Borri B8031FXS 10kVA User manual

Rev. Descrizione
Description Data Date Emesso Issued Approvato Approved Lingua Language Pagina Page di Pag. of Pag.
D Added sizes UPS 50-60kVA 08.04.14 E. Biancucci F. Berti E 1
49
Codice / Code
OMD91046
English
PRODUCT MANUAL
UNINTERRUPTIBLE POWER SUPPLIES
B8031FXS 10kVA (3PH / 1PH)
B8031FXS 15kVA (3PH / 1PH)
B8031FXS 20kVA (3PH / 1PH)
B8033FXS 10kVA (3PH / 3PH)
B8033FXS 15kVA (3PH / 3PH)
B8033FXS 20kVA (3PH / 3PH)
B8033FXS 30kVA (3PH / 3PH)
B8033FXS 40kVA (3PH / 3PH)
B8033FXS 50kVA (3PH / 3PH)
B8033FXS 60kVA (3PH / 3PH)

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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 safe usage.
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.
BORRI holds itself responsible only for the equipment in its original configuration.
Any intervention that alters the structure or the operating cycle of the equipment must be carried out and
authorized directly by BORRI.
BORRI cannot be held responsible of the consequences deriving from the use of non original spare parts.
BORRI reserves the right to make technical modifications to the present manual and to the equipment without
prior warning. If any typing errors or mistakes are detected, they will be corrected in the new versions of the
manual.
BORRI holds itself responsible for the information given in the original version of the manual in Italian language.
Right of ownership – copying prohibited. BORRI protects its rights on the drawings and catalogues by law.
Borri S.p.A.
Via 8 Marzo, 2 – Soci
52010 Bibbiena (AR)
Tel. [phone] – Fax [phone]
Web site: www.borri.it – e-mail: [email protected]

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Index
1. UPS GENERAL DESCRIPTION.......................................................... 6
1.1 RECTIFIER / BATTERY CHARGER ................................................................9
1.1.1Battery charger characteristic ..............................................................10
1.2INVERTER......................................................................................................10
1.2.1Operation with non-linear load .............................................................12
1.2.2Overload management ..........................................................................12
1.2.3Short-circuit operation ..........................................................................14
1.2.4IGBT bridge protection..........................................................................14
1.3BATTERY .......................................................................................................14
1.4STATIC SWITCH............................................................................................15
1.4.1Inverter Emergency Line Transfer....................................................15
1.4.2Emergency Line Inverter transfer.....................................................15
1.5MANUAL BYPASS.........................................................................................15
2. OPERATING MODES........................................................................ 16
2.1NORMAL OPERATION ..................................................................................16
2.2BATTERY OPERATION.................................................................................17
2.3BYPASS OPERATION...................................................................................18
2.4MANUAL BYPASS.........................................................................................19
3. FRONT PANEL.................................................................................. 20
3.1FUNCTION BUTTONS ...................................................................................20
3.2FUNCTION OF MIMIC PANEL LED’S............................................................21
3.3ALARMS AND OPERATING STATUS...........................................................22
3.3.1Alarms.....................................................................................................22
3.3.2Operating status.....................................................................................22
3.4MEASUREMENTS ON THE DISPLAY...........................................................23
4. GENERAL TECHNICAL INFORMATION ......................................... 24
4.1 TECHNICAL DATA.........................................................................................24
4.2INSTRUCTIONS FOR INSTALLATION.........................................................24
4.2.1Receipt of the UPS.................................................................................24
4.2.2Storage....................................................................................................24
4.3 HANDLING OF THE UPS...............................................................................25
4.4POSITIONING AND INSTALLATION.............................................................26

