Borri B9000FXS 60kVA User manual

Rev. Descrizione
Description Data Date Emesso Issued Approvato Approved Lingua Language Pagina Page di Pag. of Pag.
F Code upgrade 20.05.13 E. Biancucci F. Berti E 1 54
Codice / Code
OMD10078
English
PRODUCT MANUAL
UNINTERRUPTIBLE POWER SUPPLIES
B9000FXS 60kVA (3PH / 3PH)
B9000FXS 80kVA (3PH / 3PH)
B9000FXS 100kVA (3PH / 3PH)
B9000FXS 125kVA (3PH / 3PH)
B9000FXS 160kVA (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.
Borri 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 Borri.
Borri cannot be held responsible of the consequences deriving from the use of non original spare parts.
Borri 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.
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 ................................................................7
1.1.1Operation with ONE charging level ........................................................8
1.2 INVERTER........................................................................................................8
1.2.1Operation with non-linear load ...............................................................9
1.2.2Overload management ..........................................................................10
1.2.3Short-circuit operation ..........................................................................11
1.2.4IGBT bridge protection..........................................................................12
1.3 BATTERY .......................................................................................................13
1.4 STATIC SWITCH............................................................................................13
1.4.1Inverter Emergency Line Transfer....................................................14
1.4.2Emergency Line Inverter Transfer....................................................14
1.5 MANUAL BYPASS.........................................................................................14
2. OPERATING MODES........................................................................ 15
2.1 NORMAL OPERATION ..................................................................................15
2.2 BATTERY OPERATION.................................................................................16
2.3 BYPASS OPERATION...................................................................................17
2.4 MANUAL BYPASS.........................................................................................18
3. FRONT PANEL.................................................................................. 19
3.1 FUNCTION BUTTONS ...................................................................................19
3.2 FUNCTION OF MIMIC PANEL LED’S............................................................19
3.3 ALARMS AND OPERATING STATUS...........................................................21
3.4 MEASUREMENTS ON THE DISPLAY...........................................................22
4. GENERAL TECHNICAL INFORMATION ......................................... 23
4.1 TECHNICAL DATA.........................................................................................23
4.2 INSTRUCTIONS FOR INSTALLATION..........................................................23
4.2.1Receipt of the UPS.................................................................................23
4.2.2Storage....................................................................................................23
4.3 HANDLING OF THE UPS...............................................................................24
4.4 POSITIONING AND INSTALLATION.............................................................25
4.4.1Base plan, static load and weights.......................................................25
4.4.2Overall dimensions................................................................................26
4.4.3Minimum distances from the walls and ventilation.............................27

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4.4.4Environmental installation conditions .................................................28
4.5 ELECTRICAL CONNECTION ........................................................................30
4.6 BACKFEED PROTECTION DEVICE..............................................................32
4.7 TERMINAL BOARDS.....................................................................................33
4.8 CONNECTION OF POWER CABLES............................................................34
4.9 CONNECTION OF AUXILIARY CABLES ......................................................35
4.9.1External manual bypass........................................................................36
4.9.2Diesel generator (DIESEL MODE).........................................................36
4.9.3Auxiliary battery contact .......................................................................36
4.9.4Remote emergency power off...............................................................36
4.10 SERIAL INTERFACES................................................................................37
4.11 POSITIONING AND CONNECTION OF BATTERIES ................................38
4.10.1External battery ..................................................................................38
5. OPTIONS........................................................................................... 41
5.1 STANDARD OPTIONS INCLUDED TO BE SET VIA SOFTWARE ...............41
5.1.1Diesel generator.....................................................................................41
5.1.2Off-line ....................................................................................................41
5.1.3Two-level charge “Boost Charge”........................................................42
5.1.4Programmable rectifier soft-start (Walk-in) .........................................43
5.1.5Sequential rectifier start for parallel systems (Hold-off) ....................43
5.1.6Frequency converter..............................................................................43
5.1.7DCM function..........................................................................................43
5.2 OPTIONS PROVIDED ON REQUEST............................................................43
5.2.1Thermal compensation of battery charge............................................44
5.2.2Bypass insulation transformer .............................................................44
5.2.3Voltage adaptation transformers..........................................................44
5.2.4Alarm card SRC (ALARM RELAY CARD).............................................45
5.2.5Serial interface RS-485 (Mod-Bus protocol) ........................................46
5.2.6SNMP adapter.........................................................................................46
5.2.7Remote panel..........................................................................................46
5.2.8Parallel kit...............................................................................................46
5.2.9Battery cabinet.......................................................................................48
5.2.10Wall mounted isolator with battery fuses.........................................48
5.2.11Connections........................................................................................48
5.2.12Technical data.....................................................................................49

