80-NET TM TechnicalManual Rev2!0!2007Mai10-2

Copyright © Chloride Power Protection 2007 All rights including translation, reproduction by printing, copying or similar methods of this document, even of parts, are reserved. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of utility model or design, are reserved. Delivery subject to availability. Important note! The technical data enclosed is for general information. Please note the operating instructions and the references indicated on the products for installation, operation and maintenance. Product designations All product designations used are trademarks or product names of Chloride S.p.A. or other companies. This publication is issued to provide outline information and is not deemed to form any part of any offer and contract. The company has a policy, of continuous product development and improvement and we therefore reserve the right to vary any information quoted without prior notice. Right of technical modification reserved.

80-NET – Technical Manual

10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 3/ 30780-NET printed: 15.05.2007, 13:09

80-NET

UNINTERRUPTIBLE POWER SUPPLY

Chloride Power Protection. All rights reserved.

The information in this manual must not be copied or disclosed to third parties without written permission from Chloride. Chloride constantly strives to improve its products and, therefore, reserves the right to make changes to the design, characteristics or components of the product without prior notice. Every effort has been made to ensure that the information in this manual is correct. As a result, Chloride declines all responsibility for any errors, accidents or damage which may arise.

Chloride Via Fornace 30

40023 Castel Guelfo (BO)

Tel. +39 0542 632111 Fax. +39 0542 632120 www.chloridepower.com

TECHNICAL MANUAL

80-NET

CODE 10H52167TM01 Rev. 2.0

http://www.chloridepower.com/


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Preamble Even the best device needs to be taken care of, if only for check-up or whether everything is within normal parameters. Due to working with dangerous voltages and high power, it is always possible, that there could happen any damage to the device. This 80-NET Technical Manual is thought for Service personal, which is trained by Chloride or Chloride authorised Trainers only. Please keep in mind that only qualified & authorized personnel is supposed to carry out any work on the UPS. The 80-NET User Handbook/User Manual is a basis to this 80-NET Technical Manual. So please keep a copy of the 80-NET User Manual ready for any work on the UPS or other 80-NET concerning matters. Both manuals should be studied before commencing work. There are further documents to this Technical Manual 80-NET (10H52167TM01):

• the Technical Manual 80-NET Circuit Diagrams (10H52167TM01_CD), • the Technical Manual 80-NET Checklists (10H52167TM01_CL), • the Technical Manual 80-NET PPVIS & PPGraph (10H52167TM01_PP).

All these documents belong together and where just separated for easier handling concerning updates and file-size. As already mentioned Chloride is keen on constantly seeking to improve its products and, therefore figures and technical data can/will change without prior notice. These data’s will not be AUTOMATICALLY updated by Chloride within this 80-NET Technical Manual and the additional documents. With every new released version of this 80-NET Technical Manual, Chloride will endeavour to update the information to the – at that time – current state. Every effort has been made to ensure that the information in this Technical Manual are correct. As a result, Chloride declines all responsibility for any errors, accidents or damage which may arise. Don’t be afraid of the high number of pages of this 80-NET Technical Manual as well as the additional documents (mentioned above). We tried to include all potentially required, relevant information about servicing the 80-NET. It is likely that some of these containing information will not be necessary for you to service your specific issue with the 80-NET. We even included procedures, checklists and their explanations for your convenience, which required a few pages in this manual.


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The following chapters will provide information starting from an overview of the principle of operation up to a detailed functional description. There will be explanations of the different boards and there interaction with each other. To complete the collection of procedures for commissioning and maintenance, we added chapters in order to provide courtesy for troubleshooting and repair. At the end of the Technical Manual you will find information – among other things – about parallel systems, options and list of components. Any work on the UPS including parameter changes should only be performed, if the reaction of the UPS is absolutely clear and not harming the UPS or its proper function. If you are not sure what the reaction will be, please contact the Chloride Service Support, before you act. For any further questions don’t hesitate to contact the Chloride Service Centre. Your Chloride Service Centre

2.0 2.0 2.0 2.0 15.05.2007 Introduction of 80-NET 160kVA and 200kVA 2.0 1.0 1.0 1.0 1.0 17.03.2006 First Release 1.0 TM CD PP CL

(Tech. Manual) (Circuit Diagrams) (PPVIS & PPGraph) (Checklists) Date Description Rev.

Note: If you order the Technical Manual concerning updates with the order no. 10H52167TM01, you will receive all 4 documents. In case you want just one of these documents, please specify within your order.


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Table of Content 1 Introduction ........................................................................................11 1.1 General .................................................................................................................. 11 1.2 Safety ..................................................................................................................... 12 1.2.1 General ............................................................................................................................. 12 1.2.2 Emergency........................................................................................................................ 12 1.2.3 Electric shock.................................................................................................................... 13 1.2.4 Precautions & Preparations .............................................................................................. 13 1.2.5 Access to electrically live UPS parts................................................................................. 14 1.3 Product variations and specifications................................................................ 15 1.3.1 Product variations ............................................................................................................. 15 1.3.2 Specification...................................................................................................................... 16 1.3.3 External Protection............................................................................................................ 20 1.4 Principle of operation........................................................................................... 21 1.4.1 General Overview ............................................................................................................. 21 1.4.2 Block diagram ................................................................................................................... 22 1.4.2.1 Operating Modes............................................................................................................................. 22 1.4.3 Intelligent Operating Modes.............................................................................................. 24 1.4.3.1 Double conversion Mode (DCM) ..................................................................................................... 24 1.4.3.1.1 Normal (DCM) ................................................................................................................................. 24 1.4.3.1.2 Overload (DCM) .............................................................................................................................. 24 1.4.3.1.3 Emergency (DCM)........................................................................................................................... 24 1.4.3.1.4 Recharge (DCM) ............................................................................................................................. 24 1.4.3.2 Digital Interactive Mode (DIM) ......................................................................................................... 25 1.4.3.2.1 Normal (DIM)................................................................................................................................... 25 1.4.3.2.2 Inverter stop (DIM) .......................................................................................................................... 25 1.4.3.2.3 Overload (DIM)................................................................................................................................ 25 1.4.3.2.4 Emergency (due to mains supply failure or variance beyond tolerance limits, DIM)........................ 26 1.4.3.2.5 Return to normal conditions (DIM)................................................................................................... 26 1.4.3.3 All modes......................................................................................................................................... 27 1.4.3.3.1 Maintenance bypass ....................................................................................................................... 27 1.4.3.3.2 Operation without battery ................................................................................................................ 27 1.4.4 Control and diagnostics .................................................................................................... 28 1.4.4.1 Vector control .................................................................................................................................. 28 1.4.4.2 Redundancy, preventive monitoring ................................................................................................ 28 1.4.4.3 Telediagnosis and Telemonitoring................................................................................................... 28 1.4.5 LCDisplay (Mimic Panel) .................................................................................................. 29

2 Functional Description......................................................................32 2.1 Overview................................................................................................................ 32 2.2 Boards ................................................................................................................... 33 2.2.1 Drawing 80-NET 60kVA/80kVA – where to find the boards ............................................. 33 2.2.2 Drawing 80-NET 100kVA/120kVA – where to find the boards ......................................... 39 2.2.3 Drawing 80-NET 160kVA – where to find the boards....................................................... 45 2.2.4 Drawing 80-NET 200kVA – where to find the boards....................................................... 51 2.2.5 I/O Signal and Serial Port Overview of the Board Interconnection................................... 57 2.2.6 CU Board - General Information ..................................................................................... 58 2.2.7 CU Board Rectifier AP1 (451909987710) ........................................................................ 60 2.2.8 CU Board Inverter AP2 (451909987710) ......................................................................... 62 2.2.9 Interface Board AP3, AP4 (15B10853G1)...................................................................... 64 2.2.10 SMPS Board AP5 (15B10860G1)..................................................................................... 66 2.2.11 Supply Interface Board AP6 (15B10848G1)..................................................................... 69 2.2.12 Bypass Control Board AP7 (15B10859G1) ...................................................................... 70



2.2.13 LCDisplay AP8 (710-01970) ............................................................................................. 71 2.2.14 Connectivity Board AP9 (15B10849G1) ........................................................................... 72 2.2.15 In/Out Board AP10 (15B10854G1) ................................................................................... 73 2.2.16 IGBT Driver Board AP11-AP17 (15B10851G1)................................................................ 74 2.2.17 IGBT Interface Board AP19-AP26, AP40-AP53 (15B10857G1) ...................................... 75 2.2.18 Fan Speed Control Board AP27, AP28, (AP29) (15B10855G1) ...................................... 76 2.2.19 Filter Board AP31-AP33 (15B10861G1).......................................................................... 77 2.2.20 Filter Board AP35 (15B10817G2)................................................................................... 77 2.2.21 Varistor Board AP36, AP37 (15B10671G5) ..................................................................... 77 2.3 Power Components .............................................................................................. 78 2.3.1 Rectifier............................................................................................................................. 78 2.3.1.1 Precharge........................................................................................................................................ 83 2.3.1.2 Current-walk-in ................................................................................................................................ 86 2.3.2 Booster/Charger (DC/DC IGBT Converter) ...................................................................... 87 2.3.3 Inverter.............................................................................................................................. 96 2.3.3.1 Pulse Width Modulation (PWM)..................................................................................................... 101 2.3.4 Bypass Static Switch ...................................................................................................... 103 2.4 Connectivity (Box) .............................................................................................. 107 2.4.1 Where to find the interfaces?.......................................................................................... 108 2.4.2 XS3 and XS6 – Slot Card Bay ........................................................................................ 108 2.4.3 X3 – RS232 Service Port................................................................................................ 109 2.4.4 X6 – Serial Interface ....................................................................................................... 111 2.4.5 X7 – Computer Relay Interface (Output Contacts)......................................................... 112 2.4.5.1 PRESET Siemens ........................................................................................................................ 113 2.4.5.2 PRESET IBM AS400.................................................................................................................... 114 2.4.6 X8 – Emergency Power Off (EPO) ................................................................................. 115 2.4.7 XT1 – External Battery Temperature Connector ............................................................ 116 2.4.8 XT2 – External Battery Switch Status............................................................................. 117 2.4.9 XT3 – EPO activated ...................................................................................................... 117 2.4.10 XT4 – Backfeed Protection activated.............................................................................. 118 2.4.11 AP10–XT6 – 4 free programmable Input Contacts......................................................... 118 2.4.12 AP10–XT5 – 2 free programmable Output Contacts...................................................... 119 2.4.13 AP10–X4 – Service Interface.......................................................................................... 120 2.4.14 Parameter Settings for Contacts in PPVIS ..................................................................... 121 2.4.15 Signal cables................................................................................................................... 129 2.5 Battery ................................................................................................................. 130 2.5.1 Battery Calculation.......................................................................................................... 131 2.5.1.1 Automatic recalibration of Discharging Characteristic ................................................................... 136 2.5.2 Battery Charging/Discharging......................................................................................... 137 2.5.2.1 Battery Charging Method............................................................................................................... 139 2.5.2.2 Initial Charging .............................................................................................................................. 143 2.5.2.3 Battery Temperature Compensation ............................................................................................. 144 2.5.3 Automatic Battery Test ................................................................................................... 145 2.5.4 Imminent Shutdown Curve ............................................................................................. 147 2.6 Service Software PPVIS ..................................................................................... 149 2.7 Firmware.............................................................................................................. 150 2.7.1 CU1 Rectifier................................................................................................................... 151 2.7.2 CU2 Inverter.................................................................................................................... 151 2.7.3 LCDisplay (incl. menu).................................................................................................... 152 2.7.4 Flashing of a CU-Board .................................................................................................. 155 2.7.4.1 Software and Hardware Requirements ......................................................................................... 155 2.7.4.2 How to flash a CU2-Board (Inverter)? ........................................................................................... 155 2.7.4.3 How to flash a CU1-Board (Rectifier)? .......................................................................................... 159



2.7.4.4 Direct connecting cable for CU-Board flashing.............................................................................. 160 2.7.5 Flashing of a LCDisplay.................................................................................................. 162 2.7.5.1 How to flash LCDisplay? ............................................................................................................... 162

3 Installation ........................................................................................169 3.1 General ................................................................................................................ 169 3.2 Placing the UPS & Battery ................................................................................. 169 3.3 Connecting the UPS & Battery .......................................................................... 170

4 Commissioning (Single Unit)..........................................................171 4.1 General ................................................................................................................ 171 4.1.1 Guided Procedures......................................................................................................... 172 4.2 Start-up Procedure ............................................................................................. 173 4.3 Shut-down Procedure ........................................................................................ 175

5 Maintenance .....................................................................................176 5.1 General ................................................................................................................ 176 5.2 Standard maintenance ....................................................................................... 177 5.3 Extended maintenance....................................................................................... 178 5.4 Battery maintenance .......................................................................................... 179

6 Troubleshooting & Repair...............................................................180 6.1 General ................................................................................................................ 180 6.2 Warnings and Faults .......................................................................................... 181 6.2.1 Warnings......................................................................................................................... 182 6.2.2 Faults .............................................................................................................................. 188 6.2.3 Additional Explanations for Warning and Faults............................................................. 196 6.2.3.1 Warning 3 – Primary supply warning............................................................................................. 196 6.2.3.2 Warning 6 – Overload Warning ..................................................................................................... 196 6.2.3.3 Warning 10 – Battery imminent end of autonomy warning ............................................................ 197 6.2.3.4 Warning 11 – Battery end of discharge warning............................................................................ 198 6.3 Trouble Locating & Testing ............................................................................... 199 6.3.1 Rectifier examination ...................................................................................................... 202 6.3.2 Inverter examination (Power Circuit Test) ...................................................................... 202 6.3.3 IGBT examination ........................................................................................................... 206 6.3.3.1 How to check the IGBTs?.............................................................................................................. 206 6.3.3.2 Changing the IGBTs...................................................................................................................... 208 6.3.4 Capacitor Reforming....................................................................................................... 209 6.3.5 Backfeed protection ........................................................................................................ 210 6.3.6 EPO in & out ................................................................................................................... 210 6.3.7 Automatic bypass test..................................................................................................... 210 6.3.8 Automatic transfer inverter to bypass and bypass to inverter ........................................ 211 6.3.9 Verify maintenance bypass switch QS3 and neutral switch QS14................................. 211 6.3.10 Temperature sensors...................................................................................................... 212 6.3.11 DC-Link Calibration......................................................................................................... 213 6.3.12 Incident Scenario Analysis – Troubleshooting................................................................ 215 6.3.12.1 Case 1: Blown overvoltage protection on AP7 and AP33............................................................ 215 6.3.12.2 Case 2: Rectifier is not starting – Frequency 60 Hz .................................................................... 218 6.4 Replacing Procedures........................................................................................ 219 6.4.1 CU-Board ........................................................................................................................ 220 6.4.2 Fans ................................................................................................................................ 221



6.5 Battery ................................................................................................................. 223 6.5.1 Battery Current Limit Setting Procedure......................................................................... 224 6.5.2 Removing one battery block ........................................................................................... 225

7 Parallel Systems ..............................................................................226 7.1 General ................................................................................................................ 226 7.2 POB Connection ................................................................................................. 228 7.3 S.B.S. (System Bypass Switch)......................................................................... 229 7.4 Installation........................................................................................................... 230 7.5 Commissioning................................................................................................... 231 7.6 Maintenance ........................................................................................................ 235

8 Frequency Converter.......................................................................237

9 Optional Equipment.........................................................................238 9.1 LIFE...................................................................................................................... 238 9.1.1 Installation and Configuration ......................................................................................... 239 9.1.2 Troubleshooting .............................................................................................................. 244 9.1.3 PPVIS Parameters for LIFE............................................................................................ 245 9.2 ManageUPS NET Adapter II ............................................................................... 247 9.2.1 ManageUPS NET Adapter II installation ........................................................................ 248 9.2.2 MUN Configuration via DCU........................................................................................... 250 9.2.3 Environmental Sensor .................................................................................................... 252 9.3 Software............................................................................................................... 253 9.3.1 MopUPS Professional..................................................................................................... 256 9.3.2 MopUPS for Parallel/Redundant Systems (MopUPS P/R)............................................. 258 9.3.3 CIO (Critical Infrastructure Overseer) ............................................................................. 260 9.3.4 Remote Shutdown Clients .............................................................................................. 262 9.3.4.1 MopUPS Network Shutdown Agent (NSA) .................................................................................... 262 9.3.4.2 Remote Control Command (RCCMD) ........................................................................................... 263 9.3.5 Hardware Configuration Software................................................................................... 264 9.3.5.1 ManageUPS Discovery and Configuration Utility (DCU) ............................................................... 264 9.4 Connectivity ........................................................................................................ 265 9.5 Remote alarm unit (R.A.U.) ................................................................................ 266 9.5.1 Connecting the R.A.U. .................................................................................................... 268 9.6 External Battery Circuit Breaker ....................................................................... 269 9.7 MBSM External Synchronisation ...................................................................... 270 9.7.1 Connecting the MBSM.................................................................................................... 271 9.7.2 Configuration of the MBSM & UPS................................................................................. 274 9.8 JBUS .................................................................................................................... 275 9.8.1 Installation....................................................................................................................... 277 9.8.2 Troubleshooting .............................................................................................................. 278 9.9 Profibus ............................................................................................................... 279 9.9.1 Installation....................................................................................................................... 279 9.9.2 Troubleshooting .............................................................................................................. 281 9.10 Battery management modules .......................................................................... 282 9.11 Dust filters ........................................................................................................... 282



9.12 Special – Input Choke ....................................................................................... 283 9.12.1 Input Choke for 80kVA.................................................................................................... 283 9.12.2 Input Choke for 120kVA.................................................................................................. 284

10 List of Components .........................................................................285

11 Circuit Diagrams ..............................................................................289

12 Appendices.......................................................................................291 12.1 Checklists............................................................................................................ 291 12.2 List of Figures ..................................................................................................... 292 12.3 List of Parameters .............................................................................................. 295 12.4 List of Abbreviations .......................................................................................... 297 12.5 Glossary .............................................................................................................. 298 12.6 Index .................................................................................................................... 299


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1 Introduction

1.1 General Please keep in mind that only qualified & authorized personnel is supposed to carry out any work on the UPS. The safety instructions on the following pages have to be followed all the time. For easier understanding and to highlight important remarks and notices we introduced the “What’s important?”-Box. In this blue box you will find basic information to understand the function of the UPS unit or any other important issue.

