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. +39 0575 509701 – Fax +39 0575 500032
Web site: www.astridups.it – e-mail: info@astridups.it
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Contents
1 INTRODUCTION................................................................................ 6
1.1 ENVIRONMENT....................................................................................................6
1.1.1ISO 14001 certification...................................................................................6
1.1.2Packing...........................................................................................................6
1.1.3Lead battery ...................................................................................................6
1.1.4Treatment of the UPS at the end of service life..............................................6
1.2 SAFETY RULES...................................................................................................6
1.2.1Safety of persons ...........................................................................................6
1.2.2Product safety ................................................................................................6
1.2.3Special precautions........................................................................................7
2UPS GENERAL DESCRIPTION........................................................ 8
2.1RECTIFIER / BATTERY CHARGER.....................................................................9
2.1.1Operation with ONE charging level ..............................................................10
2.2INVERTER ..........................................................................................................10
2.2.1Operation with non-linear load......................................................................11
2.2.2Overload management.................................................................................12
2.2.3Short circuit operation ..................................................................................13
2.2.4IGBT bridge protection .................................................................................14
2.3BATTERY ...........................................................................................................15
2.4STATIC SWITCH ................................................................................................15
2.4.1Inverter ÆEmergency Line transfer.............................................................16
2.4.2Emergency Line ÆInverter transfer.............................................................16
2.5MANUAL BY-PASS............................................................................................16
3OPERATING MODES...................................................................... 17
3.1NORMAL OPERATION ......................................................................................17
3.2BATTERY OPERATION .....................................................................................18
3.3BYPASS OPERATION .......................................................................................19
3.4MANUAL BYPASS.............................................................................................21
4USER INTERFACE (FRONT PANEL) ............................................. 23
4.1ALARMS AND OPERATING STATUS...............................................................24
4.1.1Alarms..........................................................................................................24
4.1.2Status...........................................................................................................25
4.1.3Protections ...................................................................................................25
4.2MEASUREMENTS ON THE DISPLAY...............................................................26
4.3MENU STRUCTURE...........................................................................................27
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5GENERAL TECHNICAL DATA ....................................................... 28
5.1TECHNICAL DATA SHEETS..............................................................................28
5.1.1GENERAL INFORMATION..........................................................................28
5.1.2RECTIFIER ..................................................................................................29
5.1.3INVERTER...................................................................................................30
5.1.4STATIC BY-PASS........................................................................................30
5.2INSTRUCTIONS FOR INSTALLATION..............................................................31
5.2.1Receipt of the UPS.......................................................................................31
5.2.2Handling of the UPS.....................................................................................31
5.2.3Positioning and installation...........................................................................32
5.2.3.1Base plan, static load and weights ......................................................................32
5.2.3.2Dimensions and distances...................................................................................33
5.2.4Electrical connection ....................................................................................34
5.2.4.1Terminal board ....................................................................................................34
5.2.5Battery connection and positioning...............................................................35
5.2.6External battery............................................................................................36
5.2.6.1Dimensions and weights......................................................................................37
5.2.6.2Connections ........................................................................................................38
6OPTIONS.......................................................................................... 39
6.1INSULATION TRANSFORMERS .......................................................................39
6.1.1By-pass insulation transformer.....................................................................39
6.1.2Rectifier insulation transformer.....................................................................39
6.1.3Voltage Adaptation Transformers.................................................................39
6.212-PULSE RECTIFIER .......................................................................................39
6.3IP31 PROTECTION DEGREE.............................................................................40
6.4SPECIAL PAINT.................................................................................................40
6.5FUSED SWITCH FOR THE BATTERY...............................................................40
6.5.1Connections .................................................................................................41
6.5.2Technical data..............................................................................................41
6.6REMOTE EPO.....................................................................................................42
6.7FANS MONITORING ..........................................................................................42
6.8DIESEL GENERATOR INTERFACE ..................................................................42