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4.4.1Base plan, static load and weights.......................................................26
4.4.2Dimensions and distances....................................................................27
4.4.3Installation criteria.................................................................................28
4.4.4 Environmental installation conditions .................................................28
4.5 ELECTRICAL CONNECTION ........................................................................30
4.6 BACKFEED PROTECTION DEVICE..............................................................33
4.7TERMINAL BOARDS....................................................................................34
4.7.1Electrical connection data.....................................................................35
4.8 CONNECTION OF POWER CABLES............................................................36
4.9POSITIONING AND CONNECTION OF BATTERIES....................................37
4.9.1External battery cabinet ........................................................................38
4.10SERIAL INTERFACES................................................................................41
5. OPTIONS........................................................................................... 43
5.1 STANDARD OPTIONS INCLUDED TO BE SET VIA SOFTWARE ...............43
5.1.1Off-line ....................................................................................................43
5.1.2Programmable rectifier soft-start (Walk-In) .........................................43
5.1.3Sequential rectifier start for parallel systems (Hold-off) ....................43
5.1.4Frequency converter..............................................................................43
5.2 OPTIONS PROVIDED ON REQUEST............................................................44
5.2.1Thermal compensation of battery charge............................................44
5.2.2Bypass insulation transformer .............................................................45
5.2.3Separate input kit...................................................................................45
5.2.4Voltage adaptation transformers..........................................................45
5.2.5Alarm card ..............................................................................................46
5.2.6Serial interface RS-485 (Mod-Bus protocol) ........................................47
5.2.7SNMP adapter.........................................................................................47
5.2.8Remote panel..........................................................................................47
5.2.9Parallel kit...............................................................................................47
5.2.10Connection kit for external battery cabinet......................................48
5.2.11Wall mounted isolator with battery fuses.........................................48
5.2.12Special painting..................................................................................48
5.2.13Diesel generator .................................................................................49
5.2.14External manual bypass.....................................................................49
5.2.15Remote emergency power off (EPO) ................................................49
5.2.16BACK FEED (protection from power return to mains) ....................49

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Index of figures
Picture 1 – UPS block diagram .................................................................................................................... 6
Picture 2 – B8031FXS 10÷20kVA interconnections..................................................................................... 7
Picture 3 – B8033FXS 10÷60kVA interconnections..................................................................................... 8
Picture 4 – Rectifier...................................................................................................................................... 9
Picture 5 – Battery charger characteristic .................................................................................................. 10
Picture 6 – Inverter and static switch.......................................................................................................... 10
Picture 7 – Operation with non-linear load................................................................................................. 12
Picture 8 – Thermal image characteristic................................................................................................... 12
Picture 9 – Overload with bypass available................................................................................................ 13
Picture 10 – Overload with bypass not available ....................................................................................... 13
Picture 11 – Short-circuit characteristic (bypass not available).................................................................. 14
Picture 12 – Normal operation.................................................................................................................... 16
Picture 13 – Battery operation.................................................................................................................... 17
Picture 14 – Bypass operation (manual changeover)................................................................................ 18
Picture 15 – Bypass operation (automatic changeover) ............................................................................ 18
Picture 16 – Manual Bypass for functional tests........................................................................................ 19
Picture 17 – Manual Bypass for repair or maintenance works................................................................... 19
Picture 18 – UPS front panel...................................................................................................................... 20
Picture 19 – Handling of a UPS unit up to 60kVA...................................................................................... 25
Picture 20 – Base plan ............................................................................................................................... 26
Picture 21 – Dimensions and distance from the walls................................................................................ 27
Picture 22 – Terminal board B8031FXS 10-15-20kVA .............................................................................. 34
Picture 23 – Terminal board B8033FXS 10-15-20kVA .............................................................................. 34
Picture 24 – Terminal board B8033FXS 30-40kVA.................................................................................... 34
Picture 25 – Terminal board B8033FXS 50-60kVA.................................................................................... 34
Picture 26 – Base plan of the external battery cabinet............................................................................... 38
Picture 27 – Dimensions of the external battery cabinet............................................................................ 39
Picture 28 – Battery cabinet and UPS connection..................................................................................... 40
Picture 29 – Interfaces of UPS B8000FXS................................................................................................. 42
Picture 30 – Charging voltage / temperature curve.................................................................................... 44
Picture 31 – Example of UPS units connected in parallel.......................................................................... 48
Picture 32 – Block diagram of Diesel Generator interface......................................................................... 49

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1. UPS GENERAL DESCRIPTION
The UPS of the B8031FXS 10÷20kVA and B8033FXS 10÷60kVA 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 32 bit microprocessor, implementing full
digital control of the system.
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 indicated real time on the display.
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 mains 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 monitoring devices
Auto-diagnostic feature and troubleshooting support
Flexibility of complete bypass configuration
Full access from the front and from the roof for maintenance

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The UPS of the B8031FXS and B8033FXS series consists of three single-phase
AC/AC conversion modules connected to each other in order to obtain UPS units with
single or three-phase output, based on the configuration required. The microprocessor
checks the operating parameters of each module. The pictures below show the
interconnections of the UPS with single or three-phase output.
Picture 2 – B8031FXS 10÷20kVA interconnections

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Picture 3 – B8033FXS 10÷60kVA interconnections