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5.2.13Cables inlet from the top....................................................................50
5.2.14Special painting..................................................................................51
5.2.15“Load-Sync-Bus” kit for single unit..................................................52
5.2.16Kit “Parallel system Load-Sync-Bus”...............................................53
5.2.17Back feed (protection from power return to mains) ........................54
Index of pictures
Picture 1 – UPS block diagram .................................................................................................................... 6
Picture 2 – Rectifier...................................................................................................................................... 7
Picture 3 – Operation with ONE charging level............................................................................................ 8
Picture 4 – Inverter....................................................................................................................................... 8
Picture 5 – Operation with non-linear load................................................................................................... 9
Picture 6 – Thermal image characteristic................................................................................................... 10
Picture 7 – Overload with bypass available................................................................................................ 10
Picture 8 – Overload with bypass not available ......................................................................................... 11
Picture 9 – Short-circuit characteristic (Bypass not available)................................................................... 11
Picture 10 – IGBT bridge protection........................................................................................................... 12
Picture 11 – Static switch and manual bypass........................................................................................... 13
Picture 12 – Normal operation.................................................................................................................... 15
Picture 13 – Battery operation.................................................................................................................... 16
Picture 14 – Bypass operation (manual changeover)................................................................................ 17
Picture 15 – Bypass operation (automatic changeover) ............................................................................ 17
Picture 16 – Manual Bypass for functional tests........................................................................................ 18
Picture 17 – Manual Bypass for repair or maintenance works................................................................... 18
Picture 18 – UPS front panel...................................................................................................................... 19
Picture 19 – UPS mimic panel.................................................................................................................... 19
Picture 20 – Handling of UPS B9000FXS.................................................................................................. 24
Picture 21 – Base plan ............................................................................................................................... 25
Picture 22 – Overall dimensions of UPS B9000FXS.................................................................................. 26
Picture 23 – Minimum distances from the walls......................................................................................... 27
Picture 24 – Position of power terminals of B9000FXS ............................................................................. 33
Picture 25 – Position of auxiliary terminals of B9000FXS.......................................................................... 35
Picture 26 – Auxiliary terminals of B9000FXS............................................................................................ 36
Picture 27 – Interfaces of UPS B9000FXS................................................................................................. 37
Picture 28 – Dimensions of the external battery cabinet............................................................................ 39
Picture 29 – Base plan of the external battery cabinet............................................................................... 39
Picture 30 – Battery cabinets connections................................................................................................. 40
Picture 31 – Block diagram of Diesel Generator interface......................................................................... 41

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Picture 32 – BOOST charge diagram......................................................................................................... 42
Picture 33 – Charging voltage / temperature curve.................................................................................... 44
Picture 34 – Example of UPS units connected in parallel.......................................................................... 47
Picture 35 – Battery isolator connection..................................................................................................... 48
Picture 36 – Technical data of battery isolator........................................................................................... 49
Picture 37 – UPS dimensions with additional cabinet for cables inlet from the top ................................... 50
Picture 38 – UPS dimensions with additional cabinet for cables inlet from the top ................................... 50
Picture 39 – Base plan of UPS with additional cabinet for cables inlet from the top ................................. 51
Picture 40 – Example of UPS units in Sync-Load configuration – single configuration............................. 52
Picture 41 – Example of UPS units in Sync-Load configuration – single configuration............................. 53
Picture 42 – Example of UPS units in Sync-Load configuration – parallel configuration........................... 53
Picture 43 – Example of UPS units in Sync-Load configuration – parallel configuration........................... 54