What’s important?

Description of Function

Figure x-x: Office material

The grey “Why? … Additional Technical Information”-Box whereas is for more detailed background information, which are not necessarily essential to handle the 80-Net UPS, but which could be helpful in understanding the problem more clearly.

Why? … Additional Technical Information

Detailed Description Of BACKGROUND INFORMATION Technical Details


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1.2 Safety

1.2.1 General Chloride puts personal safety before all other considerations. For this reason, before carrying out any work on the UPS units, you must carefully read all the safety procedures indicated in this manual as well as in the user manual and apply them.

What’s important?

80-Net contains dangerous voltages. As a result, any work which requires opening of the protective panels must only be carried out by technical personnel authorised by Chloride .

Any maintenance work carried out in the UPS units must always be done with the machine in bypass state, as indicated in the user manual. Before starting to service the UPS, be sure to read this manual carefully for a correct and safe operation.

Warning: The intermediate circuit contains voltages, even after the mains power supply voltage has been disconnected. Before operating inside the equipment, always disconnect the batteries using the disconnecting switch and make sure that the voltages in the intermediate circuit has dropped to 0V. The connections between the rectifier and the inverter remain live for a considerable time.

Any work on the UPS including parameter changes should only be performed, if the reaction of the UPS is absolutely clear and not harming the UPS or its proper function. If you are not sure what the reaction will be, please contact the Chloride Service Support, before you act.

1.2.2 Emergency In the event of an emergency, you can immediately cut the power supply to the machinery by simply opening all of the switches in the unit. Open output switch QS4 first, before opening the other switches. These switches are located behind the door on the front of the 80-NET. You can also cut the power by pressing the EPO emergency stop push button, if this option is installed.

Warning: In case of using the EPO, be aware that the battery voltage is still present on the UPS!!



1.2.3 Electric shock In the event of an accident caused by an electric shock, immediately open all machine switches, or use a dry insulating material to isolate the casualty from live wires.

What’s important?

Do not touch the casualty with your hands until he or she has been isolated from all the live parts.

After this seek immediately help.

1.2.4 Precautions & Preparations What’s important?

Provide an adequate over current protection on the bypass line. In this UPS the bypass line doesn’t have internal fuses!

Provide protections against possible power components failure. The power transistors, the input transient suppressor and the power capacitors may explode.

Never remove the second access panels of the machine unless you have completed a qualification course with Chloride or recognised companies. CAUTION: Removing these panels exposes live components.

Never work alone. Ensure that there is always someone present, able cutting the power and able providing assistance if required.

Always place a mat made of an insulating material in front of the 80-NET before carrying out any operations on it. In addition before working on the machine remove watches, rings, metal pens and any other metal object which could cause a short circuit.

Do not touch the printed circuit boards, except when the UPS unit is in the Bypass state (wait for the voltages in the intermediate circuit to drop to 0V) and for any maintenance operation use completely insulated tools only.

Batteries contain poisonous and corrosive acid, which could cause burning on contact with skin or eyes. In case acid is spilt on clothes or gets into eyes, wash well with plenty of clean water. Batteries are electrically live at all times and can give off explosives gases. Keep sparks, flames, and lighted cigarettes away. Even when damaged batteries are still capable of supplying high short circuit currents.

For replacing the fans, put the 80-NET into maintenance bypass. Wait for the fans to stop rotating!



1.2.5 Access to electrically live UPS parts.

What’s important?

It must always be remembered that, once the second access panels are removed, live components are exposed.

As a consequence, be careful managing tools and always remember that capacitor units and boards could be electrically live even if all the switches are off. Once maintenance is finished carefully replace the second access panel to avoid compromising the electrical isolation.


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1.3 Product variations and specifications This specification describes a continuous operating three-phase, solid state, full IGBT double conversion uninterruptible power supply (UPS). The UPS is automatically providing continuity of electrical power, within defined limits and without interruption, upon failure or degradation of the commercial AC source. The continuity of conditioned electric power is delivered for the time period defined by the battery system. The rectifier, the inverter, and other mission critical converters within the UPS, are driven by vector control algorithms running on dedicated digital signal processor (DSP) systems.

1.3.1 Product variations The 80-NET product range includes the following three-phase input/output models: MODEL Rating (kVA) Order number (basic model) 80-NET/60 60 CH8006 0AA00 0AA0 (1)(2) 80-NET/80 80 CH8008 0AA00 0AA0 (1)(2) 80-NET/100 100 CH8010 0AA00 0AA0 (1)(2) 80-NET/120 120 CH8012 0AA00 0AA0 (1)(2) 80-NET/160 160 CH8016 0AA00 0AA0 (1)(2) 80-NET/200 200 CH8020 0AA00 0AA0 (1)(2)

(1) For Siemens branded units there will be “6SU23” instead of the “CH80 ” For Masterguard branded units there will be “SU63” instead of the “CH80”

(2) For non standard products, please refer to the catalogue for any other configuration (options).

Figure 1-1: Picture 80-NET/80kVA

Figure 1-2: Picture 80-NET/120kVA

There are several options available e.g. remote alarm unit, dust filters, LIFE.net. For more details please refer to the “UPS catalogue 80-NET” and chapter 9 of this manual.



1.3.2 Specification The UPS provides high quality AC power for electronic equipment loads and offers the following features:

• Increased power quality • Full input Power Factor Correction (PFC) and very low THDi (Top version only) • Full compatibility with any installation and/or any standby power generator • Full compatibility with all types of loads • Power blackout protection • Full battery care • Energy saving features

The input and output neutral connection are the same, i.e. they are solidly tied together. 80-NET should be used in installation with grounded neutral. ALL following Technical Data Tables (Version from November 2006) will not be updated!!! Please check the Partner website for the newest version. UPS Unit Rating 60 80 100 120 160 200 Primary input Nominal input voltage(1) (V) 400 (3Ph +N) Voltage range (V) 340 to 460 Minimum voltage without battery discharge (V) 320

Mains configuration Symmetrical 3Ph mains+N, e.g. TN-C, TN-S, TN-C-S

Nominal frequency + range (Hz) 50 (60 selectable) ±6% Maximum input current @ ambient temperature within the range 0° to 40°C(11) (A) 94 125 156 185 250 312

Power factor @ nominal load and inputconditions(2) ≥0,99

I/p current distortion @ nominal i/p conditions(2)

and maximum i/p power (3) (11) (%) <3

Maximum input current distortion(3) (11) (12) (%) ≤5 Walk in/Soft start (sec) 10 (1-90 selectable) Rectifier Hold-Off (sec) 1 (1-180 selectable) Inrush current / Imax input (4) ≤1 Rectifier efficiency without charging current @nominal i/p conditions (2) with resistive load: Half load(7) Full load(7)

(%)

≥94,9 ≥96,5

≥96,2 ≥97

≥95,9 ≥97

≥96,2 ≥97

≥96,1 ≥97

≥95,9 ≥97



UPS Unit Rating 60 80 100 120 160 200 Battery Permissible battery voltage range (V) 390 to 700 Recommended no. of cells: VRLA (5) WET NiCd

240 240 375

VRLA float voltage @ 20°C (6) (V/cell) 2,27 VRLA end cell voltage (V/cell) 1,65 VRLA float voltage temp. compensation -0,11% per °C DC ripple current in float mode for a 10 min.autonomy as per VDE0510 (5) < 0,05C10

Float voltage stability in steady state condition (%) ≤1 DC ripple voltage without battery (%) ≤1 Optimum battery temperature (°C) 15 to 25 Battery recharge current setting range for 240cells @ Vi/p = 400V (A) 0-23 0-31 0-39 0-44 0-62 0-77

Battery recharge current setting range: for 240 cells @ Vi/p = 340V (A) 0-6 0-8,5 0-10,5 0-10,5 0-17 0-21

Battery output power in discharge mode withnominal load (kW) 50,2 67 83,7 100,5 134 167,5

End battery voltage for 240 cells (V) 396 End battery current for 240 cells with nominalload (A) 127 169 211 254 338 423

UPS Unit Rating 60 80 100 120 160 200 System data Maximum primary input current @ ambienttemperature within the range 0° - 40°C (A) 94 125 156 185 250 312

AC/AC double conversion efficiency withoutcharging current @ nominal i/p conditions (2) with resistive load: (11) 25% load (7) 50% load (7)

75% load (7) 100% load (7) Digital interactive (7)

(%)

82,8 90

92,7 93 98

86 92,5 93 94 98

87,1 92

93,4 94 98

88 92,5 93,8 94 98

88 92,3 93,4 94 98

87 92 93 94 98

Heat dissipation at nominal input conditions andoutput load: (11) Float mode Recharge mode Digital i/p active mode

(kW)

3,6 4,3 1

4,1 4,9 1,3

5,1 6,1 1,6

6,1 7,3 1,9

8,2 9,8 2,6

10,2 12,2 3,3

Noise @ 1 meter as per ISO 3746 + range (dBA) 65±2 68±2 70±2 Protection degree with open doors IP20 Mechanical dimensions: Height (mm) 1780 Width (mm) 570 845 1120 1245 Depth including front handle and vents (mm) 858 Depth w/o front handle and vents (mm) 830 No. of cabinets 1 Frame color (RAL) 7035 Weight (kg) 290 390 500 600 Floor area (m²) 0,49 0,72 0,96 1,07 Floor loading (kg/m²) 617 557 520 560 Cable entry Bottom/Side Access Front Cooling (8) Forced ventilation with fan redundancy



UPS Unit Rating 60 80 100 120 160 200 Inverter output Nominal apparent power @ 40°C ambient (kVA) 60 80 100 120 160 200 Nominal active power (kW) 48 64 80 96 128 160 Nominal output current (A) 87 116 145 174 232 290 Maximum active power up to 100% of nominal apparent power (11) Conditions apply (10)

Overload at VOUT NOM. for 10 minutes (%) 125 Overload at VOUT NOM. for 1 minute (%) 150 Short circuit current for 10ms/<5s (%) 200/150 Nominal output voltage (V) 400 (380/415 selectable, 3Ph + N) Nominal output frequency (Hz) 50 (60 selectable) Voltage stability in steady state condition forinput (AC & DC) variations and step load (0 to100%)

(%) ±1

Voltage stability in dynamic condition for inputvariation (AC & DC) and step load (0 to 100% and vice versa)

(%) Complies with IEC/EN 62040-3, Class 1

Voltage stability in steady state for 100% loadimbalance (0, 0, 100) (%) ±3

Output frequency stability: synchronised with bypass mains synchronised with internal clock

(%)

±1 (2, 3, 4 selectable) ±0.1

Frequency slew rate (Hz/sec) <1 Output voltage distortion with 100% linearload (%) <3

Output voltage distortion @ reference nonlinear load as for IEC/EN 62040-3 (%) <5

Load crest factor without derating the UPS (Ipk/Irms) 3:1 Phase angle accuracy with balanced loads (degrees) 1 Phase angle accuracy with 100% unbalancedloads(11) (degrees) <3

Inverter efficiency @ nominal input conditions with resistive load: Half load (7) Full load (7)

(%)

≥94,9 ≥96,5

≥96,2 ≥97

≥95,9 ≥97

≥96,2 ≥97

≥96,1 ≥97

≥95,9 ≥97

Neutral conductor sizing 1.7 nominal current Output power upgrading with ambienttemperature: At 25°C At 30°C At 40°C

(%)

110 105 100



UPS Unit Rating 60 80 100 120 160 200 Static bypass Nominal bypass voltage (1) (V) 400 (380/415 selectable, 3Ph + N) Bypass voltage tolerance (%) ±10 Nominal frequency (Hz) 50 (60 selectable) Frequency range (%) ±1 (2, 3, 4 selectable) Maximum overload capacity: For 10 minutes For 1 minute For 600 milliseconds For 100 milliseconds

(%)

125 150 700

1000 (A2s) 80000 125000 320000 SCR

I²t @ Tvj=125°C; 8.3-10ms ITSM @ Tvj=125°C; 10ms (A) 4000 5000 8000 Transfer time whit inverter synchronous tobypass: Inverter to Bypass Bypass to Inverter

(ms)

no break no break

Default transfer delay time (inverter to bypass)with inverter not synchronous to bypass (ms) <20

UPS Unit Rating 60 80 100 120 160 200 Environmental Temperature: Operating Max average daily (24hrs) Maximum (8 hrs)

(°C)

0-40 35 40

Maximum relative humidity @ 20°C (noncondensing) (%) Up to 90 %

Max altitude above sea level without derating (m) 1000 (for higher altitudes 80-NET complies with IEC/EN 62040-3)

Climate class according to IEC 721 Better than 3K2, see notes about installation site; check in accordance with IEC 68-2

(1) In case of a split bypass configuration, the primary input and the bypass input must have a common earth. The neutral conductor

could be part only to the bypass or primary mains but it must be present . (2) At nominal voltage and nominal frequency. (3) With input voltage at nominal value and with voltage distortion THDv ≤1%. (4) “Imax input” can be calculated using the maximum input power @ 400V in battery recharge mode. (5) Permitted number of cells = 240-300. Special battery cabinets needed for more then 240 cells. (6) There are several possible charging methods.. See chapter 2.5.2 for details. (7) For tolerances see IEC/EN 60146-1-1 or DIN VDE 0558; values ae referred to 80 and 120kVA ratings. (8) Redundant cooling system. With one fan OFF the UPS can supply continuously 70% of the nominal output power @ 25°C

ambient. (9) Including front handle; without handle 830mm (10) Nominal apparent power loads with PF > 0.8 can be supplied with marginal limitations to other performances. Please contact

Chloride Technical Support for further details. (11) Top version only. SP version data: THDi < 25% (at nominal output load) and PF > 0.90; AC/AC double conversion efficiency at

nominal output load: 92%; rectifier efficiency at full load: 95%; maximum output active power 80% of nominal apparent power; heat dissipations at nominal output load: +30%.

(12) For output load >25% of nominal output power. General conditions for the Technical Data table: The data shown are typical and not definable in other ways; furthermore the data refer to 25°C ambient temperature and PF= 1 where not specified. Not all the data shown apply simultaneously and may be changed without prior warning. Data apply to the standard version, if not otherwise specified. If the options described in chapter 9 are added, the data shown in the Technical Data Table may vary. For test conditions and measurement tolerances not specified in the table refer to the Witness Test Report procedure.



1.3.3 External Protection The 80-NET is equipped with manual switches intended only for Service Bypass and Internal Service operations. It is, therefore, essential that the customer install external protection devices at the installation site. These must be installed near the unit and labelled as the mains separation device for the UPS. Concerning more detailed information about the characteristics of the external protection and labelling of the external protection please refer to the User Manual chapter “4.4 External Protection Devices”. In particular, there is NO fuse protection, as standard, on the input of the bypass line. To ensure protection for the UPS, the customer is asked to provide a External Protection for the bypass line, which complies to the following requirements: (for more details please refer to the user manual) 1) It must protect the bypass thyristors in case of short circuit downstream of the UPS; 2) It must be coordinated with the internal inverter fuses (selective release);

in case of a short circuit upstream to the inverter, only the inverter output fuses should blow to disconnect the faulty inverter, but the load should be kept supplied by the bypass line.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 21/ 307Chapter: 1 Introduction 1.4 Principle of Operation printed: 15.05.2007, 13:09

1.4 Principle of operation

1.4.1 General Overview 80-NET operates according to the online principle (double conversion operation). In online operation, the alternating voltage (AC) of the mains is converted into direct voltage (DC). This DC voltage is used simultaneously to charge the battery and supply the inverter. The inverter converts the direct voltage (DC) into interference-free alternating voltage (AC) at a fixed frequency and amplitude, from which are supplied the connected loads. This protects the load from mains supply disturbances and provides a secure supply for electrical loads (PCs, network servers, multi-console systems). In case of a mains failure, the batteries provides uninterrupted power to the loads for a given period, dependent on battery capacity and connected load. The single line diagram of the UPS is shown in Figure 1-3. The systems operates on two DSP (digital signal processor) -driven IGBT converters (IGBT Rectifier and IGBT Inverter). The vector control technology will enhance the performance of these converters. In order to increase system redundancy, an independent electronic static bypass is integrated into the UPS. By adding system components, such as parallel kits, CROSS switches, safety and disconnecting devices, system bypass switches, in addition to software and communications solutions, it is possible to set up elaborate systems to ensure the complete protection of the loads. Operation and control of the UPS is provided through the use of microprocessor-controlled logic. Indications, measurements and alarms, together with battery autonomy, is shown on an illuminated, 8 lines x 12 character liquid crystal display (LCD). 80-NET adopts intelligent double conversion technology which allows the UPS to operate in double conversion or digital interactive mode according to the selected priority. (For more details, please, see further down within these chapter.)



1.4.2 Block diagram

Figure 1-3: 80-NET single block system diagram

1.4.2.1 Operating Modes Online mode Normal UPS operating mode. The connected loads are supplied from the mains via the inverter. The batteries are charged as necessary. The inverter reliably filters mains disturbances and provides a stable, interference-free supply to the load. On the control panel, when the UPS is in online operation, the green “OK” LED is illuminated. Figure 1-4: Operating Mode – Online

In this operating mode, the UPS switches to battery operation if a mains failure occurs. If an overload or short circuit occurs at the UPS output, or if there is a fault in the inverter, the UPS switches to bypass operation.



Battery mode In this operating mode, the connected load is supplied from the batteries via the inverter. In the event of power failure, battery operation is automatically activated and supplies the loads without interruption. If the power failure lasts longer than 30 s, the UPS signals a Warning condition (Warning 18i1). Figure 1-5: Operating Mode - Battery

In battery operation, the “OK” LED (green) on the control panel and the “WARNING” LED (yellow) are flashing. From this operating mode, the UPS automatically returns to online operation within the backup time once the mains supply returns. If the power failure lasts longer than the loads can be supplied by the battery, the UPS provides relevant information via its interfaces. Computers can be automatically powered down with additional software (optional).