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The block diagram in picture 1 shows the UPS subsystems that will be analysed in
the following chapters:
Rectifier/Battery Charger (R)
Inverter (I)
Battery (B)
Static Switch: Static Inverter Switch (SSI) and Static Bypass Switch (SB)
Manual Bypass (MB)
NOTE
The description and the diagrams in the various sections always refer to the single
conversion module.
1.1 RECTIFIER / BATTERY CHARGER
The Rectifier/Battery charger converts the AC input voltage to DC voltage, feeding
the inverter and keeping the battery charged.
Picture 4 – Rectifier
The rectifier is based on a full-digital control of the IGBT bridge, which allows to
minimize the harmonics re-injected into the mains and reduces the harmonic distortion
of the current to less than 3%. The trend of the power absorbed by the mains is almost
sinusoidal with a power factor higher than 0,99, thanks to the PFC (Power Factor
Correction) technology.
Each IGBT of the rectifier bridge operates on a battery polarity, and the neutral
conductor of the input line represents the central point.
Current transducer TA1 provides the feedback for the input current waveform, that is
used by the microprocessor to vary the modulation (PWM) of the IGBT’s.
The battery recharging current is automatically limited by the control software, using
the feedback signals provided by the transducers TA3-TA4.
Inductors L3-L4, installed as an OPTION, reduce the current ripple to optimize the
expected battery life.

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1.1.1 Battery charger characteristic
A single-level charge is used. This is an optimal solution 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 5 – Battery charger characteristic
1.2 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 two 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.
Picture 6 – Inverter and static switch

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Inductance L2 forms, together with the AC capacitors, a low-pass filter that provides
to eliminate the high frequency ripple and keep the total harmonic distortion (THD) of
voltage lower than 2% (with linear load).
The stability of output voltage and the dynamic response are optimized by using two
nested current and voltage loops. The DC component on the output voltage is controlled
by a separate loop (Anti Saturation Loop “ASL”).
The total harmonic distortion of output voltage is kept very low with both linear and
non-linear load (see description in paragraph 2.2.1) via "CBG" (Current Boost Gain)
control.
The selectivity in case of short-circuit (see picture 12) is very high, and the voltage
recovery time is digitally controlled (Soft Short Recovery Loop “SSRL”).
The inverter, thanks to its manufacturing technology and to the microprocessor
control, is able to supply indifferently inductive or capacitive loads. . In case the load is
highly capacitive (p.f. < 0.9) contact the sales department to verify whether a slight
power de-rating is necessary or not.

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1.2.1 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 voltage 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.
Picture 7 – Operation with non-linear load
1.2.2 Overload management
The inverter can provide continuously 100% of nominal load and can tolerate
overload conditions up to 125% for 10 minutes or 150% for 30 seconds.
Peak conditions such as take-off of engines or magnetic parts are managed limiting
the output current to 200% for 5 cycles, then reducing to 150%.
Any time output power grows above 100% the inverter keeps feeding the loads, while
the microprocessor activates the “thermal image” algorithm to calculate the power
overload based on the output current and duration of the overload.
User loads are powered by inverter output up to the end of maximum allowed time,
then the static switch transfers the load to the emergency line without interruption of
output power.
Picture 8 – Thermal image characteristic

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Picture 9 – 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 threshold value is
reached the load is
transferred to bypass.
To allow a safe cooling of the
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 10 – 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 threshold value is
reached the inverter is
switched off to avoid severe
damages to the components.
As soon as the bypass is
available again the load is
supplied by the static bypass
switch.
After 30 minutes the inverter
is switched on again and the
load is transferred again to
the primary supply.
WARNING: this operation
causes the loss of the
supply to the load

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1.2.3 Short-circuit operation
As soon as an output short-circuit is detected (alarm A11), 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 current to 200% for 100ms, and then to 150% for 5 seconds, after that it is switched
off (according to EN 62040-3 / EN 50091-3).
Picture 11 – Short-circuit characteristic (bypass not available)
1.2.4 IGBT bridge protection
The power semiconductors of the inverter bridge are protected by ultra-quick fuses
connected on the bridge input.
1.3 BATTERY
On the UPS of the B8000FXS 10÷20kVA series the battery can be installed inside
the UPS for 10 – 15 – 20kVA units (max. 60 or 62 9Ah battery blocks), or in an external
cabinet for higher battery capacities, where as for the 30...60kVA series the battery is
always installed in an external cabinet. The lead-acid sealed battery consists of two
banks composed of 180 cells + 180 cells (60 battery blocks in total), or 186 cells + 186
cells (62 battery blocks in total).
The battery charger control logic is completely integrated inside the rectifier control
board; the battery is charged, according to the DIN 41773 Standard, every time it has
been partially or completely discharged. It is kept floating, even when it is charged, to
compensate any auto-discharge.