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1. UPS GENERAL DESCRIPTION
The UPS of the B9000FXS 60÷160kVA 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
The block diagram shows the UPS subsystems that will be analysed in the following
chapters:
Rectifier/Battery Charger (R)
Inverter (I)
Battery (B)

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Static Switch: Static Inverter Switch (SSI) and Static Bypass Switch (SB)
Manual Bypass (MB)
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 2 – Rectifier
The AC/DC conversion is carried out by a three-phase three-level PWM rectifier,
combining a three-phase diode bridge with a DC/DC step-up converter. The full-digital
control of the IGBT bridge allows to minimize the harmonics re-injected into the mains
and reduces the harmonic distortion of the current to a very low value even with low
loads. 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.
The current transducers TA1-TA2-TA3 provide 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 transducer TA4.

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1.1.1 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
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 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 current transducer CT provides for the monitoring of the input current. Its
feedback signal is managed by the microprocessor to activate the current limitation (see
2.2.3) and the IGBT protection (see 2.2.4).
Picture 4 – Inverter
The output transformer provides galvanic insulation between DC and AC side, as
well as voltage adaptation. Its integrated inductance forms, together with the AC

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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 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.
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 5 – Operation with non-linear load

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1.2.2 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, then reducing to 125%.
Any times 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 6 – Thermal image characteristic
Picture 7 – 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.

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Picture 8 – 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
1.2.3 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 current to 200% for 100ms, and then to 125% for 5 seconds, after that it is switched
off (according to EN 62040-3 / EN 50091-3).
Picture 9 – Short-circuit characteristic (Bypass not available)

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1.2.4 IGBT bridge protection
The inverter input current monitoring is carried out by the 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 does not reach the
protection threshold.
In case of short-circuit in the inverter bridge, the DC input current increases
immediately and there is no possibility of limitation but stopping the PWM.
In this case the alarm A12 – Max Current Stop is activated and must be reset
manually after having verified the status of the semiconductors.
Picture 10 – IGBT bridge protection

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1.3 BATTERY
On the B9000FXS 60÷160kVA UPS, the battery is always installed in external
additional cabinets.
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.
1.4 STATIC SWITCH
Static switch is composed of thyristors, rated to work continuously at 150% of
nominal output power.
The components connected to the bypass line are protected by fuses.
Picture 11 – Static switch and manual bypass
Thanks to the transfer logic integrated in the control, the load is supplied by the
bypass line even in case of microprocessor failure.

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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
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
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 double 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. For the full
navigation of the display, refer to the Operating Manual 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
Increases 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
3.2 FUNCTION OF MIMIC PANEL LED’S
Picture 19 – UPS mimic panel

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LED 1 GREEN AC line on rectifier input within tolerance
  GREEN Wrong phase rotation
OFF AC mains failure on rectifier input
LED 2
GREEN AC bypass line within tolerance
  GREEN Wrong phase rotation
OFF AC bypass line out of tolerance
AC bypass line failure
LED 3
  GREEN Rectifier off or faulty
RED DC voltage out of tolerance
GREEN Rectifier on and DC voltage within tolerance
LED 4
GREEN circuit breaker BCB closed and battery charging
  GREEN Battery discharging or under TEST
  ORANGE Circuit breaker BCB open
RED Battery fault (following a battery test)
OFF Battery not available
LED 5 GREEN Inverter voltage within tolerance and static switch
closed
  GREEN Inverter overload or short-circuit
OFF Inverter off or voltage out of tolerance
LED 6
  ORANGE Re-transfer blocked
ORANGE Static bypass switch closed
OFF Static bypass switch open
LED 7 GREEN output circuit breaker OCB closed
OFF Output circuit breaker OCB open
LED 8 ORANGE Manual bypass switch MBCB closed
OFF Manual bypass switch MBCB open
LED 9 RED Emergency power off (EPO) activated
OFF Normal operation
LED 10
  ORANGE Maintenance request (slow flashing)
  ORANGE Critical alarm (fast flashing)
OFF Normal operation