6.9THERMAL COMPENSATION BATTERY CHARGE ..........................................43
6.10BOOST CHARGE...............................................................................................43
6.11PARALLEL REDUNDANT CONFIGURATION...................................................44
6.12ARC – FREE VOLTAGE CONTACT CARD.......................................................45
6.13ADDITIONAL ALARMS (INT5ARC + 2ARC) .....................................................45
6.14REMOTE PANEL................................................................................................46
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6.15TELEPHONE CONNECTION KIT.......................................................................46
6.16MONITORING SOFTWARE VOYAGER/E .........................................................47
6.17UPS MANAGEMENT SOFTWARE.....................................................................48
6.18ADDITIONAL LICENSES FOR UPS MANAGEMENT SOFTWARE..................48
6.19SNMP (SIMPLE NETWORK MANAGEMENT PROTOCOL) ADAPTER ...........48
6.20JBUS/MODBUS INTERFACE.............................................................................48
6.21SELECTION OF THE UPS-USER INTERFACE.................................................49
7SPARE PARTS LIST ....................................................................... 50
7.1INTRODUCTION.................................................................................................50
7.2SPARE PARTS FOR HALLEY/E 20KVA ...........................................................51
7.2.1Level 1..........................................................................................................51
7.2.2Level 2..........................................................................................................51
7.2.3Level 3..........................................................................................................51
7.2.4Additional spares..........................................................................................51
7.3SPARE PARTS FOR HALLEY/E 30KVA ...........................................................52
7.3.1Level 1..........................................................................................................52
7.3.2Level 2..........................................................................................................52
7.3.3Level 3..........................................................................................................52
7.3.4Additional spares..........................................................................................52
7.4SPARE PARTS FOR HALLEY/E 40KVA ...........................................................53
7.4.1Level 1..........................................................................................................53
7.4.2Level 2..........................................................................................................53
7.4.3Level 3..........................................................................................................53
7.4.4Additional spares..........................................................................................53
7.5SPARE PARTS FOR HALLEY/E 60KVA ...........................................................54
7.5.1Level 1..........................................................................................................54
7.5.2Level 2..........................................................................................................54
7.5.3Level 3..........................................................................................................54
7.5.4Additional spares..........................................................................................54
7.6SPARE PARTS FOR HALLEY/E 80KVA ...........................................................55
7.6.1Level 1..........................................................................................................55
7.6.2Level 2..........................................................................................................55
7.6.3Level 3..........................................................................................................55
7.6.4Additional spares..........................................................................................55
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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
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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.
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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.
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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)
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•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).
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2.1.1 Operation with ONE charging level
This type of charge is generally used with sealed lead acid batteries that, owing to the
manufacturing technology, have a very narrow voltage range. In fact, the nominal charging
voltage ranges between 2,25÷2,27 V/cell, with a maximum value of 2,3 V/cell.
The picture below shows the charging curves at different charging currents; the higher is
the current, the higher is the restored capacity versus time, the lower is the recharging
time.
Picture 3 – Operation with ONE charging level
2.2 INVERTER
The inverter converts the DC input voltage to AC voltage, stabilized in frequency and RMS
value.
The DC voltage is converted by the IGBT bridge, that uses six switches, controlled using
PWM (Pulse Width Modulation) technology at high commutation frequency. The PWM
generation as well as the control of the operating variables is completely managed by the
microprocessor.
The DC current transducer CT provides for the monitoring of the inverter input current. Its
feedback signal is managed by the microprocessor to activate the output short circuit
current limitation (see 2.2.3) and the IGBT protection (see 2.2.4).
Picture 4 – Inverter
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The output transformer provides the galvanic insulation between DC and AC side, as well
as voltage adaptation. Its integrated inductance forms, together with the AC capacitors, a
low-pass filter that provides to eliminate the high frequency ripple and keep the total
harmonic distortion of the inverter waveform (THD) lower than 2% (with linear load).
The inverter, thanks to its manufacturing technology and to the microprocessor control, is
able to supply indifferently inductive or capacitive loads. The maximum apparent power
varies slightly in case the load is highly capacitive (p.f. < 0,9) and a de-rating factor,
according to the picture 5, must be applied. The data “100% kW” indicates the maximum
active power that the UPS can supply to a resistive load (ex: for a 100kVA UPS
Pmax=80kW). The table that follows the diagram shows an example of calculation for a
60kVA UPS.
Picture 5 – Diagram of the power
Example: UPS 60kVA Pmax = 48kW
cos ϕ(capacitive) cos ϕ(inductive)
0,6 0,7 0,8 0,9 1 0,8 0,7 0,6
P / Pmax 1 1 1 0,875 0,75
Max active power (kW) 32 37,3 42,6 48 48 48 42 36
Reactive power (kVar) 42,6 38 32 23 - 36 42,8 48
Apparent power (kVA) 53,3 53,3 53,3 53,3 - 60 60 60
2.2.1 Operation with non-linear load
A non-linear load is characterized by a high peak current versus its RMS value, that in
normal condition would introduce a distortion on the output waveform.