Bypass mode In this operating mode, the connected loads are supplied from the mains via the electronic bypass. The electronic bypass serves to further ensure power to the loads. If an overload or short-circuit at the UPS output occurs, it is automatically activated to ensure uninterrupted power supply to the loads.

Figure 1-6: Operating Mode - Bypass

The “WARNING” LED (yellow) on the control panel illuminates and every 30 seconds a acoustic signal is given. From this operating mode, the UPS automatically returns to online operation after the fault is corrected.

Maintenance bypass mode In this operating mode, the connected loads are supplied directly from the mains supply. The Mimic Panel (LCDisplay) is disabled. Maintenance bypass is used to supply the connected loads during maintenance work on the UPS.

Figure 1-7: Operating Mode – Maintenance

Bypass



1.4.3 Intelligent Operating Modes 1.4.3.1 Double conversion Mode (DCM) 1.4.3.1.1 Normal (DCM)

The UPS inverter continuously supplies the critical AC load. The rectifier derives power from the commercial AC source and converts it into DC power for the inverter and the battery charger/booster. The battery charger/booster keeps the battery in a fully charged and optimum operational condition. The inverter converts the DC power into clean and regulated AC power which is supplied to the critical load (conditioned line). The static switch monitors and ensures that the inverter tracks the bypass supply frequency. This ensures that any automatic transfer to the bypass supply (due to an overload etc.) is frequency synchronised and does not cause interruption to the critical load.

1.4.3.1.2 Overload (DCM) In the event of an inverter overload the static switch automatically transfers the critical load to the bypass line without interruption. And back to the inverter if selected in PPVIS.

1.4.3.1.3 Emergency (DCM) Upon failure or reduction of the commercial AC source (see the Technical Data Table for tolerances) the inverter supplies the critical load, drawing power from the associated battery through the battery charger/booster. There is no interruption to the critical load upon failure, reduction or restoration of the commercial AC source. While the UPS is powered by the batteries, indications show the actual autonomy time remaining (if the battery settings are done properly), as well as the duration of the mains failure .

1.4.3.1.4 Recharge (DCM) Upon restoration of the commercial AC source, even where batteries are completely discharged, the rectifier is restarting automatically, 'walk in' and gradually taking over both the inverter and battery charger. This function is fully automatic and causes no interruption to the critical load.



1.4.3.2 Digital Interactive Mode (DIM) If priority has been set to digital interactive mode, intelligent double conversion technology allows 80-NET to continuously monitor the condition of the input supply including its failure rate to ensure maximum reliability for critical users. On the basis of the analysis performed, it is decided whether to supply the load through the bypass line (bypass) or the conditioned line. This operational mode, which allows significant energy savings by increasing the overall AC/AC efficiency of the UPS, is primarily intended for general purpose ICT applications. However, it does not provide the same output power quality as with the UPS operates in double conversion mode. Therefore it will be necessary to verify whether this mode is appropriate for special applications.

What’s important?

Digital Interactive Mode is not available for parallel systems.

1.4.3.2.1 Normal (DIM) The operating mode will depend on the quality of the mains supply in the short-term past. If the line quality has remained within permitted tolerance parameters in this timeframe, the bypass line will provide continuous supply to the critical AC load through the bypass static switch. The IGBT inverter control will remain in constant operation and synchronisation with the bypass line without driving the IGBT. This ensures that the load can be transferred to the conditioned line without any break in supply where there is a deviation from the selected input power tolerance levels. If the bypass line failure rate has been outside permitted parameters, 80-NET supplies the load from the conditioned line. The battery charger/booster supplies the energy necessary for maintaining maximum charge to the battery.

1.4.3.2.2 Inverter stop (DIM) If the inverter is stopped for any reason there is no transfer to the conditioned line and the load continues to be supplied by the bypass line. The mains voltage and frequency values must be within the tolerance limits specified.

1.4.3.2.3 Overload (DIM) In the event of an overload with a duration in excess of the maximum capacity specified for the bypass static switch, load is maintained on bypass line and fault 52 is issued to indicate the potential risk of this condition. By setting the parameter PNU567 bit 0 = 1 it is possible to change the behaviour when F52 is set. The bypass static switch is turning off and the load is transferred to conditioned line. Settings of PNU 567 “Control of Overload Reaction” are important for the behaviour.



Parameter Number

Parameter name Description

value range Dimension

Factorysetting

Control of Overload Reaction This parameter defines the behaviour at overload. Each individual bit of this parameter has a different meaning:

0 – 65535 6 567

CU2

Bit 0 = 1; Bypass will switch off when the kW-protection counter threshold is reached;

Bit 1 = 1; Retransfer from bypass to inverter is blocked for a load above 95% (enabled only for single block)

Access Level 4: URL

Bit 2 = 1; Transfer from inverter to bypass is done when kW-protection counter reaches a certain part of overload threshold; (only for single block; bit 1 must also be set;)

1.4.3.2.4 Emergency (due to mains supply failure or variance beyond tolerance limits, DIM) If 80-NET is supplying the load via bypass line and it varies beyond tolerance levels (adjustable using the software), the load will be transferred from bypass line to conditioned line. The load is powered from the mains via the rectifier and inverter, (provided the input mains remains within the tolerances). Should the input mains fall below the lower limit the battery is used to power the load via the inverter. The user is alerted to the battery discharge by visual and audio alarms and the remaining autonomy is displayed on the LCD. During this process, it is possible to extend the remaining autonomy by switching off non-essential loads.

1.4.3.2.5 Return to normal conditions (DIM) When the mains supply returns to within tolerance limits, 80-NET will continue to supply the load via the conditioned line for a period of time dependant on the bypass line failure rate (the conditioned line draws power from the mains not the battery). When the bypass line has stabilised, 80-NET returns to normal operation. The battery charger/booster automatically begins to recharge the battery, to guarantee a maximum autonomy in the shortest possible time.



1.4.3.3 All modes 1.4.3.3.1 Maintenance bypass

If, for any reason, it is necessary to take the UPS out of service for maintenance or repair, the UPS is fitted with an internal maintenance bypass switch QS3 which enables a load transfer to a bypass supply with no interruption of power to the critical load. Bypass isolation is complete, all serviceable components such as fuses, power modules etc. are isolated. Transfer/retransfer of the critical load may be accomplished by automatic synchronisation of the UPS to the bypass supply and paralleling the inverter with the bypass source, before opening or closing the bypass switch as appropriate. Before carrying out any work in the UPS, open the Neutral Switch QS14. This is important, due to the fact, that the neutral is not necessarily on earth potential.

1.4.3.3.2 Operation without battery If the battery is taken out of service for maintenance, it has to be disconnected from the UPS by means of an external switch (e.g. situated in the battery cabinet)and also the Battery Switch QS9 needs to be opened. The UPS will continue to operate and meet the performance criteria specified with the exception of the battery backup time.



1.4.4 Control and diagnostics Control of the power electronic modules is optimised in order to provide:

optimum three-phase supply of the load controlled battery charging minimum phase effects upon the supply network.

By using digital signal processors (DSP) 80-NET implements the most advanced digital control.

1.4.4.1 Vector control To ensure the quick and flexible processing of measuring data, special arithmetic algorithms are implemented in DSP, rapidly generating controlled variables as a result. This will allow a real-time control of the inverter electronics, resulting in obvious advantages concerning the performance of the power components. These advantages will be:

Improvement of short circuit behaviour, as individual phases can be controlled more quickly

Synchronisation or phase angle precision between UPS output and bypass supply even in the case of a distorted mains voltage

High flexibility in parallel operation – parallel blocks may be housed in separate rooms.

Several algorithms included in the Vector Control firmware are covered by patents owned by Chloride (95 P3875, 95 P3879 and 96 P3198).

1.4.4.2 Redundancy, preventive monitoring In order to maximise the reliability of the system, the control unit monitors a wide number of operating parameters for the rectifier, inverter and battery. All vital operating parameters, such as temperatures, frequency and voltage stability at the system input and output, load parameters and internal system values are constantly monitored and controlled for irregularities at all times. The system reacts automatically before a critical situation arises either for the UPS or the load, in order to ensure the supply of the load even in these difficult conditions.

1.4.4.3 Telediagnosis and Telemonitoring In all the above mentioned modes of operation, the UPS may be monitored and controlled from a remote location such as a service centre, in order to maintain the reliability of the system at nominal levels. Even during complete shutdown of the UPS, information relating to the operating parameters are not lost thanks to non volatile EEPROM, which will store the information for up to 10 years.



1.4.5 LCDisplay (Mimic Panel) The control panel of 80-NET includes a back-lit Liquid Crystal Display (LCD of 8 lines x 12 characters, displaying graphic diagrams and symbols) for complete UPS monitoring and control. Complete access to all LCDisplay menus is possible through navigation push buttons located below the screen. This navigation group includes two buttons - “up” and “down” - for menu scrolling and two software-assigned push buttons – the functions linked to these two buttons is displayed on the lower right and lower left corners of the LCD during navigation. A single-line diagram of the UPS is continuously displayed on the default page. The main functional blocks and power paths of the UPS are displayed using simple universal technical symbols, instantly communicating the overall status of the UPS. The same screen also permanently displays the output load percentage measurement, using three histograms (one for each output phase). When the UPS is not in normal operating mode, it is possible to access the “Warning and Alarm” summary page directly from the default page. Warnings and faults are identified by text strings and codes. In battery operation, the display switches between warning code and estimated backup time in minutes. After 30 seconds of inactivity (i.e. without buttons being pressed) the display reverts to the default page. The text displayed by the LCD is available in English, Italian, French, German, Spanish, Portuguese and Turkish selectable by the user.

LEGEND:

1 Navigation button - Left soft key

2 Navigation button - Up

3 Navigation button - Down

4 Navigation button - Right soft key

5 Inverter “ON” push button

6 Inverter “OFF” push button

7 System Normal LED

8 Warning LED

9 Alarm LED

10 Reset push button

Figure 1-8: Mimic panel

11 Command keyboard lock



The Start and Stop push buttons consider a safety feature to prevent inadvertent operation yet still allow for rapid shutdown in the event of an emergency. To stop the inverter the user must press and hold the Stop button for five seconds. An audio alarm is activated during this delay time. The mimic panel is equipped with a front panel key that allows users, once the lock is set in the Off position, to disable any command which may be entered through the LCDisplay. In this state, if the operator attempts to perform any of the following actions, a message reading “COMMANDS DISABLED” will be appear on the LCD:

• Start Inverter • Stop Inverter • Set/reset Battery Test • Set/reset Autonomy Test • Set/reset Service Input • Reset Fault • Reset Delay Call • LIFE Manual Call • Set/reset I/O Configuration

What’s important?

Freeze LCD function This function was established to speed up the serial communication between an external application, like PPVIS, and the CU2 (Inverter) through the LCD. To enable this function, simultaneously press the UP and DOWN key on the front panel for at least 2 seconds (only possible in the main synoptic window). While the function is active, the message “LCD frozen” will be displayed. When the function is activated, no diagnostics will be present on the LDC because communication with the CU has temporarily been suspended. If no request is sent through the Service serial port (X3) towards the LCD, the function disables after 10 minutes. (meaning e.g. the PPVIS cable is removed) This function also can be disabled by pressing the UP and DOWN keys again.

General Status LED With the three LED indicators it is possible to obtain a quick and general understanding of the UPS status, as described below:

• OK LED (green) Normal Operation When this light is on (not flashing), the system is running normally and neither warnings nor alarms are present. During mains failures (all other conditions being at nominal level), this LED will flash.

• Warning LED (yellow) Warning Condition(s) This indication is activated by the presence of anomalous conditions, which could affect the nominal functioning of the UPS. These conditions are not originated with the UPS, but may be caused either by the surrounding environment or by the electrical installation (mains side and load side). It is possible to read the description of the active warning(s) by browsing the relevant LCDisplay menus.



• Alarm LED (red) Alarm Condition When this light is on, immediate attention should be given to the severity of the alarm, and service should be done promptly. It is possible to read the description of the active alarm(s) by browsing the relevant LCDisplay menus. A manual reset after clearing the fault is necessary.

LCDisplay menus description By using the appropriate push buttons it is possible to browse the following menus:

• Rectifier and Booster/Battery Charger converter menu displays - rectifier status - booster/charger status - alarms - voltage - total DC current - battery current with polarity - battery temperature

When the inverter is supplied by the battery, the LCDisplay main page is showing the remaining autonomy time. A change in load shall cause the autonomy indicator to display the new autonomy time.

• Inverter menu displays - alarms - phase to neutral voltages - frequency measurements - inverter heat-sink temperature - cooling air temperature

When the inverter is in overload condition, the remaining overload timeout time is displayed on the LCD main page.

• Bypass Supply menu displays - Alarms - phase to neutral voltages - frequency measurements

• Load/Bypass Static Switch menu displays - Alarms - current per phase - frequency measurements - load percentage capacity per phase - the peak factor Ipk/Irms for each phase of the load current

It is possible to display the total time the load has been supplied by the inverter, and by bypass, the number of mains failures and the total duration of these failures.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 32/ 307Chapter: 2 Functional Description 2.1 Overview printed: 15.05.2007, 13:09

2 Functional Description For deeper understanding of the 80-NET and the interior of it, schematic drawings and descriptions of the boards functions can be found in this chapter. Furthermore a account of how the single power components are working will be given in the subchapter “Power Components”. For example the function of the rectifier will be described in detail. In addition to this, all kind of information about communication with the UPS, e.g. interfaces, Service Software PPVIS, Firmware and so on can be found here as well.

2.1 Overview The UPS consists of the following major components:

• IGBT Rectifier: It is converting the mains AC voltage into a DC voltage, supplying the battery and inverter;

• IGBT Battery Charger / Booster: Keeps the battery charged;

• IGBT Inverter: It is converting the DC voltage (from rectifier or battery) into a regulated AC voltage to supply the load. (with Pulse-Width-Modulation);

• Dedicated DSP control systems for each IGBT converter: Through the vector control technology, the performance of the converter is enhanced;

• Electronic static switch and bypass supply: If the application requirements exceed the possibilities of the UPS, the load is automatically switched without break from inverter mode to bypass;

• Manual maintenance bypass switch: For service requirements;


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 33/ 307Chapter: 2 Functional Description 2.2 Boards printed: 15.05.2007, 13:09

2.2 Boards

2.2.1 Drawing 80-NET 60kVA/80kVA – where to find the boards

Figure 2-1: Drawing 80-NET 60/80kVA – IGBTs & SCRs

Function Board Item Code V1 U IGBT (VT2 400A 1200V) Mains input 10H44112P4312 V2 V IGBT (VT2 400A 1200V) Mains input 10H44112P4312 V3 W IGBT (VT2 400A 1200V) Mains input 10H44112P4312 V4 Booster/Charger IGBT (VT2 400A 1200V) 10H44112P4312 V4’ Booster/Charger IGBT (VT2 400A 1200V) 10H44112P4312 V5 U1 SCR (V2 130A 1600V) Bypass input 00B44095PT016 V6 V1 SCR (V2 130A 1600V) Bypass input 00B44095PT016 V7 W1 SCR (V2 130A 1600V) Bypass input 00B44095PT016 V9 U2 IGBT (VT2 400A 1200V) UPS output 10H44112P4312 V10 V2 IGBT (VT2 400A 1200V) UPS output 10H44112P4312 V11 W2 IGBT (VT2 400A 1200V) UPS output 10H44112P4312



Figure 2-2: Drawing 80-NET 60/80kVA – Boards 1

Function Board Item Code AP5 SMPS Board 15B10860G1 AP6 Supply Interface Board 15B10848G1 AP7 Bypass Control Board 15B10859G1 AP19-AP26 IGBT Interface Board 15B10857G1 QS14 Neutral Switch 10B46426P54C FU1-FU3 FU 200A 500V Extra Quick Blow 00B46117PC200 FU4-FU6 FU 200A 500V Extra Quick Blow 00B46117PC200 TA4-TA6 TA 200Adc 10B48279P1 TA9-TA11 TA 200Adc 10B48279P12 KM1 230Vac 125A/80A 10B48317P72 KM3 24Vdc 20A/9A 10B48317P71 C1-C3, C1’-C3’ C8-C10, C8’-C10’ C 100µF 275Vdc 10H42088P01




Function Board Item Code AP11-AP17 IGBT Driver Board 15B10851G1 L1- L3 L1 250 µH 120A 10H48572P01 L6- L8 L1 250 µH 120A 10H48572P01




Function Board Item Code AP1-AP2 CUX Board 451909988311 AP3-AP4 Interface Board 15B10853G1 AP27-AP28 Fan Speed Control Board 15B10855G1 L4 L1 250 µH 160A 10H48573P01




Function Board Item Code AP31-AP33 Filter Board 15B10861G1

Backside of Switches Figure 2-6: Drawing 80-NET 60/80kVA – Boards 5

Function Board Item Code AP36-AP37 Varistor Board 15B10671G5 FU7-FU8 Battery Fuses 00B46117PE250 TA1-TA3 Mains Input TA 200A/200mA 00B48018P10 TA12-TA14 Output TA 200A/200mA 00B48018P10 TA15-TA17 Bypass Input TA 200A/200mA 00B48018P10



Figure 2-7: Drawing 80-NET 60/80kVA – Boards 6 – Connectivity

Function Board Item Code AP9 Connectivity Board 15B10849G1 AP10 In/Out Board 15B10854G1 AP38 DC Modem LIFE.NET 15B10840G1

Figure 2-8: Connectivity Box – Interfaces AP10-XT5, AP10-X4 and AP10-XT6



2.2.2 Drawing 80-NET 100kVA/120kVA – where to find the boards

Figure 2-9: Drawing 80-NET 100/120kVA – IGBTs & SCRs

Function Board Item Code V1 / V1’ U IGBT (VT2 300A 1200V) Mains input 10H44112P3412 V2 / V2’ V IGBT (VT2 300A 1200V) Mains input 10H44112P3412 V3 / V3’ W IGBT (VT2 300A 1200V) Mains input 10H44112P3412 V4 / V4’/ V4’’ Booster/Charger IGBT (VT2 400A 1200V) 10B44112P4312 V5 U1 SCR (V2 160A 1600V) Bypass input 00B44095PT116 V6 V1 SCR (V2 160A 1600V) Bypass input 00B44095PT116 V7 W1 SCR (V2 160A 1600V) Bypass input 00B44095PT116 V9 / V9’ U2 IGBT (VT2 300A 1200V) UPS output 10H44112P3412 V10 / V10’ V2 IGBT (VT2 300A 1200V) UPS output 10H44112P3412 V11 / V11’ W2 IGBT (VT2 300A 1200V) UPS output 10H44112P3412




Function Board Item Code AP5 SMPS Board 15B10860G1 AP6 Supply Interface Board 15B10848G1 AP7 Bypass Control Board 15B10859G1 AP19-AP26 IGBT Interface Board 15B10857G1 AP40-AP46 IGBT Interface Board 15B10857G1 QS14 Neutral Switch 10B46426P54C FU1-FU3 FU 250A 500V Extra Quick Blow 10H46741PC250 FU4-FU6 FU 250A 500V Extra Quick Blow 10H46741PC250 TA4-TA6, TA9-TA11 TA 200Adc 10B8279P12

KM1, KM1’ 230Vac 125A/80A 10B48317P72 KM3 24Vdc 20A/9A 10B48317P71 C1-C3, C1’-C3’, C1’’-C3’’ 100µF 275Vdc 10H42088P01

C8-C10, C8’-C10’, C8’’-C10’’ 100µF 275Vdc 10H42088P01




Function Board Item Code AP11-17 IGBT Driver Board 15B10851G1 L1- L3 L1 170 µH 180A 10H48572P02 L6- L8 L1 170 µH 180A 10H48572P02




Function Board Item Code AP1-AP2 CU-Board 451909987710 AP3- AP4 Interface Board 15B10853G1 AP27-AP29 Fan Speed Control Board 15B10855G1 L4 L1 170µH 240A 10H48573P02




Function Board Item Code AP36-AP37 Varistor Board 15B10671G3 FU7-FU8 Battery Fuses 00B46117PE400 AP31-AP33 Filter Board 15B10861G1 TA1-TA3 Mains Input TA 600A/200mA 00B48018P30 TA12-TA14 Output TA 600A/200mA 00B48018P30 TA15-TA17 Bypass Input TA 600A/200mA 00B48018P30

Backside of Switches.