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1.4 STATIC SWITCH
The static switch, the diagram of which is shown in picture 6, is composed of
thyristors, rated to work continuously at 200% of nominal output power.
The components connected to the bypass line are protected by ultra-quick fuses.
The static switch is provided with a protection which minimizes the risk caused by a
possible return of the inverter voltage in case of emergency mains failure (back-feed
protection). Thanks to the transfer logic integrated in the control, the load is supplied by
the bypass line even in case of microprocessor failure. The overload capacity of the
static switch is shown below.
Overload capacity: 200% continuous
1000% for 1 cycle
1.4.1 Inverter Emergency Line Transfer
The transfer is activated only if the 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 voltage out of tolerance (Inverter OFF) Emergency line within tolerance limits
Overtemperature 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
1.4.2 Emergency Line Inverter transfer
As soon as inverter is correctly working and synchronized, UPS automatically
switches the load to inverter in less than 1 msec. If UPS switches back and forth more
than 6 times in two minutes an alarm will be generated, to inform the user, and the load
will be locked to emergency line. A manual reset is necessary to switch the supply back
to the inverter.
1.5 MANUAL BYPASS
To safely allow maintenance and repair of the unit, UPS is provided with a manual
bypass switch.
In this mode all the testing activities to verify the efficiency of the system can be
carried out safely. Manual bypass must be inserted by following the instructions given in
the operating manual. During the transfer to manual bypass there is no interruption of
the supply to the load.

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2. OPERATING MODES
2.1 NORMAL OPERATION
During normal operation all the circuit breakers/isolators are closed, except for MBCB
(maintenance bypass).
The three-phase input AC voltage feeds the rectifier via the filter inductor; the rectifier
supplies the inverter and compensates 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 with stabilized voltage and
frequency, and also supplies the load via its static switch SSI.
Picture 12 – Normal operation


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2.2 BATTERY OPERATION
In the event of mains failure, or rectifier failure, the battery feeds the inverter without
interruption. The battery voltage drops as a function of the magnitude of the discharge
current. The voltage drop 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 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 (black-out).
As soon as the power is restored the rectifier charges the battery. In the standard
configuration, the loads are supplied again via static switch SSB when mains is
available again. The inverter is restarted when the battery has partially restored its
capacity.
The system restart from the black-out condition can be customized based on the
requirements of the plant, in three different modes:
Bypass loads are supplied as soon as the bypass line is available
(factory configuration).
Inverter loads are supplied by the inverter (even if the bypass line is
available) when the battery voltage has reached a
programmed threshold, after the rectifier restart.
Man. Inverter the output supply is NOT restored automatically. The
system requires a confirmation to restart which can only be
done manually by the user via the front panel.
Picture 13 – Battery operation



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2.3 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 14 – Bypass operation (manual changeover)
The automatic change-over occurs for the reasons explained in paragraph 2.4.1;
basically when the power supply to the load within the specified tolerance cannot be
assured by the inverter.
Picture 15 – Bypass operation (automatic changeover)

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2.4 MANUAL BYPASS
The manual bypass operation is necessary every time the functionality of the UPS
needs to be checked or during maintenance or repair works.
The manual bypass procedure is described in the UPS operating manual and must
be followed carefully in order to avoid damages to the UPS.
During the functional check of the UPS, all the breakers can be closed, except for the
output breaker OCB, and the full functionality can be tested.
Picture 16 – Manual Bypass for functional tests
During the manual bypass operation for repair or maintenance, the UPS is
completely switched off and the load is supplied directly by the bypass mains.
Picture 17 – Manual Bypass for repair or maintenance works

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
3. FRONT PANEL
The front panel of the UPS, consisting of a four-row alphanumeric display plus 5
function keys, allows the complete monitoring of the UPS status.
The mimic flow helps to understand the operating status of the UPS.
Picture 18 – UPS front panel
3.1 FUNCTION BUTTONS
The front panel of the UPS is provided with 5 buttons whose functions are indicated
in the following table:
Button Assignedfunctions
Scrollsupthemenus
Increasesthevaluesbyoneunit
Selectsavalue
Scrollsdownthemenus
Decreasesthevaluesbyoneunit
Selectsavalue
Selectsamenu
Confirmschanges
Silencesthebuzzer(activatedduetoanalarmorafailure)
Returnstothepreviousmenu