The inverter is provided with an instantaneous voltage correction facility, completely
managed by the microprocessor, that provides to vary the PWM generation according to
the actual output waveform, in order to keep the THD within 5% even with loads having
crest factor equal to 3.
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Picture 6 – Operation with non-linear load
2.2.2 Overload management
Inverter can provide continuously 100% of nominal load and can tolerate overload
conditions up to 125% for 10 minutes or 150% for 1 minute.
Peak conditions such as take-off of engines or magnetic parts are managed limiting the
output current to 200% for 5 cycles, than reducing to 125%.
Any times output power grows above 100% the inverter keeps feeding the loads, while the
microprocessor activates the “thermal image” algorithm (technical figure) to calculate
thermal image based on output current and duration of the overload in function of the time.
User loads are powered by inverter output up to the end of maximum allowed time, then
the static bypass switches to emergency line without interruption of output power.
Picture 7 – Thermal image characteristic
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Picture 8 – Overload with bypass available
1) BYPASS AVAILABLE
As soon as an overload is
detected the algorithm starts to
calculate the increment of the
energy.
When the limit is reached the
load is transferred to bypass.
To allow a safe cooling of the
inverter power components
(IGBT’s, transformer) the
inverter is switched off for 30
minutes.
When this time has elapsed the
inverter is switched on again
and the load transferred back
to the primary supply.
Picture 9 – Overload with bypass not available
2) BYPASS NOT AVAILABLE
As soon as an overload is
detected the algorithm starts to
calculate the increment of the
energy.
When the limit is reached the
inverter is switched off to avoid
severe damages to the power
components.
As soon as the bypass is
available again the load is
supplied by the bypass static
switch.
After 30 minutes the inverter
is switched on again and the
load re-supplied.
WARNING: this operation
causes the loss of the
supply to the load
2.2.3 Short circuit operation
As soon as an output short circuit is detected (alarm A25) the load is transferred
immediately to the emergency line that provides to eliminate the fault thanks to its higher
short circuit current.
In case the bypass is not available the inverter reduces its output voltage and limits its
output current to 200% for 100ms, and then to 125% for 5 seconds, after that it’s switched
off (according to EN 62040-3 / EN 50091-3).
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Picture 10 – Short circuit characteristic (By-pass not available)
2.2.4 IGBT bridge protection
The inverter current monitoring is carried out by the DC current transducer connected
upstream the inverter bridge. Therefore the control logic is able to distinguish an output
short circuit from an IGBT short circuit.
The behaviour of the inverter in case of short circuit on the load has been described at
2.2.3; the output current is limited and the IGBT bridge current doesn’t reach the protection
threshold.
In case of short circuit in the inverter bridge the DC input current increases immediately
and there’s no possibility of limitation but stopping the PWM.
In this case the alarm A24 – Current stop is activated and must be reset manually after
having verified the status of the semiconductors.
Picture 11 – IGBT bridge protection
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2.3 BATTERY
On the HALLEY/E 20-30kVA UPS, the battery can be installed inside the UPS for
autonomy from 5 up to 15 minutes depending on the UPS power (see following table); if
the requested back-up time is longer the battery is installed inside external cabinets. On
the HALLEY/E 40÷80kVA UPS the battery is always installed in external cabinets.
The battery charger control logic is completely integrated inside the total-controlled rectifier
control board; the battery is charged, according to the DIN 41773 Standard, every time it
has been partially or completely discharged and it is kept floating, even when it’s charged,
to compensate any auto-discharge.
UPS BATTERIES
QUANTITY TYPE
20 kVA – 5 minutes 32 12 Ah
30 kVA – 5 minutes 64 7 Ah
20 kVA – 10 minutes 64 7 Ah
30 kVA – 10 minutes 32 24 Ah
20 kVA – 15 minutes 32 18 Ah
2.4 STATIC SWITCH
Static switch is based on power semiconductor (thyristors), rated to work continuously at
150% of nominal output power.
The thyristors connected to the main power are protected by fuse. On the HALLEY/E
40÷80kVA UPS the fuses are installed inside the switch SBCB.
Picture 12 – Static switch and Manual by-pass
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Thanks to the transfer logic integrated in the control, the load is supplied by the bypass
static switch even in case of microprocessor failure.