Figure 2-14: Drawing 80-NET 100/120kVA – Boards 6 – Connectivity

Function Board Item Code AP9 Connectivity Board 15B10849G1 AP10 In/Out board 15B10854G1 AP38 DC Modem LIFE.NET 15B10840G1 Q8-Q10 FU 2A 500V Slow Blow 6,3x32 10B46209P05R




2.2.3 Drawing 80-NET 160kVA – where to find the boards

Figure 2-16: Drawing 80-NET 160kVA – IGBTs & SCRs

Function Board Item Code V1 / V1’ U IGBT (VT2 400A 1200V) Mains input 10H44112P4312 V2 / V2’ V IGBT (VT2 400A 1200V) Mains input 10H44112P4312 V3 / V3’ W IGBT (VT2 400A 1200V) Mains input 10H44112P4312 V4 / V4’/ V4’’ / V4’’’

Booster/Charger IGBT (VT1 300A 1200V) 10B44112P3412

V5 U1 SCR (V2 250A 1600V) Bypass input 00B44095PT416 V6 V1 SCR (V2 250A 1600V) Bypass input 00B44095PT416 V7 W1 SCR (V2 250A 1600V) Bypass input 00B44095PT416 V9 / V9’ U2 IGBT (VT2 400A 1200V) UPS output 10H44112P4312 V10 / V10’ V2 IGBT (VT2 400A 1200V) UPS output 10H44112P4312 V11 / V11’ W2 IGBT (VT2 400A 1200V) UPS output 10H44112P4312



Figure 2-17: Drawing 80-NET 160kVA – Boards 1

Function Board Item Code AP5 SMPS Board 15B10860G1 AP6 Supply Interface Board 15B10848G1 AP7 Bypass Control Board 15B10859G1 AP19-AP26 IGBT Interface Board 15B10857G1 AP40-AP47 IGBT Interface Board 15B10857G1 QS14 Neutral Switch 10B46426P54C FU1-FU3 FU 350A 500V Extra Quick Blow 10H46117PC350 FU4-FU6 FU 350A 500V Extra Quick Blow 10H46117PC350 TA4-TA6, TA9-TA11 TA 200Adc 10B48279P4 KM1, KM1’ 230Vac 125A/80A 10B48317P72 C1-C3, C1’-C3’, C1’’-C3’’, C1’’’-C3’’’ 100µF 275Vdc 10H42088P01

C8-C10, C8’-C10’, C8’’-C10’’, C8’’’-C10’’’ 100µF 275Vdc 10H42088P01

Q1, Q1’ FU 2A 500V Slow Blow 6,3x32 10B46209P05R




Function Board Item Code AP11-17 IGBT Driver Board 15B10851G1 L1-L3, L1’-L3’ L1 250µH 120A 10H48572P01 L6- L8, L6’-L8’ L1 250µH 120A 10H48572P01




Function Board Item Code AP1-AP2 CUX 451909988311 AP3- AP4 Interface Board 15B10853G1 AP27-AP30 Fan Speed Control Board 15B10855G1 KM3 24Vdc 20A/9A 10B48317P71 R1, R2 R 8R2 125W 10% 10H40037P01




Function Board Item Code AP31-AP33 Filter Board 15B10861G1 AP36-AP37 Varistor Board 15B10671G5 FU7-FU8 Battery Fuses 00B46117PE500 TA1-TA3 Mains Input TA 600A/200mA 00B48018P30 TA12-TA14 Output TA 600A/200mA 00B48018P30 TA15-TA17 Bypass Input TA 600A/200mA 00B48018P30




Figure 2-21: Drawing 80-NET 160kVA – Boards 6 – Connectivity

Function Board Item Code AP9 Connectivity Board 15B10849G1 AP10 In/Out board 15B10854G1 AP38 DC Modem LIFE.NET 15B10840G1 Q8-Q11 FU 2A 500V Slow Blow 6,3x32 10B46209P05R




2.2.4 Drawing 80-NET 200kVA – where to find the boards

Figure 2-23: Drawing 80-NET 200kVA – IGBTs & SCRs

Function Board Item Code V1 /V1’ /V1’’ U IGBT (VT2 400A 1200V) Mains input 10B44112P4312 V2 /V2’ /V2’’ V IGBT (VT2 400A 1200V) Mains input 10B44112P4312 V3 /V3’ /V3’’ W IGBT (VT2 400A 1200V) Mains input 10B44112P4312 V4 /V4’ /V4’’ /V4’’’ Booster/Charger IGBT (VT2 400A 1200V) 10B44112P4312 V5 U1 SCR (V2 250A 1600V) Bypass input 00B44095PT416 V6 V1 SCR (V2 250A 1600V) Bypass input 00B44095PT416 V7 W1 SCR (V2 250A 1600V) Bypass input 00B44095PT416 V9 /V9’ /V9’’ U2 IGBT (VT2 400A 1200V) UPS output 10B44112P4312 V10 /V10’ /V10’’ V2 IGBT (VT2 400A 1200V) UPS output 10B44112P4312 V11 /V11’ /V11’’ W2 IGBT (VT2 400A 1200V) UPS output 10B44112P4312




Function Board Item Code AP5 SMPS Board 15B10860G1 AP6 Supply Interface Board 15B10848G1 AP7 Bypass Control Board 15B10859G1 AP19-AP26, AP40-AP53 IGBT Interface Board 15B10857G1

FU1-FU3 FU 500A 500V Extra Quick Blow 00B46117PC500 FU4-FU6 FU 500A 500V Extra Quick Blow 00B46117PC500 TA4-TA6, TA9-TA11 TA 400Adc 10B48279P13 KM1, KM1’, KM’’ 230Vac 125A/80A, 50-60Hz 10B48317P72 C1-C3, C1’-C3’, C1’’-C3’’, C1’’’-C3’’’, C1’’’’-C3’’’’ 100µF 275Vdc 10H42088P01

C8-C10, C8’-C10’, C8’’-C10’’, C8’’’-C10’’’, C8’’’’-C10’’’’ 100µF 275Vdc 10H42088P01

Q1, Q1’, Q1’’ FU 2A 500V Slowblow 6,3x32 10B46209P05R




Function Board Item Code AP11-17 IGBT Driver Board 15B10851G1 L1- L3, L1’-L3’ L1 170 µH 180A 10H48572P03 L6- L8, L6’-L8’ L1 170 µH 180A 10H48572P03



Figure 2-26: Drawing 80-NET 200kVA - Capacitors

Function Board Item Code C4, C4’, C4’’, C4’’’, C4’’’’, C5, C5’, C5’’, C5’’’, C5’’’’, 100µF 275Vac 10H42088P01

C11 – C13 30 µF 470Vac 00B42004P0219


Function Board Item Code AP1-AP2 CUX 451909988311 AP3- AP4 Interface Board 15B10853G1 AP27-AP30, AP54 Fan Speed Control Board 15B10855G1 KM3 24Vcc 20A/9A 50-60Hz 10B48317P71 R1-R2 8R2 125W 10% 10H40037P01




Function Board Item Code AP31-AP33 RFI Filter Board 15B10861G1 AP36-AP37 Varistor Board 15B10671G5 FU7-FU8 Battery Fuses 00B46117PE800


Function Board Item Code TA1-TA3 TA 600A/200mA 00B48018P30 TA12-TA14 TA 600A/200mA 00B48018P30 TA15-TA17 TA 600A/200mA 00B48018P30 XS1-XS2 Socket 16A 250V 10B46521P01 Q4-Q7 FU 2A 500V slowblow 6,3x12 10B46209P05R




Figure 2-30: Drawing 80-NET 200kVA – Boards 6 – Connectivity

Function Board Item Code AP9 Connectivity Board 15B10849G1 AP10 In/Out board 15B10854G1 AP38 DC Modem LIFE.NET 15B10840G1 Q8-Q12 FU 2A 500V Slowblow 6,3x12 10B46209P05R




2.2.5 I/O Signal and Serial Port Overview of the Board Interconnection This figure is showing how the I/O signals and serial ports are running along the mentioned boards. The interfaces are named.

Figure 2-32: Communication Input/Output



2.2.6 CU Board - General Information As the name Control Unit is already suggesting, the CU Board is the “brain” of the UPS. This board contains the Firmware. The Firmware is the software which is needed to perform the following main tasks:

• Communication • Configuration of UPS (with PPVIS) • Time/task management • State sequential control • Actual value measurement (via DSP) • Monitoring of UPS characteristic values • Power module open loop/closed loop control (via DSP) • Supplying diagnostic tools (e.g. Power Circuit test of Inverter and Rectifier,

oscilloscope, Database memory for monitoring ...) To fulfil these tasks, the CU family (CU4, CU41, CUVeCon, CUdSMC and CUX) uses two processors, a microcontroller (C165 family) and an signal processor (VECON or dSMC).


What is a microcontroller? A microcontroller is a computer-on-a-chip optimised to a control devices. It is a type of microprocessor highlighting self-sufficiency and cost-effectiveness, in contrast to a general-purpose microprocessor, the kind used in a PC. A typical microcontroller contains all the memory and I/O interfaces needed, whereas a general purpose microprocessor requires additional chips to provide these necessary functions. Microcontroller can be found in almost any electrical device. They are the vast majority of all processor chips sold. Over 50% are "simple" controllers, and another 20% are more specialized digital signal processors (DSPs). A typical home in the Western world is likely to have only one or two general-purpose microprocessors but somewhere between one and two dozen microcontroller.

What is a digital signal processor (DSP)? A digital signal processor (DSP) is a special-purpose programmable microprocessor designed to manipulate in real time a communications stream of large amounts of digital data in order to improve its quality or modify it in specific ways.

The interfacing on the VeCon digital part is a serial interface. The digital chip contains the C165-µP for the control software and the dSMC digital signal processor for time critical control. The two processors are linked to each other inside the chip by a shared memory. The entire system is supplied with data and programs over the C165 µP bus system and over the port lines linked to serial memories. The data and address bus of the VeCon-DSP are only available inside the chip; access to the memory must therefore always be handled over the C165. The “VeCon analog” processor is used mainly for acquiring analogue signals such as currents and voltages (e.g. DC-link voltage). It is linked to the DSP of the digital circuit over a serial interface and has therefore access to analogue resources.



The EPROM’s contain all the software which is needed by the C165 µP and the dSMC DSP. This software is “flashed” into the EPROM. (How to flash the CU please refer to the corresponding chapter.) The RAM is for the exclusive use of the C165.

Figure 2-33: Picture of CU-Board with explanation of parts



2.2.7 CU Board Rectifier AP1 (451909987710) Item code: 451909987710 The CU1 Rectifier CU-Board AP1 is connected with its “own” interfaces to other boards interfaces: AP1(CU1)_X109 AP3 (Rectifier Interface Board)_X109 AP1(CU1)_X110 AP3 (Rectifier Interface Board)_X110 AP1(CU1)_X120 AP10 (In/Out Board)_X2 AP1(CU1)_X130 AP2 (CU2 Inverter CU-Board)_X130 AP1(CU1)_X130 Aux. Contacts, Temp. Measurement The hardware of the Rectifier CU-Board CU1 and the Inverter CU-Board CU2 is the same. The only difference between the two CU-Boards in the 80-NET is the different Firmware on CU1 and CU2.

What’s important?

The DIP switches on the CU-Board must be closed! Also the jumper settings are important!

The interface X107 on the CU1 board is not used on 80-NET UPS. The X109 interface is a connection to the rectifier interface board, which is used for communication/exchange of certain values (for details please refer to the figure 2-17) The X110 interface is also a connection to the rectifier interface board, which is used for the signalling of the actual measured current and voltage values. X120 is responsible for the communication from and to the LCDisplay. E.g. to display the measured values, for signalling a start or stop command from the LCDisplay. The communication between the two CU-Boards is managed with the X130 (contacts 1-4 via RS485). Temperature measurement signal and the signal from the auxiliary contact QS1 are just two examples for signals, which are handled with X130. The CU1 board is detecting the temperatures of:

- Rectifier (measuring channel ST-S-IN) - Booster/Charger (measuring channel ST-B) - Battery (measuring channel input contact XT1)



Figure 2-34: AP1 CU1 Rectifier CU-Board



2.2.8 CU Board Inverter AP2 (451909987710) Item code: 451909987710 The CU2 Inverter CU-Board AP2 is connected with its “own” interfaces to other boards interfaces: AP2(CU2)_X109 AP4 (Inverter Interface Board)_X109 AP2(CU2)_X110 AP4 (Inverter Interface Board)_X110 AP2(CU2)_X120 AP10 (In/Out Board)_X1 AP2(CU2)_X120 AP8 (COM Display)_X1 AP2(CU2)_X130 AP1 (CU1) (Rectifier CU-Board)_X130 AP2(CU2)_X130 Aux. Contacts, Temp. Measurement AP2(CU2)_X130 Command keyboard lock The hardware of the Rectifier CU-Board CU1 and the Inverter CU-Board CU2 is the same. The only difference between the two CU-Boards in the 80-NET is the different Firmware on CU1 and CU2.

What’s important?

The DIP switches on the CU-Board must be closed! Also the jumper settings are important!

The interface X107 on the CU2 board is only used for parallel connection with other 80-NET UPS of the same power-range. The X109 interface is a connection to the rectifier interface board, which is used for communication/exchange of certain values (for details please refer to the figure 2-17) The X110 interface is also a connection to the inverter interface board, which is used for the signalling of the actual measured current and voltage values. X120 is responsible for the communication from and to the LCDisplay. E.g. to display the measured values, for signalling a start or stop command from the LCDisplay. The communication between the two CU-Boards is managed with the X130 (contacts 1-4 via RS485). Temperature measurement signal and the signal from the auxiliary contact QS2 and QS3 are just three examples for signals, which are handled with X130. The CU2 board is detecting the temperatures of:

- Inverter (measuring channel ST-S-OUT) - Ambient (measuring channel ST1) - Inverter/Neutral Stabiliser Converter (measuring channel ST-R-OUT)

-optional-



Figure 2-35: AP2 CU2 Inverter CU-Board



2.2.9 Interface Board AP3, AP4 (15B10853G1) Item code: 15B10853G1 Diagram Reference: 10H70843

Figure 2-36: AP3, AP4 Interface Board

The hardware of these two interface boards AP3 and AP4 is identically, only AP3 is used for measuring specific values for the rectifier and AP4 for specific values for the inverter. These boards are supplied by the SMPS board AP5. The power supply is than transformed to 5V, +/- 15V and 24V. These voltages are used to supply the board logic and to reform the input signals, bringing them to a level the CU-board is requiring them. With “AC voltage reading circuits” will be read the Input Voltage in case of AP3 and in case of AP4 the Output Voltage. With “AC current reading circuits” will be read the Input Current in case of AP3 and in case of AP4 the Output Current.



