot be held responsible for damages caused by incorrect, wrong and
unreasonable use.
Astrid Energy Enterprises holds itself responsible only for the equipment in its original configuration.
Any intervention altering the structure or the operating cycle of the equipment has to be carried out and authorized
directly by Astrid Energy Enterprises.
Astrid Energy Enterprises cannot be held responsible of the consequences deriving from the use of non original spare
parts.
Astrid Energy Enterprises reserves its right to carry out technical modifications on the present manual and equipment
without giving any notice. If any typing errors or mistakes are detected they will be corrected in the new versions of the
manual.
Astrid Energy Enterprises holds itself responsible for the information given in the original version of the manual in
Italian language.
Right of ownership – copying prohibited. Astrid Energy Enterprises protects its rights on the drawings and catalogues
by law.
Astrid Energy Enterprises S.p.A.
Viale Europa, 22 – Loc. Ponte d’Arno
52018 Castel San Niccolò (AR)
Tel. [phone] – Fax [phone]
Web site: www.astridups.it – e-mail: [e-mail]

OM226142 rev C
2
Contents
1 INTRODUCTION................................................................................ 6
1.1 ENVIRONMENT....................................................................................................6
1.1.1ISO 14001 certification...................................................................................6
1.1.2Packing...........................................................................................................6
1.1.3Lead battery ...................................................................................................6
1.1.4Treatment of the UPS at the end of service life..............................................6
1.2 SAFETY RULES...................................................................................................6
1.2.1Safety of persons ...........................................................................................6
1.2.2Product safety ................................................................................................6
1.2.3Special precautions........................................................................................7
2UPS GENERAL DESCRIPTION........................................................ 8
2.1RECTIFIER / BATTERY CHARGER.....................................................................9
2.1.1Operation with ONE charging level ..............................................................10
2.2INVERTER ..........................................................................................................10
2.2.1Operation with non-linear load......................................................................11
2.2.2Overload management.................................................................................12
2.2.3Short circuit operation ..................................................................................13
2.2.4IGBT bridge protection .................................................................................14
2.3BATTERY ...........................................................................................................15
2.4STATIC SWITCH ................................................................................................15
2.4.1Inverter ÆEmergency Line transfer.............................................................16
2.4.2Emergency Line ÆInverter transfer.............................................................16
2.5MANUAL BY-PASS............................................................................................16
3OPERATING MODES...................................................................... 17
3.1NORMAL OPERATION ......................................................................................17
3.2BATTERY OPERATION .....................................................................................18
3.3BYPASS OPERATION .......................................................................................19
3.4MANUAL BYPASS.............................................................................................21
4USER INTERFACE (FRONT PANEL) ............................................. 23
4.1ALARMS AND OPERATING STATUS...............................................................24
4.1.1Alarms..........................................................................................................24
4.1.2Status...........................................................................................................25
4.1.3Protections ...................................................................................................25
4.2MEASUREMENTS ON THE DISPLAY...............................................................26
4.3MENU STRUCTURE...........................................................................................27

OM226142 rev C
3
5GENERAL TECHNICAL DATA ....................................................... 28
5.1TECHNICAL DATA SHEETS..............................................................................28
5.1.1GENERAL INFORMATION..........................................................................28
5.1.2RECTIFIER ..................................................................................................29
5.1.3INVERTER...................................................................................................30
5.1.4STATIC BY-PASS........................................................................................30
5.2INSTRUCTIONS FOR INSTALLATION..............................................................31
5.2.1Receipt of the UPS.......................................................................................31
5.2.2Handling of the UPS.....................................................................................31
5.2.3Positioning and installation...........................................................................32
5.2.3.1Base plan, static load and weights ......................................................................32
5.2.3.2Dimensions and distances...................................................................................33
5.2.4Electrical connection ....................................................................................34
5.2.4.1Terminal board ....................................................................................................34
5.2.5Battery connection and positioning...............................................................35
5.2.6External battery............................................................................................36
5.2.6.1Dimensions and weights......................................................................................37
5.2.6.2Connections ........................................................................................................38
6OPTIONS.......................................................................................... 39
6.1INSULATION TRANSFORMERS .......................................................................39
6.1.1By-pass insulation transformer.....................................................................39
6.1.2Rectifier insulation transformer.....................................................................39
6.1.3Voltage Adaptation Transformers.................................................................39
6.212-PULSE RECTIFIER .......................................................................................39
6.3IP31 PROTECTION DEGREE.............................................................................40
6.4SPECIAL PAINT.................................................................................................40
6.5FUSED SWITCH FOR THE BATTERY...............................................................40
6.5.1Connections .................................................................................................41
6.5.2Technical data..............................................................................................41
6.6REMOTE EPO.....................................................................................................42
6.7FANS MONITORING ..........................................................................................42
6.8DIESEL GENERATOR INTERFACE ..................................................................42
6.9THERMAL COMPENSATION BATTERY CHARGE ..........................................43
6.10BOOST CHARGE...............................................................................................43
6.11PARALLEL REDUNDANT CONFIGURATION...................................................44
6.12ARC – FREE VOLTAGE CONTACT CARD.......................................................45
6.13ADDITIONAL ALARMS (INT5ARC + 2ARC) .....................................................45
6.14REMOTE PANEL................................................................................................46