Overload capability: 150% continuously
200% for 1 minute
2000% for 1 cycle
2.4.1 Inverter ÆEmergency Line transfer
The transfer is activated only if emergency line is in tolerance (in less than 0,5 ms), for the
following reasons:
CAUSES COMMUTATION CONDITIONS
Output short circuit Emergency line within tolerance limits
Fault of inverter or inverter voltage out of
tolerance Emergency line within tolerance limits
DC over-voltage/under-voltage (Inverter OFF) Emergency line within tolerance limits
Over-temperature Emergency line within tolerance limits
Thermal image shut down Emergency line within tolerance limits
Forced commutation by “BYPASS SWITCH”
(test or service) Emergency line within tolerance limits
AND synchronized inverter
2.4.2 Emergency Line ÆInverter transfer
As soon as inverter is correctly working and synchronized, UPS automatically switches to
inverter in less than 1 msec. If UPS switches back and forth more than 6 times in two
minutes, an alarm will be generate, to inform the user, and UPS will be locked to
emergency line until a manual reset will clear the faulty condition.
2.5 MANUAL BY-PASS
To safely allow maintenance and repair of the unit, UPS is provided with a manual bypass
switch.
In bypass mode all the repairing and testing activities to verify the efficiency of the whole
UPS can be carried out safely. Manual by-pass can be inserted by following the relevant
instructions. During manual by-pass operation there’s no interruption of the supply to the
load.
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3 OPERATING MODES
3.1 NORMAL OPERATION
During normal operation all the circuit breakers/switches are closed except MBCB
(maintenance bypass).
The three-phase input AC voltage feeds the rectifier via the filter inductor; the rectifier
supplies the inverter and compensate mains voltage fluctuations as well as load variation,
maintaining the DC voltage constant. At the same time it provides to keep the battery in
stand-by (floating charge or boost charge depending on the type of battery).
The inverter converts the DC voltage into an AC sine-wave, stabilized in voltage and
frequency, and provides to supply the load through its static switch SSI.
Picture 13 – Normal Operation
Section Status Further explanation
Rectifier Mains available and within the tolerance range
RCB CLOSED
Rectifier ON
Battery available and within the tolerance range
BCB CLOSED
Inverter ON
Bypass Mains available and within the tolerance range
BYPASS SWITCH “NORMAL”
SBCB CLOSED
Static Switch SSI ON
Static Switch SB OFF
OCB CLOSED
MBCB OPEN
Output Voltage available and within the tolerance range
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3.2 BATTERY OPERATION
In the event of mains failure, or rectifier failure, the inverter is no longer supplied by the
rectifier, so the battery, that is connected to the DC intermediate circuit, is called up
immediately and without interruption to supply the load. The battery voltage drops as a
function of the magnitude of the discharge current. The voltage drops has no effect on the
inverter output voltage since it is kept constant by varying the PWM modulation.
As the battery approaches the discharge limit an alarm is activated. In case the power is
restored (even using a diesel generator) before the limit is reached the system switches
automatically back to normal operation, if not, the inverter shuts down and the load is
transferred to the bypass (bypass operation). If the bypass mains is not available or
outside the tolerance range the complete system shuts down as soon as the lowest battery
level is reached.
As soon as the power is restored the rectifier charges the battery, and, depending on the
depth of the discharge, the charging current is limited by means of the battery current
limitation.
Picture 14 – Battery operation
Section Status Further explanation
Rectifier Mains NOT available or outside the tolerance range
RCB CLOSED
Rectifier OFF
Battery available and within the tolerance range
BCB CLOSED
Inverter ON
Bypass Mains available and within the tolerance range (may be
outside the tolerance range)
SBCB CLOSED
BYPASS SWITCH “NORMAL”
Static Switch SSI ON
Static Switch SB OFF
OCB CLOSED
MBCB OPEN
Output Voltage available and within the tolerance range
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3.3 BYPASS OPERATION
Bypass operation may occur for both manual or automatic change-over. The manual
transfer is due to the BYPASS SWITCH, that forces the load to bypass. In the event of a
bypass failure the load is transferred back to inverter without interruption.
Picture 15 – Bypass operation (manual change-over)
Section Status Further explanation
Rectifier Mains available and within the tolerance range (may be
outside the tolerance range)
RCB CLOSED
Rectifier OFF / ON
Battery available and within the tolerance range
BCB CLOSED
Inverter ON
Bypass Mains available and within the tolerance range
BYPASS SWITCH “BYPASS”
SBCB CLOSED
Static Switch SSI OFF
Static Switch SB ON
OCB CLOSED
MBCB OPEN
Output Voltage available and within the tolerance range
The automatic change-over occurs for the reasons explained in the UPS technical
description (see paragraph 2.4.1); basically when the power supply to the load within the
specified tolerance cannot be assured by the inverter.
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