The “Temperature detection circuit” is reading the temperatures depending in the CU-Board: - for CU1 (rectifier): Rectifier, Booster/Charger, Battery - for CU2 (inverter): Inverter, Ambient, Inverter/Neutral Stabiliser Converter The “Inverter PWM signal” is adapting the PWM signal sent from the CU-Board for the actual PWM. The “Booster/Charger” in case of AP3, what would be “Neutral Booster” on AP4, is generating the PWM signal for these two sections. The generated and adapted signal for the fans is provided with “Fan control”. A STS Bypass control signal is as well set up by the Interface Board. The isolated contacts on the Interface Board are used depending on the type of application:

AP3 AP4 KM1 EPO Backfeed KM2 Input contactor Not used

The “current detector” can also be found on the Interface Board. In case of board replacement the jumpers JP1-JP5 on the Interface Board need to be set either for AP3 or AP4 settings: (see also AIF 108) JP1 JP2 JP3 JP4 JP5 AP3 (Rectifier) OFF OFF OFF OFF ON AP4 (Inverter) ON OFF OFF OFF OFF



2.2.10 SMPS Board AP5 (15B10860G1) Item code: 15B10860G1 Diagram Reference: 15C70556 DC input voltage: 230V to 550V Output power: 500W maximum The SMPS supplies the following outputs: +8V 2,5A (isolated) for Inverter Drive Board +8V 0,3A (isolated) interface (RS232) +/- 17V 0,5A (isolated) for Inverter Driver Board

Figure 2-37: AP5 SMPS Board

There are two distinct power stage converters:

• a Buck, to supply a regulated uninsulated voltage of 150V • a Push-Pull, powered by 150V, to obtain the above mentioned insulated output

supplies



The “Buck” stage: The Buck converter is controlled by

• a Siemens TDA4919 (IC1), • a PWM single ended controller operating in voltage mode, • a internal under-voltage comparator with hysterisis is used to inhibit the output

driver of IC1 when the DC rail falls under 165V. The operating frequency (about 20kHz) is set up by the values of C21 and R37 while the PWM ramp slope is determined by the value of C4 and by R32, R33 and R34 which perform a feed forward control action. Resistors R8 and R7 sense the Buck current, and the ratio of R43 and to R28 sets the threshold level of the current limiter. A multiple RC network (R24, C16, R41 and C20) is used to clean up the current signal. Soft start action is present to limit the current when the output capacitors are charged, the duration of the soft start can be programmed by the size of the capacitor C10. A voltage reference of 2,5V is available at pin 11, which provides a highly constant temperature characteristic and it is used as reference signal for the under-voltage comparator, the current limiter comparator and as a set-point in the output voltage control. The power switch consists of 2x T03P N channel power MOSFETs, rated at 1000V Vdc and 8A Id @ 25_C, connected in parallel. The free wheeling diode (D1) is a 1000V 12A, very fast recovery, epitaxial diode. A voltage dependent resistor (VR1) protects the circuit against the risk of voltage spikes present on the DC rail. At start-up, IC1 is powered by a linear power supply (S3, T1, Z4) which is locked out when feedback from an auxiliary output of the Push-Pull transformer (TR1) is present, when this action is performed a green LED (DL1) lights up. The input rectifier voltage feedback is obtained from a voltage divider (R62, 63, 64, 65 and 66), this signal is available at connector 2M. Toroidal inductor L1 and capacitor C31 from the output filter. The output voltage is sensed by a differential amplifier IC3. The feedback control network uses the TDA4919. Trimmer P1 sets the output voltage to 150V. Trimmer P2 is used to set the max Vdc alarm trip which switches on a red LED (DL2). When the alarm trips, the rectifier is locked out. The “Push-Pull” stage: The Push-Pull converter is controlled by

• a Siemens TDA4918 (IC2), • a PWM controller operating in voltage mode, • an internal overvoltage comparator with hysterisis is used to inhibit the output

drivers of IC2 if the buck output goes over 190V, due to a buck failure. The operating frequency (about 50kHz) is set up by the value of C36 and R93, while the PWM ramp slope is determined by the value of C3. No feed forward actions is performed in this stage and the duty cycle is fixed at 50%, the dead time is generated inside the TDA4918 and can be externally modified. Resistors R73 and R74 sense the Push-Pull current and the ratio of R89 and R87 sets up the threshold level of the current limiter, a multiple RC network (R86, C41, R88 and C43) is used to clean up the current signal. A soft start action is present to limit the current when the output capacitors are charged, the duration of the soft start can be programmed by the size of the capacitor C35. A voltage reference of 2,5V is available at pin 11, it exhibits a highly constant



temperature characteristic and it is used as reference signal for overvoltage comparator and current limiter. At start-up IC2 is powered by a linear power supply (S8, T2 and Z11) which is locked out when there is feedback from an auxiliary output of the Push-Pull transformer (TR1). Transformer TR1 is connected in parallel with the output of the Push-Pull stage to deliver the supplies needed to power the circuits. The secondary has a rectifier with two capacitors, an electrolytic capacitor to smooth and a ceramic one to remove high frequency noise. The outputs of the PWM controller ICs are active high and can deliver all the current needed to drive power MOSFET transistors, the voltage supply of this stage is separated from the logic so as to prevent noise in the control circuits.



2.2.11 Supply Interface Board AP6 (15B10848G1) Item code: 15B10848G1 Diagram Reference: 15H70837

Figure 2-38: AP6 Supply Interface Board

This board is introduced to increase the possibilities of supporting important boards with power in the UPS. The AP6 is getting power (400Vac) from the bypass line (QS2 closed) and the mains line (QS1 closed), which is transformed to a DC voltage. A third power supply is coming from the DC Bus, supplied by mains input or battery. The DC voltage from this Supply Interface Board is supplied to the SMPS board. The SMPS board is reducing the voltage and is supplying it back to this Supply Interface Board. From here it is supplying AP3, AP9 and AP10 with power. It is also providing a additional isolation for the LCDisplay, due to the present transformer. (The supply back to the AP6 board from the SMPS board and than out to the other boards AP3, AP9 and AP10 is mainly done because of design reasons.)



2.2.12 Bypass Control Board AP7 (15B10859G1) Item code: 15B10859G1 Diagram Reference: 15H70848

Figure 2-39: AP7 Bypass control Board

The duty of the Bypass Control Board is to forward the signal for switching to/from bypass line. This is either done because of a manual request to transfer or because of any fault situation causing the bypass to connect through. This board has its own power supply, it is powered by L1 and L2 of the bypass line, of course only as fare as QS2 is closed. The 400Vac are transformed to 24Vdc. The separate power supply is important in case the SMPS board is defective, because with its own power supply the bypass control board is still able to transfer the load from inverter to bypass line to ensure the uninterruptible power supply for the load. The output of this board is used for the thyristor gate drive. The task of the “Bypass supply detector” is to check if there are still 24V present from the bypass line. If this is not the case a fault message “Error 50 Index 5” will be issued. This signal is sent out over “Bypass Good” (X3_3, X3_4) to the CU2.



2.2.13 LCDisplay AP8 (710-01970) Item code: 710-01970 This board contains the Flash-prom for the LCD firmware.

Figure 2-40: AP8 LCDisplay

On this board you can find the Jumper CN11, which is needed to speed up the communication between LCDisplay and CU-Board while flashing the CU2 Board. The DIP-switch SW1 is necessary to flash new firmware to the LCDisplay.

What’s important?

Freeze LCD function This function was established to speed up the serial communication between an external application, like PPVIS, and the CU2 (Inverter) through the LCD. To enable this function, simultaneously press the UP and DOWN key on the front panel for at least 2 seconds (only possible in the main synoptic window). While the function is active, the message “LCD frozen” will be displayed. When the function is activated, no diagnostics will be present on the LDC because communication with the CU has temporarily been suspended. If no request is sent through the Service serial port (X3) towards the LCD, the function disables after 10 minutes. (meaning e.g. the PPVIS cable is removed) This function also can be disabled by pressing the UP and DOWN keys again.



2.2.14 Connectivity Board AP9 (15B10849G1)

Item code: 15B10849G1 Diagram Reference: 15H70838

Figure 2-41: AP9 Connectivity Board

This board is the interface between the LCD and the EPO interface, the Plug-in LIFE.NET modem and other connectivity like a SNMP-Adapter.



2.2.15 In/Out Board AP10 (15B10854G1) Item code: 15B10854G1 Diagram Reference: 15H70844

Figure 2-42: AP10 In/Out Board

This board contains 4 potential free digital input contacts (interface X6) and 2 potential free digital output contacts (interface X5), which can be parameterised with PPVIS. It also contains the X4 interface, which is only used for flashing the CU1 board.



2.2.16 IGBT Driver Board AP11-AP17 (15B10851G1) Item code: 15B10851G1 Diagram Reference: 15H70841

Figure 2-43: AP11- AP17 IGBT Driver Board

This board is used for rectifier, inverter, booster/charger and neutral booster IGBTs. The function of this board is to dress and decouple the signals from the CU-boards. This signals need to be of good quality to gate drive the IGBTs. The way through the UPS from the CU-board to the IGBT Driver Board is a long one, therefore the dressing and decoupling is necessary. These “cleansed” signals will be send to the IGBT Interface Boards, which are sitting directly beneath this IGBT Driver Board on top of the IGBT.



2.2.17 IGBT Interface Board AP19-AP26, AP40-AP53 (15B10857G1) Item code: 15B10857G1 Diagram Reference: 15H70842

Figure 2-44: AP19-22, AP23, AP24-26 IBT Interface Board

This boards is used for rectifier, inverter, booster/charger and neutral booster IGBTs. The IGBT Interface Board is receiving dressed and decoupled signals from the IGBT Driver Board for the gate drive of the IGBTs. The temperature will be measured nearby the IGBT and forwarded to the Interface Board AP3/AP4. This signal is the base for the decision on which speed the fans are running and when to turn off/shut down the converter.



2.2.18 Fan Speed Control Board AP27, AP28, (AP29) (15B10855G1) Item code: 15B10855G1 Diagram Reference: 15H70845

Figure 2-45: AP27-30 Fan Speed Control Board

The “Fan Failure Detector” is monitoring the current flowing towards the fans. If there is no current present or a current higher than normal, the fans are defective. There is a jumper on that board to check if an error message is displayed in case of faulty fans. Remove it and the error message “54” should appear on the LCDisplay. The signal on which the fan speed is decided is also implemented on this board by switching a relay. For 60Hz operation of the 80-NET, it is necessary to set the jumper JP1 accordingly.

JP1 50Hz No 60Hz Yes



2.2.19 Filter Board AP31-AP33 (15B10861G1) Item code: 15B10861G1 Diagram Reference: 15H70849

Figure 2-46: AP31-AP33 Filter Board

Present to comply to the specified standards concerning EMI.

2.2.20 Filter Board AP35 (15B10817G2) Item code: 15B10817G2 Diagram Reference: 15H70816 Present to comply to the specified standards concerning EMI.

2.2.21 Varistor Board AP36, AP37 (15B10671G5) Item code: 15B10671G5 Diagram Reference: 15B70681

Figure 2-47: AP36-AP37 Varistor Board


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 78/ 307Chapter: 2 Functional Description 2.3 Power Components printed: 15.05.2007, 13:09

2.3 Power Components

2.3.1 Rectifier A rectifier can be composed of different types of semiconductors: Diode I and V are not in-phase and the shape is not

very sinus-like

Thyristor I and V are not in-phase and the shape is not very sinus-like

Figure 2-48: Current Thyristor Rectifier

IGBT The 80-NET pulse frequency of the IGBT is 6kHz; Advantages: - efficiency - acoustic noise - size and weight - voltage and current are in-phase - with the TOP version of the 80-NET there

are just 3% circuit feedback - a diesel generator can be designed 1:1,

because of voltage and current being in-phase and low circuit feedbacks(1:1 meaning … for a 100kVA UPS a 100kVA diesel is needed; for other rectifier types a factor of 1:1,6 would be needed [100kVA UPS, 160kVA diesel])

Figure 2-49: Current IGBT Rectifier

How does the Rectifier work (Principal of operation)? The three-phase current taken from the commercial AC source is converted to a regulated DC voltage by the IGBT rectifier. In order to protect the power components within the system, each phase of the rectifier input is individually fitted with a fast-acting fuse. As shown in the block diagram (Figure 1-3), the IGBT rectifier is providing DC power to the DC/AC output converter (IGBT inverter) and to the DC/DC battery converter (booster/charger) when the latter is working in battery charger mode. The IGBT rectifier is a step up converter. It is controlling, through proper PWM, the output DC link stabilising the positive value with respect to Neutral at 365Vdc and the negative value with respect to the Neutral at -365Vdc and simultaneously it is controlling the three input AC currents to have the specified input current distortion (THDi).



What are the main components of the Rectifier? • Mains supply switch (QS1) • IGBTs (V1, V2, V3) • CU1 Board Rectifier (AP1) • Rectifier Interface Board (AP3) • IGBT Driver Boards (AP11, AP12, AP13) • IGBT Interface Boards (AP19, AP20, AP21) • Precharge Contactor (KM3) • Mains Contactor (KM1) • Filter Chokes (L1, L2, L3)


What is an IGBT? IGBT stands for Isolated Gate Bipolar Transistor and it is used – simple spoken – as a switch. It is a power switching device that can be easily driven as a FET and can carry current like a BJT (Bipolar Junction Transistor).

Why is it used in a UPS? And not some other semiconductor e.g. thyristor? Because it is a fast switching and easy to control semiconductor, despite a higher VCEsat. The IGBT accepts a higher current as the rated value without any significant variation in its voltage capacity. Through the voltage control in the IGBT, the power to control the IGBT is low, at least concerning low switching frequencies. E.g. the control power for a bipolar transistor is more or less constant whatever the frequency is. The characteristic of the IGBT is like this because the input impedance is mainly capacitive with negligible leakage current.

Figure 2-50: IGBT diagram

Please be aware of ESD handling instructions (see chapter 6.3.4.2 Changing the IGBTs). The IGBT modules are devices sensitive to electrostatic discharge on the gates. The IGBT-MOS gate could become damaged.



Notice:

Total Input Harmonic distortion (THD) and Power Factor (PF) The maximum voltage THD (THDV) permitted on the rectifier input (either from the utility or generator) is 15% (normal operation is guaranteed up to 8%). The maximum current THD injected into the mains (THDI) is less than 3% (Top version only) at maximum input power and input voltage THDV < 1% (nominal input voltage and current). Under these conditions the input power factor (PF) will be > 0.99 (Top version only). Under other input conditions and with other output load fractions the THDI will be < 5% (Top version only). This means that the 80-NET in double conversion mode is seen by the primary mains sources and distribution as a resistive load (i.e. it will absorb only active power and the current waveform will be practically sinusoidal),thus ensuring total compatibility with any power source. 80-NET includes all the performances offered by load active filtering devices as standard.

Operation with diesel generator In order to obtain the required THD on input voltage, the coordination between diesel generator and UPS shall be based on the generator’s subtransient reactance, as opposed to its short-circuit reactance.



Figure 2-51: Rectifier – Overview



QS1 Input mains supply switch TA1, TA2, TA3 Measure the actual input current; to show on display (AC CT) TA4, TA5, TA6 Input current limitation to protect the rectifier (DC CT) FU1, FU2, FU3 Input fuses for phase L1, L2 and L3 KM1 Mains contactor KM2A Aux. contact on rectifier interface board AP3

For mains contactor KM3 Precharge contactor Phase L1/L2 Mains supply for the supply interface board L1, L2, L3 Filter chokes; for a interim filter out of spikes from the mains supply Temp. choke L1-L3

Threshold for thermal protection: 180°C Normally closed, when it opens the CU1 shuts down the rectifier, then the UPS goes into battery mode.

C1, C2, C3 Input filters capacitors Input voltage sense

Measure the actual Input voltage, to show on display; Measure the rotating field; and a mains failure;

Hereafter is described how the rectifier is working when switched on. For a detailed procedure for commissioning including checks for e.g. installation, parameters and so on, please refer to the according chapter “4 Commissioning (Single Unit)” and additional document “Technical Manual 80-NET Checklists” (10H52167TM01_CL). 1. Closing QS2 Board are supplied and therefore communication with

the CU-boards is possible;

2. Check certain parameters with PPVIS

With the different “SETs” it is possible to check the most important parameters the set should be saved to provide the possibility to go back to the factory setting, when needed;

3. Closing QS1 Precharge is started; the DC capacitors of the DC-Link will be precharged (see chapter Precharge).

4. KM1 will be closed, when precharge is done

No fault occurred while precharge.

5. Rectifier start up KM1 closed After internal verification (everything within parameters) and waiting for a defined hold-off-time, the converter is synchronizing and is starting in soft start.

Parameter

Number Parameter name Description


Factorysetting

Converter Temperature Threshold Measuring the temperature in the Rectifier. It is possible to change the temperature thresholds for achieving the below described actions. Nevertheless this is NOT recommended.

0 –120 [°C]

value

1174 (150)

CU1

i01: Threshold for turning fans to high speed 80 i02: Threshold for Rectifier warning 85 Access

Level 4: URL, IBS i03: Threshold for Rectifier fault 90



2.3.1.1 Precharge

Why to precharge the DC-Link capacitors? Because in the first moment, when QS1 is closed and the capacitors are not charged, a very high input current is present, which could cause the fuses to blow. Therefore the capacitors will be precharged with resistor R1/R2. This limits the input current to Imax.

Figure 2-52: Voltage and Current for a capacitor

How is the precharge working? Before starting the precharge process, QS1, KM1 (mains contactor) and KM3 (precharge contactor) are open. Through closing QS1, the precharge process of the DC-link capacitors is started. The precharge contactor KM3 will be closed. As long as the minimal VDC is not reached (set with PNU 1159.2 +20V), the precharge process is continued. If VDCdelta per second is getting smaller than 10V, KM2A (on Rectifier interface) is closing and the KM1 contactor choke is caused to operate and therefore the mains contactor KM1 is closing, KM3 is opening. The precharge has stopped. The precharge threshold voltage VDC- /VDC+ is defined within parameter PNU1159.2 +20V (Half VDC link minimal voltage, rectifier mains contactor threshold), the factory setting is 250V, meaning 270V for the threshold of stopping precharge. The time frame for the precharge is defined through the hardware of resistor and capacitor, and therefore not changeable.