OM226142 rev C
4
6.15TELEPHONE CONNECTION KIT.......................................................................46
6.16MONITORING SOFTWARE VOYAGER/E .........................................................47
6.17UPS MANAGEMENT SOFTWARE.....................................................................48
6.18ADDITIONAL LICENSES FOR UPS MANAGEMENT SOFTWARE..................48
6.19SNMP (SIMPLE NETWORK MANAGEMENT PROTOCOL) ADAPTER ...........48
6.20JBUS/MODBUS INTERFACE.............................................................................48
6.21SELECTION OF THE UPS-USER INTERFACE.................................................49
7SPARE PARTS LIST ....................................................................... 50
7.1INTRODUCTION.................................................................................................50
7.2SPARE PARTS FOR HALLEY/E 20KVA ...........................................................51
7.2.1Level 1..........................................................................................................51
7.2.2Level 2..........................................................................................................51
7.2.3Level 3..........................................................................................................51
7.2.4Additional spares..........................................................................................51
7.3SPARE PARTS FOR HALLEY/E 30KVA ...........................................................52
7.3.1Level 1..........................................................................................................52
7.3.2Level 2..........................................................................................................52
7.3.3Level 3..........................................................................................................52
7.3.4Additional spares..........................................................................................52
7.4SPARE PARTS FOR HALLEY/E 40KVA ...........................................................53
7.4.1Level 1..........................................................................................................53
7.4.2Level 2..........................................................................................................53
7.4.3Level 3..........................................................................................................53
7.4.4Additional spares..........................................................................................53
7.5SPARE PARTS FOR HALLEY/E 60KVA ...........................................................54
7.5.1Level 1..........................................................................................................54
7.5.2Level 2..........................................................................................................54
7.5.3Level 3..........................................................................................................54
7.5.4Additional spares..........................................................................................54
7.6SPARE PARTS FOR HALLEY/E 80KVA ...........................................................55
7.6.1Level 1..........................................................................................................55
7.6.2Level 2..........................................................................................................55
7.6.3Level 3..........................................................................................................55
7.6.4Additional spares..........................................................................................55