Figure 2-53: Precharge

While the precharge is running, Warning 5 is displayed. When KM1 is closed warning 5 will disappear, because precharge is finished. If Warning 3 Index 2 and Warning 7 Index 2 appears, a wrong phase sequence is present at the input of the UPS. KM3 and KM1 are kept open by the CU1 board. Fault 142 Index 1 (“Precharge short circuit”) is displayed, when QS1 is closed and the VDC voltage (PNU 1159.1) is not reaching the predefined value within 1 seconds. (This time frame is hardwired in the Firmware can not be changed.) The CU1 opens the KM3. Fault 142 Index 2 (“Precharge not finished”) is displayed, if the DC voltage didn’t reach the threshold value (PNU 1159.2 +20V) within a defined time frame (about 10 seconds). (This time frame is hardwired in the Firmware can not be changed.) Fault 142 Index 3 (“Precharge contactor feedback”) is displayed, if the auxiliary switch of KM1 is not giving a feedback within a defined time of 2 seconds after closing (when precharge is done). The CU1 board is receiving a signal form the QS1 auxiliary contact, that QS1 was closed. The various processes happening in the UPS will be controlled from the CU boards. The actual input currents will be measured via the TA1-TA3, the actual input voltage will be measured via the input voltage sense. The supply interface board (AP6) is supplied from the mains input (if not from one of the other possibilities – see description of the board).



Parameter



Factorysetting

Half VDC link minimal Voltage 0-65535 value

1159 (135)

CU1

i01: Threshold for precharge short circuit detection. If this value is not reached within 1 second after KM3 was closed Short Circuit.

150

Access Level 3: URL, IBS

i02: Threshold to open/close the rectifier mains contactor KM1. KM1 will be closed, if VDC- and VDC+ are higher (+20V) than the defined threshold. If VDC- and VDC+ are lower than the threshold, KM1 will open. Note: Depending on the actual % of the nominal input voltage (70% - 100%) this threshold is varied as well in the same % range; Meaning e.g. actual voltage = 80% of nominal input voltage Threshold = 80% of 250V

250



2.3.1.2 Current-walk-in The current-walk-in is a input current limitation, where the current from the mains is ramped up in a defined time. With the UPS in battery mode, after applying the mains input voltage, the rectifier starts the additional current-walk-in procedure. This procedure causes the current, taken from mains input, to gradually increase and the current taken from the batteries to decrease. The total current for the inverter on the DC-link stays constant. To avoid the simultaneous start-up of different rectifiers, it is possible to programme a hold-off dedicated start delay (1-180 seconds, changeable with PNU 1158 [134]) for each unit. This hold-off delay ensures that standby generators are progressively introduced into the UPS input. In addition, the UPS includes an ‘on generator’ function which, when activated via floating contact, provides the possibility of inhibiting either battery charging, synchronisation of the inverter to the bypass line supply or transfer to the bypass line. The time frame in which the current-walk-in is done, meaning the time in which 100% current is reached, can be defined with PNU 1166 [142]. The input current is limited with PNU75.17. (100% = 32767)

Figure 2-54: Rectifier current-walk-in

Parameter



Factorysetting

Rectifier hold-off delay 1158 (134) CU1 Delay before the rectifier restarts after resumption of mains power. 1-180

[s] 10

Access Level 3: URL, IBS, PRU

Parameter



Factorysetting

Current-walk-in time 1166 (142) CU1 Time for the Rectifier walk-in from 0% to 100% nominal current

limit 10-90

[s] 15

Access Level 3: URL, IBS, PRU, BYP, BTR



2.3.2 Booster/Charger (DC/DC IGBT Converter) The functions of the Booster / Battery Charger (DC/DC Converter) are: • Charger/Buck Mode to recharge the batteries:

taking the power from the DC bus, when the primary input mains is within the given tolerances.

• Booster Mode to discharge the batteries to provide the full DC power: taken from the batteries, to the IGBT output inverter if the primary mains is unavailable.

Buck Mode (Battery Charger Mode) There are several charger methods available to obtain optimum battery charge. All of them are selectable through PPVIS.

What’s important?

The recharge method depends on the battery type and battery manufacturer recommendation. 80-NET is operable with the following types of batteries: • Lead Acid (VLA) • Sealed Lead Acid (VRLA) • Ni - Cd

After setting certain parameters, the selection of the optimum charging method is completely managed by the microprocessor. The following shows the concept for Firmware Version 1.7 and higher: For more details about these parameters and their functions and interactions, please refer to chapter 2.5 Battery.

PNU1424 (400) for manual PNU1555 (531) for autom.

U,I

Manual charging: PNU1424 (400) PNU1554 (530) PNU1626 (602)

Automatic charging: PNU1617(593), PNU1578(554),PNU1547(523), PNU1555(531),PNU1622(598), PNU1624(600),PNU1626(602), PNU1618(594),PNU1619(595), PNU1620(596),PNU1161(137), PNU1540(516),PNU1554(530), PNU1629(605)

Charging method PNU 1617

(593)

Manual or automatic charging

PNU 1436 (412)

Temperature correction

PNU 1540 (516)



There are different charging methods available: 1. 1-Stage charging with charging pause (PNU 1617 = 0)

This is a gentle method to charge the batteries. After a mains failure, the cycle restarts always with the charging phase.

Figure 2-55: Charging method: 1-stage charging with pause

2. 1-Stage charging without charging pause (PNU 1617 = 1)

This is also a gentle method to charge the batteries. After a mains failure, the cycle restarts always with the charging phase.

Figure 2-56: Charging method: 1-stage charging without pause

3. 2-Stage charging with charging pause (PNU 1617 = 2)

Charging with regeneration properties. The elevated voltage in charge stage 2 causes the battery to gas slightly, with the result that deposits are cleaned off the plates.




4. 2-Stage charging without charging pause (PNU 1617 = 3)

Not recommended for the types of battery in use at this time, but can be selected for other types. Always follow the manufacturers instruction.


Parameter Number



Factorysetting

Charging Method Defines the used charging algorithm. 0-3 1 Value: 0: 1-stage charging with charging pause

1617 (593)

CU1

1: 1-stage charging without charging pause 2: 2-stage charging with charging pause Access

Level 3: URL, IBS 3: 2-stage charging without charging pause



Figure 2-59: Booster/Charger 80-NET (80kVA)



QS9 Battery switch FU7, FU8 Battery fuses TA7 Battery current (Charging/discharging current measuring) Temp. choke Threshold for thermal protection: 180°C

Normally closed, when it opens the CU1 shuts down the booster/charger.

C6, C9 (C28, C29)

DC-Link filters C28 and C29 are only present in the 80kVA/100kVA

R6, R7 For discharging of the electronics when UPS was shut down C27 Capacitor for EMI purpose L4 Choke Temp. Measurement IGBT

Measuring the temperature of an IGBT.

Functional description of Boost/Charge Mode There are two IGBT branches V4 and V4’ in parallel for splitting the current in the Booster/Charger. To make it an ideal device for describing the function of the Booster/Charger, only one branch is used. The IGBT is shown here with its Diodes separately. Boost Mode

Figure 2-60: Boost-Mode functional sketch

The Boost-Mode is for discharging the Batteries respectively to keep the VDC up while mains failure is present. (For this mode IGBT 1 is not needed.) To maintain VDC while mains failure, energy needs to be taken from the batteries and given to the DC-link respectively the capacitors C6 and C7. To do so IGBT 2 is switched through, causing a restoring of energy from battery to L4 (green line). This is caused due to UBatt impresses current into the choke L4, meaning the current ID is increasing.



After opening IGBT 2, this current flow is looking for another way (dashed green line). It is using Diode D1 to transfer the energy from L4 further to the capacitors C6 and C7, to keep them charged. The current ID is decreasing. To keep the current “flowing” the IGBT 2 is closed again…. And so it starts again until the batteries are not able to provide the necessary voltage any more. A controlled PWM is deciding about the IGBT 2 switching intervals and as a result keeps the energy constant in the capacitor C6 and C7, meaning the VDC stable. Buck-Mode (Charge Mode)

Figure 2-61: Buck Mode (Charger Mode) functional sketch

To charge the batteries after a mains failure, the Buck-Mode is used. (For this mode IGBT 2 is not needed.) With IGBT 1 closed, a current is impressed into choke L4, meaning energy is stored in L4. Because it flows in the opposite direction like in the Boost-Mode, IL4 is negative. This is easy to understand, because energy has to be brought to the batteries, contrary to the boost mode were energy is taken from the batteries. While charging the batteries, the load still need to be supported. Meaning that only a part of the energy, coming from the rectifier, can be used to charge the batteries. This energy is limited to Pcharge = Pmax – Ploadsupport with Pmax = Ilimit * Umax . If IGBT 1 would not open again, more than Pcharge would be used to charge the batteries, and therefore the load support is not ensured any more. (IGBT 1 = closed IL4 is increasing) But the batteries can still be charged while IGBT 1 is open (dashed line), because the energy, saved in L4, will now be transferred to the battery. IL4 is using D2. (IGBT 1 = open IL4 is decreasing) Again through the controlled PWM (50Hz) energy is keep nearly constant in C6 and C7 and therefore VDC stable.



Voltage regulation, temperature compensation The battery charger voltage is operated within narrow parameters. In order to ensure optimum battery charging, regulation is automatically adjusted to the ambient temperature. The IGBT rectifier is capable of supplying the battery charger and the IGBT inverter with DC voltage at rated power, even if the input voltage is below the nominal voltage specified. This will not require the discharging of the batteries. This connection is illustrated in this Figure:

Figure 2-62: Battery status during reduction of the commercial AC source.

Residual ripple filtering The battery charger output has a residual voltage ripple of <1% RMS. Capacity and charging characteristics When the mains input is not suitable to supply the rectifier, the DC/DC converter (booster mode) will provide the required power to the inverter. The rectifier is capable of supporting the inverter at nominal power and supplying the batteries with charging current. The following charging methods are an example of the methods available, giving the possibility of matching the different types of accumulators:

• Sealed, maintenance-free lead acid accumulators: Charging is at constant current up to the maximum floating voltage level. Thereafter the voltage is kept at a constant level within narrow limits (single-step charging method).

• Sealed, low-maintenance lead acid accumulators or NiCd accumulators: Charging is at increased charging voltage and constant charging current (boost charge phase). When the charging current falls short of a lower threshold value the battery charger is automatically returning to floating voltage level (two-step charging method).

Overvoltage protection The battery charger is automatically switching off if the DC battery voltage exceeds the maximum value associated with its operational status.



Battery management Using advanced battery care (ABC) the 80-NET series increases battery life up to 50%. The main battery care features are described as follows. • Operating parameters

When operating with a maintenance free, value regulated lead acid battery (VRLA), the parameters per cell shall be as follows: - End of discharge voltage (V) 1.65 - Shutdown imminent alarm (V) 1.75 - Minimum battery test voltage (V) 1.9 - Nominal voltage (V) 2.0 - Battery discharging alarm (V) 2.20 @ 20°C - Float voltage (V) 2.27 @ 20°C - High voltage alarm (V) 2.4

• Automatic battery test The operating condition of the batteries is automatically tested by the control unit at selectable intervals, e.g. weekly, fortnightly or monthly. A short-time discharge of the battery will be made to confirm that all the battery blocks and connecting elements are in good working order. In order to preclude a faulty diagnosis the test will be launched 24 hours after the latest battery discharge at the earliest (PNU 1438.4). The battery test is performed without any risk to the load, even if the battery is completely defective. Users will be alerted to a detected battery fault. The battery test will not cause any degradation in terms of the battery system life expectancy.

• Ambient temperature compensated battery charger The float voltage and battery discharge alarm is automatically adjusted as a function of the temperature in the battery compartment (-0.11% per °C) in order to maximise battery operating life.

• Remaining battery life 80-NET uses sophisticated algorithms to determine the battery life remaining based on real operating conditions such as temperature, discharge and charging cycles, and discharge depth.

• Time compensated end of discharge voltage With PNU511 and PNU513 a discharge compensation curve is described, which is automatically increases the shutdown voltage according to that curve. For more details refer to chapter “2.5 Battery”.

Parameter



Factorysetting

Minimal Battery Voltage 1426 (402) CU1 Battery voltage in V/Cell that will

Produce the warning 11 “Battery undervoltage” Determines the end of the autonomy test

0-10 [0,01V]

Indices: i01: Battery undervoltage limit 1,6 Access

Level 3: URL, IBS i02: End of autonomy test battery voltage 1,7



Parameter Number



Factorysetting

Cell Number 1629 (605) CU1 Amount of battery cells. 108-500 240


For more detailed about setting please refer to chapter “2.5 Battery” and the additional document “Technical Manual 80-NET Checklists” (10H52167TM01_CL) where you can find a procedure for commissioning including checks for e.g. installation, parameters and so on.



2.3.3 Inverter AC voltage generation From the DC voltage of the intermediate circuit the inverter is generating sinusoidal AC voltage for the user load on the basis of pulse-width modulation (PWM). By means of the digital signal processor (DSP) on the CU-Board, the inverter IGBT is dividing up the DC voltage into pulsed voltage packets. Thanks to a low-pass filter the pulse-width modulated signal is converted into sinusoidal AC voltage. No isolation transformer is needed for the IGBT inverter, with the great benefits of: • energy conversion efficiency, • physical size and • weight of the modules.

Voltage regulation The inverter output voltage on the three phases is individually controlled to achieve the following performances: • Steady state

The inverter steady state output voltage is not deviate by more than ±1% in a steady state condition for input voltage and load variations within the quoted limits.

• Voltage transient response The inverter transient voltage is not exceed Class 1 limits when subjected to application or removal of 100% load as defined by IEC/EN62040-3.

Frequency regulation The inverter output frequency is controlled to achieve the following performances: • Steady state

The inverter steady state output frequency, when synchronised to bypass supply, it is not deviate by more than ±1% adjustable to ±2%, ±3%, ±4%.

• Frequency slew rate (PNU 105 “Delta Frequency”) (The frequency slew rate is <1 Hz per second.) The output frequency of the inverter is controlled by a quartz oscillator which can be operated as a free running unit or as a slave for synchronised operation with a separate AC source. The accuracy of the frequency control is ±0.1% when free-running.

Total Harmonic Distortion The inverter provides harmonic neutralisation and filtering to limit the THD on the voltage to less than 3% with a linear load. For reference non-linear load (as defined by IEC/EN62040-3) the THD is limited to less than 5%. Neutral sizing The sizing of the inverter neutral is oversized on all ratings in order to cope with the combination of harmonics on the neutral wire when driving single-phase reference non-linear loads. The inverter neutral is sized 1,7 times in relation to the phase. Overload The inverter is capable of supplying an overload of 125% for 10 minutes and 150% for one minute of the nominal power.



Inverter shutdown In the event of an internal failure the inverter is immediately shut down by the control unit. The UPS device or the parallel-operated UPS systems continues to supply the load from the bypass supply without interruption, if it is within permissible limits. Output voltage symmetry The inverter guarantees the symmetry of the output voltages at ±1% for balanced loads and ±3% for 100% unbalanced loads. Phase displacement The phase angle displacement between the three-phase voltages is: • 120° ± 1° for balanced loads • 120° ± 3° for unbalanced loads (0, 0, 100%)

Short circuit If the bypass is NOT present, the inverter short circuit capacity of 80-NET for the first 10ms is >200% for any short circuit configuration. After the first 10ms, it limits the current to >150% for not more than 5s, then it will shut down. Automatic upgrade of inverter rated power The inverter automatically upgrades its power as a function of ambient and operating temperatures, as shown in below Figure. In the most common conditions (25°C) 80-NET provides 10% more power than nominal. In these conditions the battery charge will be reduced correspondingly.

Figure 2-63: Automatic power upgrade



Figure 2-64: Overview Inverter



IGBT Pulsed with 6kHz IGBT Temp. Measurement

Measuring of the temperature in the inverter

Temp. choke L6-L8

Threshold for thermal protection: 180°C Normally closed, when it opens the CU2 shuts down the inverter. Load is transferred to bypass.

C8-C10’ Output Filters for a “nice” sinus from the PWM (different for SP and TOP version)

L6, L7, L8 Temp. Sensor Chokes to filter out harmonics to provide a “nice” sinus; Is switching on/off when a high temperature is reached

TA9, TA10, TA11

Inverter output current measuring for controlling the inverter (DC CT) for I2T detection

TA12, TA13, TA14

Output current measuring (AC current supplied to the load from the UPS) for showing on display (AC CT for overload detection)

FU4, FU5, FU6 Output Fuses for phase L1, L2 and L3 QS4 Output switch Output voltage sense

Measure the actual Inverter Output voltage; Used as feedback for the control of Inverter

What’s important?

The inverter is not switching on, if the following is present: • the DC input voltage for the inverter is lower than PNU101 “VDC min” • the QS4 is not closed • the QS3 is not open

Parameter Number



Factorysetting

Line Voltage Setting the rated voltage. 0-4 0 Values:

71

CU2

0: 230V / 400V 1: 220V / 380V

2: 240V / 415V 3: 120V / 208V Access

Level 3: URL, IBS 4: 127V / 220V



Parameter



Factorysetting

Mains Frequency Setting the rated frequency. 0-6 3 Values:

72

CU2

0: 50 Hz 1: 60 Hz 2: Special frequency 3: Auto – default = 50 Hz

4: Auto – default = 60 Hz 5: HU Contact on = 50 Hz / HU Contact off = 60 Hz Access

Level 3: URL, IBS 6: HU Contact on = 60 Hz / HU Contact off = 50 Hz

Parameter Number



Factorysetting

Bypass installed Bypass in place. 0-4 1

73

CU2 Values: 0: No Access

Level 3: URL, IBS 1: Yes

Parameter Number



Factorysetting

Separate lines Separate lines for bypass and rectifier supply in place. 0-1 1

74

CU2 Values: 0: No Access

Level 4: URL 1: Yes

Parameter Number



Factorysetting

V correction 118

CU2 Correction of the output voltage to compensate for line losses, for example.

-10 - 10 [0,1%]

0




2.3.3.1 Pulse Width Modulation (PWM) When is it used? It is used to convert a DC voltage to a AC voltage. Concerning the 80-NET it is used in the inverter to generate the output AC voltage. Why is it used? Advantage:

- Inverter output voltage can be controlled with the DC voltage - Harmonics are reduced with this method

Disadvantage:

- Switching losses are higher due to the high PWM frequency - Available voltage is reduced - High-order harmonics cause EMI problems

How is it managed? There is a delta (triangular) voltage Vtri functioning as a trigger for the PWM. E.g. for phase L1: For Vtri > Vcontrol L1 : Each time the delta voltage is getting higher than the phase control

voltage Vcontrol L1, the IGBT is closed. This means the L1 voltage VL1 is falling to 0V.

For Vtri < Vcontrol L1 : The opposite is happening when Vtri is falling under Vcontrol L1, then the IGBT is opening.

The frequency of the control voltage fc is the voltage of the output. The frequency fs is the PWM frequency. The frequency modulation mf = fs / fc is a reference to the proper working UPS.

- if mf is not a integer, then subharmonics could exist at the output voltage - if mf is not odd, then a DC component may exist and subharmonics

could exist at the output voltage - mf should be a multiple of 3 for a three-phase PWM inverter - if mf is even a odd multiple of 3 than harmonics are suppressed



Figure 2-65: Pulse Width Modulation



2.3.4 Bypass Static Switch The bypass static switch is a fully rated, high speed, solid-state transfer device and rated for continuous duty operation. The following transfer and retransfer operations is provided by the electronic static switch:

• Uninterrupted automatic transfer to the bypass supply in the event of: - inverter output overload - battery voltage outside limits in backup mode - over-temperature - inverter failure

• If inverter and bypass supply are not synchronised at the time of a necessary transfer, a switching delay can be set to protect the critical load. This prevents possible damage to the load by unintentional phase shift. A delay of 20ms will be preset as a standard value.

• Uninterrupted manual transfer/retransfer to and from bypass supply is initiated from the control panel.

• Uninterrupted automatic transfer/retransfer to and from bypass supply by activation of the digital interactive mode (DIM).

• Uninterrupted automatic retransfer from bypass supply, as soon as the inverter regains the capacity to supply the load.

• The uninterrupted transfer from inverter to bypass supply is inhibited in the following situations: - bypass supply voltage outside limits - failure of electronic bypass switch.

• The uninterrupted automatic retransfer may be inhibited in the following situations: - manual switching to bypass supply via the maintenance switch - UPS output overload.

Voltage The nominal voltage of the bypass line is 230/400 VRMS. Any transfer from inverter to bypass line will be inhibited if the voltage is beyond a limit of ±10% (standard setting) of the nominal voltage. Transfer time (double conversion) The switching time for a transfer from the inverter to the bypass supply or vice versa is less than 0.5ms when synchronised. The system ensures that the inverter is stable and operating normally before permitting a retransfer of the load back to inverter. The transfer time when out of synchronisation is 20 milliseconds to prevent damage to the load by phase reversal. Overload The bypass static switch is capable of supporting the following overloads:

• 125% for 10 minutes • 150% for 1 minute • 700% for 600 milliseconds • 1000% for 100 milliseconds



Manual maintenance bypass It is possible to implement a manual uninterrupted bypass of the complete system in order to enable maintenance work to be carried out on the system. The bypass supply will continue to feed the load. In this case the UPS will be voltage-free as it will be disconnected from the supply networks. In this case, maintenance work on the UPS can be carried out without affecting the connected electric load. Backfeed protection This feature shall prevent any potential risk from electric shock on the UPS bypass input AC terminals in the event of failure of the bypass static switch SCR. The control circuit includes a contact (available for the user) which activates an external isolating device, such as an electromechanical relay or a tripping coil, upon backfeed detection. The external isolating device is not included in the UPS, in compliance with IEC/EN 62040-1. The external isolating device is a 4 pole (3 phases plus neutral) air gap isolator.

Parameter Number



Factorysetting

Asynchronous Transfer Enable connection of the bypass after interrupt. 0-1 [s] 1

115

CU2 Values: 0: No

Access Level 3: URL, IBS, PRU, BYP 1: Yes

Parameter Number



Factorysetting

Bypass delay 116

CU2 Delay for connection of bypass after interrupt. (Only if the Asynchronous Transfer has been enabled PNU 115)

0,02-4 [0,01 s]

0,02




Figure 2-66: Static Bypass Overview



QS2 Bypass supply switch C11-C13 Backfeed Load Capacitors TA15, TA16, TA17

Measure if there is a current supplied back to the mains. If so, output contact XT4 will be activated. (e.g. a customer supplied contact can be opened to prevent backfeed.)

Voltage Feedback Synch.

Measuring and correcting the phase shift between mains and bypass to possibly 0; Vcontrol for PWM

Mains Input Supply Interface

This is the power supply for the boards; the intelligence of the UPS is than present;

Mains Input STS Power Supply

Power Supply for AP7 (STS Driver Board); this board does have his own intelligence to make sure, that there is always power for the STS to connected through;


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 107/ 307Chapter: 2 Functional Description 2.4 Connectivity Box printed: 15.05.2007, 13:09

2.4 Connectivity (Box) Hereafter will be shown the possibilities to communicate with the UPS. The interfaces can be used for:

• Direct communication between UPS and computer systems • Integration of the UPS as client into a network via MopUPS or ManageUPS • Transfer of operational states to external alarm systems • Receive operational states from external systems

The customizing of the interfaces can be done via the display and/or PPVIS (service software tool). The following interfaces are present on 80-NET:

Interface Description Input/

Output/ Serial

X3

Standard serial interface RS232 COM configured for use with PPVIS or external connectivity solutions - female - Available, when the XS3 slot is empty or a MUN card is installed;

Serial

X6

Standard serial interface RS232 COM configured for data transfer protocol, modem or external connectivity solutions - male - Not available, when a slot modem is installed;

Serial

X7 An AS400 compatible contact interface for signal exchange - female - Output

X8 An interface to provide emergency shut down of the bypass, inverter and rectifier (EPO) Input

XT1 External battery temperature sensor connection Input XT2 External battery switch status Input XT3 EPO activated Output XT4 Backfeed protection activated Output

AP10-X4 Optional I/O connection (behind cover): Service interface Serial

AP10-XT5 Optional I/O connection (behind cover): 2 free programmable output contact Output

AP10-XT6 Optional I/O connection (behind cover): 4 free programmable input contact Input

XS3 Slot available for use with a connectivity option, typically ManageUPS Net SNMP adapter Serial

XS6 Slot for the LIFE.net slot modem, fitted as standard (user removable) Serial

The serial interfaces are isolated and RS232 compatible. The inputs are opto-isolated and can be driven by external dry-contacts (e.g. relay contacts); the outputs are 1A, 24Vdc or 110Vac rated relay contacts.



2.4.1 Where to find the interfaces?

Figure 2-67: Overview interfaces connectivity

2.4.2 XS3 and XS6 – Slot Card Bay 80-NET is equipped with two slot bays XS3 and XS6, available for communication card options. The Slot XS6 is equipped with the LIFE.net slot modem, fitted as standard (user removable). The XS3 slot is available for connectivity options. If no cards are fitted into these slots XS3 and XS6, the interfaces X3 and X6 can be used for other connectivity applications. (Refer to correspondent chapters for more details.) XS3 and X3 as well as XS6 and X6 can not be used simultaneously. (For further details refer to Chloride Connectivity Solutions.)

Figure 2-68: Slot XS3

Figure 2-69: Slot XS6



2.4.3 X3 – RS232 Service Port 80-NET is equipped with one 9-pin, D-type connector (female) for serial RDS232C communication. The connector has the following pin functions: Pin Signal Explanation 1 Not used 2 TxD Send RS232 3 RxD Receive RS232 4 Not used 5 SIG GND Signal ground RS232 for receive and send 6 Not used 7 Not used 8 Not used 9 Not used

:5

X3 / RS232Sub-D 9pin female

TxD

RxD

:2

:3

SIG GRD Figure 2-70: Interface X3

USS-protocol is used for communication. This RS232 port X3 normally should not be used simultaneously with the corresponding slot bay XS3. You may use X3, while a SNMP adapter is built in the XS3 slot, but the service port is very slow.



Interaction between X3 and XS3 X3 being the Service port means, that for Service use a notebook with PPVIS is connected via according cable to the X3 interface. While X3 is used, PPVIS is communicating with the CU via the blue (dark) way. The USS protocol is defined for communication with the CU. If slot XS3 is going to be used e.g. with a ManageUPS internal SNMP Adapter, then while inserting the ManageUPS a contact “1” is closed and the switch “A” is changing position.

Figure 2-71: Interface X3 and slot XS3 interaction

It is no longer possible to communicate with the CU via the direct (blue/dark) way from X3. Because the ManageUPS in slot XS3 is now communicating with the CU (green/light). Meaning only one or the other communication is possible. BUT there is a ”hardwired” connection between X3 and XS3 (orange), which is also closed by inserting a ManageUPS into XS3. This connection is necessary to configure the ManageUPS. And because of this existing connection it is still possible to communicate with the CU from interface X3. The information sent from X3 will follow the orange way to XS3, the ManageUPS is receiving the information and will forward it to the CU (via green way). Returned information follow the reverse way. NOTE: Every now and then, the ManageUPS wants to communicate with the CU itself, therefore there are “breaks” between the X3 XS3 CU communication, caused by the ManageUPS talking to the CU. This is slowing the communication down. It is NOT possible to operate a LIFE.net modem in slot XS3, because this slot is only able to communicate with USS protocol, not with the for LIFE.net necessary Lifenet-protocol. Which is only available on XS6.



2.4.4 X6 – Serial Interface 80-NET is fitted with a slot modem for LIFE.net connection as standard in slot XS6. If this slot modem is removed, the interface X6 may be used for other connectivity applications. This is also a D-type 9-pin male connector for serial RDS232C communication. Pin Signal Explanation 1 Not used 2 RxD Receive RS232 3 TxD Send RS232 4 Not used 5 SIG GND Signal ground RS232 for receive and send 6 Not used 7 Not used 8 Not used 9 Not used

TxD

RxD:2

:3

:5SIG GRD

X6 / RS232Sub-D 9pin male

Figure 2-72: Interface X6

LIFE.net-protocol is used for communication. This RS232 port X6 cannot be used simultaneously with the corresponding slot bay XS6. If XS6 is not used with the LIFE.net modem, but with e.g. ManageUPS internal SNMP Adapter and therefore the protocol is changed from LIFE.net (standard in XS6) to USS protocol (needed for ManageUPS), than the same “possibilities of use” like X3/XS3 are possible (described under “Interaction between interface X3 and Slot XS3 within the previous chapter).



2.4.5 X7 – Computer Relay Interface (Output Contacts) The interface X7 is providing four voltage-free contacts, which can either be preset with IBM AS/400 or Siemens configurations or they can be parameterised according to customer requirements. This interface is wired via a 9-pin female D-type socket. The voltage-free contacts are rated at 1A, 24Vdc or 110Vac.

What’s important?

To change the function of input or output contacts, the UPS must be switched to Bypass as well as the Commissioning mode must be entered. After performing a change, a power reset is necessary to activate the new function configuration.

Listed below are the most significant functions; the complete list is published in the User Manual or you can find all possibilities under the description of Parameter 81 (PNU 81): Fan (On-Off) In Battery Compartment Battery Fuse Monitor Battery Compartment Overheated Generator On Hydrogen Present Remote Inverter Stop SBS Bypass Switch Closed Air conditioning failure SBS Output Switch Open



2.4.5.1 PRESET Siemens Pins used Closed Pin Description of its function

NC X7.1 to X7.5

UPS in inverter mode; X7.1,6 Bypass Active (AK 2)

NO X7.6 to X7.5

If the UPS goes to bypass mode or maintenance mode, the relay is caused to operate. Reaction delay time is 200ms;

NC X7.2 to X7.5

Battery time ok; X7.2,7 Battery low(AK 3) NO

X7.7 to X7.5 If the battery support time has fallen below a default value of 180 seconds (changeable with PNU 117 the alarm “Remaining battery time” is active and causes the relay to operate.

NC X7.3 to X7.5

NONE of the other alarms is active (“Line-Fail”, “Battery-Low” or “Bypass-Active”)

X7.3,8 Summary Alarm (AK 1)

NO X7.8 to X7.5

If one of the other alarms is active, the relay is caused to operate. OR an other warning/fault is present. Reaction delay time is 200ms;

NC X7.4 to X7.5

No mains failure is present X7.4,9 Line-Fail (AK 4) NO

X7.9 to X7.5 If there is a mains failure for a default value time of more than 30 seconds (changeable with PNU 110 [CU2]/1134 [CU1]), the relay is caused to operate. It only returns, to the “normal” state (Pin 4 and 5 closed), after 10 seconds of mains power.

Figure 2-73: Interface X7 – PRESET Siemens



2.4.5.2 PRESET IBM AS400 Pins used Closed Pin Description of its function

NC X7.1 to X7.5

UPS in inverter mode; X7.1,6 Bypass Active (AK 2)

NO X7.6 to X7.5

If the UPS goes to bypass mode or maintenance mode, the relay is caused to operate. Reaction delay time is 200ms;

NC X7.2 to X7.5

Battery time ok; X7.2,7 Battery low(AK 3) NO

X7.7 to X7.5 If the battery support time has fallen below a default value of 180 seconds (changeable with PNU 117 the alarm “Remaining battery time” is active and causes the relay to operate.

NC X7.3 to X7.5

UPS is in Inverter mode. X7.3,8 UPS on (AK 1) NO

X7.8 to X7.5 Inverter is off;

NC X7.4 to X7.5

No mains failure is present X7.4,9 Line-Fail (AK 4) NO

X7.9 to X7.5 If there is a mains failure for a default value time of more than 30 seconds (changeable with PNU 110 [CU2]/1134 [CU1]), the relay is caused to operate. It only returns, to the “normal” state (Pin 4 and 5 closed), after 10 seconds of mains power.

Figure 2-74: Interface X7 – PRESET IBM AS400



2.4.6 X8 – Emergency Power Off (EPO) (Input Contact) Pin Signal Explanation 1-2 EPO activation (NC) EPO active when open

The activated EPO electronically shuts down the rectifier, the inverter and opens the static bypass switch. The “EPO activated” feedback control command is associated with a dedicated contact output terminal XT3 (refer to the User Manual for further details). The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 . In accordance with the European Harmonized Document HD384-4-46 S1, an Emergency Switching Device (E.S.D.) has to be fitted into the installation, downstream of the UPS. As soon as the cause for the emergency, which triggered the switch, is removed, turn off all UPS switches (input, output, battery disconnector, and all external battery switches) and repeat the start-up.

Warning: The battery voltage is still present on the UPS!! The rectifier is stopped as well as the Inverter and the Static Bypass Switch is open. This means there is still voltage present on the input terminals (mains and bypass) and on the DC-link (from battery).



2.4.7 XT1 – External Battery Temperature Connector (Input contact)

Figure 2-75: Interface XT1

Pin Signal Explanation 1-2 Temperature sensor Temperatures sensor

To install an external sensor for measuring battery cabinet temperature, connect an optional temperature sensor to the Interface XT1. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 . The temperature sensor is a NTC Thermistor. (Chloride part no. 10H46738P02 incl. sensor (Chloride part no. 10H46738P01), cable (Chloride part no. 10H46739PCF) and plug (Chloride part no. 10H46739PF02V). A few important values of the NTC:

- Nominal resistance at 25°C = 2000Ω - Wire length 150mm - Temperature range: -40°C to +125°C



2.4.8 XT2 – External Battery Switch Status (Input contact)


Pin Signal Explanation 1-2 Battery Switch (NC) Battery connected when closed

To monitor if an external battery breaker is open, connect an available auxiliary contact to the interface XT2. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .

2.4.9 XT3 – EPO activated (Output contact)


Pin Signal Explanation 1-2 EPO activated (NO) EPO active when closed

If the EPO function is activated, the EPO status is forward to an input contact of an external alarm system, which is connect to the interface XT3. If the contact X8 is activated, a feedback signal is send to this XT3 contact. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .



2.4.10 XT4 – Backfeed Protection activated (Output contact)


Pin Signal Explanation 1-2 Backfeed protection activated (NO) Backfeed detected when closed

To forward a status, if the backfeed protection is activated, connect the interface XT4 to an switch which isolates the UPS input side. The interface is a 2 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .

2.4.11 AP10–XT6 – 4 free programmable Input Contacts (Input contacts) Behind the I/O cover, the interface AP10-XT6 provides 4 input contacts. These contacts can be parameterised to perform various functions. The interface is a 8 pole screw terminal connector (Phoenix MC 1,5/ 8-STF-3,81 [1827761]) for wires up to 0.75 mm2 .

Figure 2-79: Interface AP10-XT6

Pin Signal Explanation 1-2 Input contact XT6_1-2 Input Contact 1 3-4 Input contact XT6_3-4 Input Contact 2 5-6 Input contact XT6_5-6 Input Contact 3 7-8 Input contact XT6_7-8 Input Contact 4



2.4.12 AP10–XT5 – 2 free programmable Output Contacts (Output contacts) Behind the I/O Cover, the interface AP10-XT5 provides 2 output contacts. These contacts can be parameterised to perform various functions. The interface is a 12 pole screw terminal (Phoenix MC 1,5/ 2-STF-3,81 [1827703]) connector for wires up to 0.75 mm2 .

Figure 2-80: Interface AP10-XT5

Pin Signal Explanation 1 XT5-KM1 common Common ground KM1 2 Not used 3 XT5-KM1 (NO) Normally open 4 Not used 5 XT5-KM1 (NC) Normally closed 6 Not used 7 Not used 8 XT5-KM2 common Common ground KM2 9 Not used

10 XT5-KM2 (NO) Normally open 11 Not used 12 XT5-KM2 (NC) Normally closed



2.4.13 AP10–X4 – Service Interface (Serial) Behind the I/O Cover, the interface AP10-X4 provides service function only for trained service technician.

Figure 2-81: Interface AP10-X4

This interface is used only for flashing the CU1 (CUX of the Rectifier) board.



2.4.14 Parameter Settings for Contacts in PPVIS For changes in the parameterisation of the contacts the following Parameters are needed:

Parameter Number



Factorysetting

Fast off

Quick stop. X8 This parameter is used to show whether quick stop (bypass and inverter of) via serial interface is allowed. Note: When a modem with external access is to be connected “Quick stop” should by all means be disabled for reasons of safety.