OM226142 rev C
5
Index of pictures
Picture 1 – UPS block diagram.......................................................................................................................... 8
Picture 2 – Rectifier ........................................................................................................................................... 9
Picture 3 – Operation with ONE charging level............................................................................................... 10
Picture 4 – Inverter .......................................................................................................................................... 10
Picture 5 – Diagram of the power.................................................................................................................... 11
Picture 6 – Operation with non-linear load ...................................................................................................... 12
Picture 7 – Thermal image characteristic........................................................................................................ 12
Picture 8 – Overload with bypass available..................................................................................................... 13
Picture 9 – Overload with bypass not available............................................................................................... 13
Picture 10 – Short circuit characteristic (By-pass not available) ..................................................................... 14
Picture 11 – IGBT bridge protection................................................................................................................ 14
Picture 12 – Static switch and Manual by-pass............................................................................................... 15
Picture 13 – Normal Operation........................................................................................................................ 17
Picture 14 – Battery operation......................................................................................................................... 18
Picture 15 – Bypass operation (manual change-over).................................................................................... 19
Picture 16 – Bypass operation (automatic change-over) ................................................................................ 20
Picture 17 – Manual Bypass for functional tests ............................................................................................. 21
Picture 18 – Manual Bypass for repair or maintenance works........................................................................ 22
Picture 19 – Front panel .................................................................................................................................. 23
Picture 20 – Menu structure ............................................................................................................................ 27
Picture 21 – Handling of the UPS.................................................................................................................... 31
Picture 22 – Base plan..................................................................................................................................... 32
Picture 23 – Dimensions and distances from the walls................................................................................... 33
Picture 24 – Terminal board UPS 20-30kVA................................................................................................... 34
Picture 25 – Terminal board UPS 40÷80kVA.................................................................................................. 34
Picture 26 – Wiring 4 batteries for tray............................................................................................................ 35
Picture 27 – Wiring 8 batteries for tray............................................................................................................ 36
Picture 28 – Dimensions of the external battery cabinets............................................................................... 37
Picture 29 – Base plan of the external battery cabinets.................................................................................. 37
Picture 30 – Battery cabinets connections ...................................................................................................... 38
Picture 31 – Rectifier 12P with galvanic isolation............................................................................................ 40
Picture 32 – Connection of the battery fused switch....................................................................................... 41
Picture 33 – Diesel generator interface block diagram.................................................................................... 42
Picture 34 – Charging voltage vs. temperature............................................................................................... 43
Picture 35 – BOOST charge diagram.............................................................................................................. 43
Picture 36 – Parallel redundant block diagram................................................................................................ 44
Picture 37 – ARC card layout.......................................................................................................................... 45
Picture 38 – Remote panel connection............................................................................................................ 46
Picture 39 – UPS-Modem connection ............................................................................................................. 46
Picture 40 – Voyager/E screen........................................................................................................................ 47

OM226142 rev C
6
1 INTRODUCTION
1.1 ENVIRONMENT
1.1.1 ISO 14001 certification
The product was manufactured in a factory certified ISO 14001 respecting eco-design
rules.
1.1.2 Packing
UPS packing materials must be recycled in compliance with all applicable regulations.
1.1.3 Lead battery
This product contains lead-acid batteries. Lead is a dangerous substance for the
environment if it is not correctly recycled by specialised companies.
1.1.4 Treatment of the UPS at the end of service life
For the UPS disposal at the end of its life cycle and for the recycling of the materials, it’s
strongly recommended to follow the regulations in force in the country of installation.
1.2 SAFETY RULES
1.2.1 Safety of persons
The UPS must be installed in a room with restricted access (qualified personnel only,
according to standard EN62040-1-2).
A UPS has its own internal power source (the battery). Consequently, the power outlets
may be energised even if the UPS is disconnected from the AC-power source.
CAUTION
If primary powers isolators are installed in other area from UPS area, the following warning
label must be placed on them.
“ISOLATE THE UPS BEFORE WORKING ON THIS CIRCUIT”
•Dangerous voltage levels are present within the UPS. It should be opened
exclusively by qualified service personnel.
•Warning, after the UPS shut-down, a dangerous voltage will be present on the
battery selector BCB.
•The UPS must be properly earthed.
•The battery supplied with the UPS contains small amounts of toxic materials. To
avoid accidents, the directives listed below must be observed.
•Never operate the UPS if the ambient temperature and relative humidity are
higher than the levels specified in the documentation.
•Never burn the battery (risk of explosion).
•Do not attempt to open the battery (the electrolyte is dangerous for the eyes and
skin).
•Comply with all applicable regulations for the disposal of the battery.
1.2.2 Product safety
A protection circuit breaker must be installed upstream and be easily accessible.
Never install the UPS near liquids or in an excessively damp environment.
Never let a liquid or foreign body penetrate inside the UPS.
Never block the ventilation grates of the UPS.

OM226142 rev C
7
Never expose the UPS to direct sunlight or a source of heat.
1.2.3 Special precautions
The UPS connection instructions contained in this manual must be followed in the
indicated order.
Check that the indications on the rating plate correspond to your AC-power system and to
the actual electrical consumption of all the equipment to be connected to the UPS.
If the UPS must be stored prior to installation, storage must be in a dry place.
The admissible storage temperature range is -10° C to +45° C.
If the UPS remains de-energised for a long period, we recommend that you energise the
UPS for a period of 24 hours, at least once every month. This charges the battery, thus
avoiding possible irreversible damage.
The UPS is designed for normal climatic and environmental operating conditions as
defined in the "appendices" chapter: altitude, ambient operating temperature, relative
humidity and ambient transport and storage conditions.
Using the UPS within the given limits guarantees its operation, but may affect the service
life of certain components, particularly that of the battery and its autonomy. The maximum
storage time of the UPS is limited due to the need to recharge its integrated battery.
Unusual operating conditions may justify special design or protection measures:
-harmful smoke, dust, abrasive dust,
-humidity, vapour, salt air, bad weather or dripping,
-explosive dust and gas mixture,
-extreme temperature variations,
-bad ventilation,
-conductive or radiant heat from other sources,
-strong electromagnetic fields,
-radioactive levels higher than those of the natural environment,
-fungus, insects, vermin, etc.,
-battery operating conditions.
The UPS must always be installed in compliance with:
-the requirements of HD 384.4.42 S1/A2 - Chapter 42: Protection from thermal
effects.
-standard IEC 60364-4-482 - Chapter 482: Fire protection.
The manufacturer declines all responsibility for damages to people or equipment
deriving from non-fulfilment of the above.

OM226142 rev C
8
2 UPS GENERAL DESCRIPTION
The UPS of the HALLEY/E series is the type “ON LINE DOUBLE CONVERSION” and is
connected between main power and user loads (see picture 1). As far as architecture and
lay-out is concerned, this project is optimised with particular care in order to make it
suitable for applications where reliability and high performances are fundamental for
critical loads.
The UPS operation is optimised by microprocessor digital control and the IGBT inverter is
based on a high frequency PWM waveform.
The whole UPS is monitored by a DSP 16 bit microprocessor, implementing full digital
control.
Procedures for power-on, power-off, switching to and from bypass are described step by
step on LCD display, so to help users to easily operate the UPS.
Results of electrical measurement, alarm, work condition, event log and battery state are
displayed real time on the LCD front panel.
Picture 1 – UPS block diagram
With this configuration UPS guarantees high quality output, needed by loads requiring
stable and clean source of power. The main features are:
•Protection for black-out, in the limits of battery autonomy
•Complete filtering of main power noise
•High quality output power, provided under any condition of input power and loads
•Stable output frequency, independent from input frequency
•Full compatibility with every type of load
•Configurable with any neutral wire configuration (under request)
•Automatic control of battery, during both charging and discharging phases
•Easy to interface with user devices
•Auto-diagnostic feature and troubleshooting support
•Flexibility of complete bypass configuration
•Full access from the front and from the roof for maintenance
The block diagram shows the UPS subsystem that will be analysed in the following
chapters:
•Rectifier/Battery Charger (R)
•Inverter (I)

OM226142 rev C
9
•Battery (B)
•Static switch: Static inverter switch (SSI) and Static Bypass switch (SB)
•Manual Bypass (MB)
2.1 RECTIFIER / BATTERY CHARGER
The rectifier/Battery charger converts the AC input voltage to DC voltage, feeding the
inverter and keeping the battery charged.
Picture 2 – Rectifier
NOTE
On HALLEY/E 40÷80kVA RCB is a fused switch and BCB is not installed.
The AC input voltage is filtered by the inductor L1 and then converted into DC by the 6
pulses phase-angle controlled rectifier, composed by six thyristors. The typical harmonic
distortion of the current absorbed by a 6 pulses rectifier is shown in the table below:
Harmonic order 1 5 7 11 13 17 19 THD
Amplitude (In/I1) 100 % 19,6 % 13,8 % 8,5 % 7,0 % 5,1 % 4,4 % 27,0 %
The inductor L3 reduces the current ripple generated by the inverter so that the battery life
is improved. During the battery discharge the inductor L3 works like a short-circuit, so that
there’s no voltage drop and the battery capacity can be completely used. The rectifier is
designed to recharge and keep charged Sealed Lead Acid Batteries, although Open-type
Lead Acid or Ni-Cd batteries can be used. Following to the manufacturer’s instructions,
each type of battery must be charged according to its manufacturing technology. Basically
there are two different charging methods:
•ONE CHARGING LEVEL (FLOATING CHARGE)
•TWO CHARGING LEVELS (FLOATING / BOOST CHARGE)
The double-level charging mode is generally used with Open-type Lead Acid or Ni-Cd
Batteries and it’s provided as option (see section OPTIONS for further details).