0 -1 0 58

CU2

value 0: No

Access level 3: URL, IBS, BYP, BTR 1: Yes

Parameter Number



Factorysetting

Output contacts Setting from the output contacts 0 -2 1

80

CU2 value

0: AS400 standard (would be PNU81 values: 0-3; with 0 =

“Inverter on”)

1: Siemens (would be PNU81 values: 0-3; with 0 = “Summary

alarm”) Access level 4: URL, IBS, BYP, BTR 2: Customized: Choose from the list of PNU 81 values.

This parameter is for setting ALL the contacts to a predefined state (either AS400 or Siemens) OR it is possible to set the Parameter 80 to “customized” what would be necessary to define/parameterise the contacts according to the wish/use of the customer.



Parameter


value rangeDimension

Factorysetting

Function of Output Contacts The required message for the output contact involved is parameterised. The parameter is valid only in conjunction with parameterisation output contacts = customer spec;

0 - 45

Indices:

81

CU2

i01: X7.3,8,5 0 i02: X7.1,6,5 1 i03: X7.2,7,5 2 i04: X7.4,9,5 3 i05: AP10_XT5.5,3,1 43 i06: AP10_XT5.12,10,8 10 i07: XT3.1,2 42 i08: XT4.1,2 46 value: 0: Inverter on/Summary alarm (for Siemens: AK1)

Active if: any warning OR any fault OR inverter not running;

NOTE: If PNU80=0 (AS400) this value equals “Inverter on”; If PNU80=1 (Siemens) this value equals “Summary alarm”; If PNU80=2 (customised) this value equals “Summary alarm”;

1: Bypass on (for Siemens: AK2) Active if: inverter not running;

2: Battery low (for Siemens: AK3) Active if: warning W10 is present;

3: Rectifier fail./Line fail. (for Siemens: AK4) Active if: warning W2 AND W3 is present;

4: Online Active if: inverter running;

5: Battery mode Active if: warning W9 is present;

6: Bypass on Active if: inverter not running AND bypass or

maintenance bypass closed;

7: Service bypass Warning Active if: warning W8 is present;

8: Self clocked Active if: inverter running AND synchronised with

bypass;

9: Shutdown active Active if: UPS sleep command present;

10: Fault Active if: any fault is present;

11: INV-Fault Active if: any inverter fault is present;

12: Bypass-Fault Active if: any bypass fault is present;

13: BAC Fault (S-Series) Active if: any rectifier fault is present;



14: Warning

Active if: any warning is present;

15: Temp. Warning Active if: warning W1 OR W30 is present;

16: Battery backup time below min. value Active if: warning W10 is present;

17: C DC-Link low Active if: warning W11 is present;

18: Overload Active if: warning W4 OR W6 is present;

19: Line Failure Active if: warning W2 OR W3 is present;

20: RF-Main Failure Active if: warning W3 is present;

21: Bypass-Main Failure Active if: warning W2 is present;

22: Batt. Temperature Active if: warning W3 is present;

23: Diesel Gen ON Active if: Mains failure and PNU108 delay passed;

24: U Batt./C. Active if: Battery cell voltage > PNU 113 value

[0,03V/cell hysteresis applied);

25: Battery 25 Active if: PNU21 “Batt. Capacity Battery” >12%;

26: Battery 50 Active if: PNU21 “Batt. Capacity Battery” >25%;;



29: Load 25 Active if: PNU566 “Max. Output” > 5%;





(threshold 105% is temp. dependent)

34: Line Active if: undelayed alarm of bypass failure;

35: General Alarm Active if: any warning OR any fault OR undelayed

alarm of bypass failure OR undelayed alarm of mains failure is present;



36: Power loss Pre-warning Active if: bypass not available undelayed AND mains

not available undelayed AND (batt. cell voltage < PNU113 value OR warning W3 present);

37: Power loss Alarm Active if: Bypass fault during bypass operation OR

(bypass not available AND inverter fault or overload);

38: Slope Up Active if: Adjustable output voltage ramp is positive

PNU59.103; Only if unit set as frequency converter;

39: Slope Down Active if: Adjustable output voltage ramp is positive

PNU59.103; Only if unit set as frequency converter;

40: Charger on command (for control of battery charger) Active if: not enabled;

41: Charger alt current limited mode Active if: not enabled;

42: Quick stop/EPO output Active if: not enabled;

43: Load on bypass Active if: not enabled;

44: External sync. Fault Active if: not enabled;

45: No action (contact is not energised at all) Active if: always FALSE (used to set a relay

constantly OFF);

Access level 4: URL, IBS, BYP, BTR

46: Backfeed fault Active if: ;

X7.3,8,5 = contact X7; pin 3, 8 and 5 Which contacts are closed, please refer to the drawings.



Parameter



Factorysetting

Negated Output Contacts The function of the output contact can be inversed (if "Yes" has been entered).

0 - 1

82

CU2

Indices: i01: Output contact X7.3,8,5 0 i02: Output contact X7.1,6,5 0 i03: Output contact X7.2,7,5 0 i04: Output contact X7.4,9,5 0 i05: Output contact AP10_XT5.5,3,1 0 i06: Output contact AP10_XT5.12,10,8 0 i07: Output contact XT3.1,2 0 i08: Output contact XT4.1,2 0

value: 0: No


Parameter Number



Factorysetting

On delay of Output Contacts Switch-on delay for contact output in 10-ms steps This parameter can be used for setting a delay between “event happened” and “event signalised”. This can be done in 10-ms steps.

0 – 60 [0,01 s]

87

CU2

Indices: i01: Output contact X7.3,8,5 0,2 i02: Output contact X7.1,6,5 0,2 i03: Output contact X7.2,7,5 0,2 i04: Output contact X7.4,9,5 0,2

i05: Output contact AP10_XT5.5,3,1 0,2 i06: Output contact AP10_XT5.12,10,8 0 i07: Output contact XT3.1,2 0

Access level 4: URL, IBS, BYP, BTR i08: Output contact XT4.1,2 0



Parameter



Factorysetting

Off delay of Output Contacts Switch-off delay for contact output in 10-ms steps This parameter can be used for setting a delay between “event stopped” and “event stopped signalised”. This can be done in 10-ms steps.

0 – 60 [0,01 s]

88

CU2

Indices: i01: Output contact X7.3,8,5 0,2 i02: Output contact X7.1,6,5 0,2 i03: Output contact X7.2,7,5 0,2 i04: Output contact X7.4,9,5 0,2 i05: Output contact AP10_XT5.5,3,1 0,2

i06: Output contact AP10_XT5.12,10,8 0 i07: Output contact XT3.1,2 0

Access level 4: URL, IBS, BYP, BTR i08: Output contact XT4.1,2 0

Parameter Number



Factorysetting

Function of Input Contacts Choose the function/effect of the input contacts.

0 - 24

*) Factory setting provides for this function at input 1; if this is changed the Siemens interface (see parameter Output contacts) will be affected.

**) If this function has been parameterised for a contact input, the key switch in the LCD is ineffective!

93

CU2

Indices: i01: Input contact X8.1,2 fast off EPO 3 i02: Input contact AP10-XT6.1,2 0 i03: Input contact AP10-XT6.3,4 0 i04: Input contact AP10-XT6.5,6 0 i05: Input contact AP10-XT6.7,8 0 value: 0: no function

Active if: do nothing;

1: Standby generator operation (not tested) Active if: Action defined by PNU 123;

Bit 1 =1 (not active) Bit 2 =1 Inverter synchronisation with bypass enabled Bit 3 =1 Bypass enabled

2: Bypass operation (not completed) Active if: Force the load on bypass; following commands

will be set: - UPS off (Inverter off) - Bypass on

3: Quick stop (UPS off with fault) Active if: Force inverter OFF and bypass OFF;



4: Manual bypass switch report Active if: Force inverter OFF and bypass ON; Set W8i1;

5: Spare (no function) Active if: not enabled;

6: Forced sync. Active if: Force inverter synchronisation with bypass out of

tolerance;

7: Start Batt. Test Active if: Set a request of battery test on CU1;

8: Shutdown *) Active if: Sleep command will be set;

9: Acknowledgement (acknowledge fault) Active if: Reset fault;

10: UPS off (inverter and bypass off!) **) Active if: Force the inverter and bypass OFF; following

commands will be set: - UPS off (Inverter off) - Bypass off

11: Cancel Shutdown (cancel on-going shutdown) Active if: Reset the UPS sleep command;

12: Condition (start battery conditioning) Active if: not enabled;

13: Stop Condition (stop battery conditioning) Active if: not enabled;

14: Output Voltage command (not in UPS mode; only active with operation of frequency converter) Active if: for unit set as frequency converter (PNU131=1)

change the output voltage;

15: Acknowledge charger is on (for control of the battery charger) Active if: not enabled;

16: Charger on command (battery charger) Active if: not enabled;

17: Current bus disabled Active if: Switch off current bus on POB;

18: Test load Active if: not enabled;

19: Force to bypass Active if: not enabled;

20: Hydrogen sensor input Active if: not enabled;

21: Bypass fuse monitor (is setting F83i2, when active) Active if: not enabled;

22: System output switch open Active if: not enabled;

23: Rectifier input transformer protection (is setting F72, when active) Active if: not enabled;

Access level 4: URL, IBS, BYP, BTR

24: Bypass input transformer protection (is setting F53, when active) Active if: not enabled;



Parameter Number



Factorysetting

Negated Input Contacts The function of the input contact can be inversed (if "Yes" has been entered).

0 - 1

94

CU2

Indices: i01: Input contact X8.1,2 fast off EPO 0 i02: Input contact AP10-XT6.1,2 0 i03: Input contact AP10-XT6.3,4 0 i04: Input contact AP10-XT6.5,6 0 i05: Input contact AP10-XT6.7,8 0

value: 0: No


Parameter Number



Factorysetting

On delay Input Contacts Switch-on delay for contact input in 10-ms steps This parameter can be used for setting a delay between “event signalised” (from contact) and “event happened” (UPS reacting to the input). This can be done in 10-ms steps.

0 - 60 [0,01 s]

90

CU2

Indices: i01: Input contact X8.1,2 fast off EPO 0,2 i02: Input contact AP10-XT6.1,2 0,2

i03: Input contact AP10-XT6.3,4 0,2 i04: Input contact AP10-XT6.5,6 0,2

Access level 4: URL, IBS, BYP, BTR i05: Input contact AP10-XT6.7,8 0

Parameter Number



Factorysetting

Off delay Input Contacts Switch-off delay for contact input in 10-ms steps. This parameter can be used for setting a delay between “event stopped signalised” (from contact) and “event stopped” (UPS reacting to the input). This can be done in 10-ms steps.

0 - 60 [0,01 s]

91

CU2

Indices: i01: Input contact X8.1,2 fast off EPO 0,2 i02: Input contact AP10-XT6.1,2 0,2

i03: Input contact AP10-XT6.3,4 0,2 i04: Input contact AP10-XT6.5,6 0,2

Access level 4: URL, IBS, BYP, BTR i05: Input contact AP10-XT6.7,8 0,2



Parameter



Factorysetting

Mains Failure Warning Delay 110

CU2

Access level 2: URL, IBS,PRU, BYP, BTR

PNU 81 (Function of output contacts) value 19 (Line Failure) This parameter is setting the duration between a mains failure and a subsequent warning signal. When the set time is over and the warning signal is issued, the contact X7.4,9,5 is caused to operate (meaning Pin 5 and 9 are than closed).

0 – 600 [s]

30

Parameter Number



Factorysetting

Battery Pre-warning Voltage Level 113

CU2 Access level 2: URL, IBS,PRU, BYP, BTR

PNU 81 (Function of output contacts) value 24 (U Batt/C) If the battery charging voltage is falling under this set voltage a warning is issued.

0 – 2,5 [0,01 V]

2,27

Parameter Number



Factorysetting

Battery stored-energy time 117

CU2 Access level 2: URL, IBS,PRU, BYP, BTR

If the remaining battery time falls below this limit an warning signal is issued. Concerning the output contacts, the relay is caused to operate, when the warning is issued respectively when the set time is under-run.

10 – 600 [s]

180

Parameter Number



Factorysetting

Battery Temperature Limits

PNU 81 (Function of output contacts) value 22 (Batt. Temperature) Min. and max. battery temperature. When one of this limits is reached, warning 19 will be issued.

0 – 100 [°C]

1557 (533) CU1

Indices:

i01: Minimal battery temperature 0 Access level 3: URL, IBS i02: Maximal battery temperature 30

2.4.15 Signal cables A detailed description (incl. drawings) of how the cables are routed through the UPS can be found in the user manual in the according chapter. Notice: The interface cables must be shielded and located away from the power cables (min. 20 cm). The shield must be connected at both ends. Control and power cables must cross at a 90° angle.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 130/ 307Chapter: 2 Functional Description 2.5 Battery printed: 15.05.2007, 13:09

2.5 Battery The battery is a critical part of the UPS system. The 80-NET is delivered with a disabled battery calculation, due to the fact, that there are no “standard” battery data to fit every battery. Each battery has its own characteristics. Only if the unit is delivered with a battery, the battery calculation is enabled (value of PNU1433=1) from factory. It is necessary to set respectively to check the specific battery date while commissioning the UPS.

What’s important?

The data sheet of the battery manufacturer is crucial for the settings of the battery values. Meaning you need the data sheet of the specific battery, which is operated with the specific

80-NET. A proper setting of the parameters is important, because if not done correctly, the batteries could become damaged. Settings are done with PPVIS. If you need any help with the battery data sheet or for the calculation of the parameters, please feel free to ask your Chloride Service Center. During battery mode the fans are running on high speed.

Parameter Number



Factorysetting

Manual/Automatic Charging 1436 (412) CU1 Indicates if the charge voltage and the charge current limitation can

be entered manually or if they are automatically calculated by the system (using the charging algorithms). In case of manual charging you have to refer to P1424 (V), P1554 (I) and P1629 (cell number) to determine both manual charge voltage and manual charge current limitation. In case of automatic charging you have to refer to P1617, P1578, P1547, P1555, P1622, P1624, P1618, P1619, P1620, P1161, P1540, P1554 and P1629 to determine both automatic charge voltage and automatic current limitation.

0 – 1 1

0: Manual charging Access

Level 3: URL, IBS 1: Automatic charging



2.5.1 Battery Calculation For the battery calculation it is necessary to tell the UPS certain data about the battery. In addition it is also essential to activated the battery calculation with parameter “Battery Calculation Active” (PNU409) . This parameter is only enabled, if a battery is delivered with the UPS and if it was “Customer Witness” tested by Chloride. Nevertheless the battery data need to be checked by the service technician. In general, this calculation should already have been done by the planner of the complete UPS system, because at that point the battery was dimensioned. With dimensioning the battery the parameters are defined. Another reason for doing it in that state is, depending on the philosophy of the customer/planner, the chosen values can vary depending on that philosophy. Chloride declines all responsibility for the correctness of the battery parameters developed through the following procedure. This is due to the not existing knowledge of the battery treatment philosophy of the planner and therefore the chosen parameters. The procedure itself is based on the experience of our own technicians.

What’s important?

Please keep in mind, if the battery calculation is disabled during mains failure, there will be NO displaying of the remaining autonomy time and the message “Battery low” appears.

The UPS needs the following information/parameter to do a calculation of the remaining autonomy time: Parameter Description PNU 1534 Power Discharge Table values in W/cell

Power values of battery discharge characteristic from battery manufacturer;

PNU 1535 PNU 511

Time Discharge Table values in min. Time values of battery discharge characteristic from battery manufacturer;

PNU 513 Shutdown Voltage Table values in 0,01V These values are used for interpolation of discharge time depending on the deep discharge voltage;

PNU 1433 Battery Calculation Active PNU 1536 Battery Calibration Values

These values can be considered for battery back-up time calculation; To detect the 5 values for each of the parameters PNU1534, PNU511/1535 and PNU513, it is necessary to have the battery data sheet and some specific information about the UPS. (The battery data sheet is either delivered with the battery system by the battery manufacturer or check the website of the battery manufacturer for the data sheet.)



Defining the parameters: 1. Calculate the “Total DC-Power Full Load” by using the following table for

“Full load” and “No load” losses: Power [kVA] Full load losses [kW] No load losses [kW]

60 3,2 1,6 80 3,6 1,6

100 7,0* 2,1* 120 8,4* 2,7* 160 10,0* 4,0* 200 12,6* 4,0*

*) this are 90-NET values; these are above the 80-NET values – which are not yet available

“Active Power Rating Output” [kW] + “Full load losses” [kW] = “Total DC-Power Full Load” [kW]

With

“Active Power Rating Output” [kW] = “Nominal Inv. Output Power” [kVA] * “Power Factor (cos phi)”

E.g. 200kVA UPS; Power Factor (cos phi) = 0,8; Active Power Rating Output = 200kVA * 0,8 = 160kW Total DC-Power Full Load = 160kW + 12,6kW = 172,6kW

2. Provide the following data: - No. of strings? _____ e.g. 2 - No. of blocks per string? _____ e.g. 40 - Total no. of blocks? _____ (=“No.of strings” * “No.of blocks/string”) e.g. 80 - No. of cells/block? _____ e.g. 6

3. To calculate the necessary W/cells respectively W/block for each of the following loads in the table, use the formulas:

“Total DC Power Full load [W]” W/Cells = “Total no. of blocks” * “No. of cells/block” * load%

“Total DC Power Full load [W]” W/Block = “Total no. of blocks” * load%

Load [%] W/Cells [W] W/Block [W] W/Block [W]

100 e.g. 2157,50 75 e.g. 1618,13 50 e.g. 1078,75 25 e.g. 539,38 5 e.g. 107,88

E.g. for “Total no. of blocks” = 80 blocks and “No. of cells/block” = 6 W/Block (100%) = ( 172600 W / 80 ) * 100% = 2157,50 W/block W/Block (75%) = ( 172600 W / 80 ) * 0,75 = 1618,13 W/block W/Block (50%) = ( 172600 W / 80 ) * 0,50 = 1078,75 W/block W/Block (25%) = ( 172600 W / 80 ) * 0,25 = 539,38 W/block W/Block (5%) = ( 172600 W / 80 ) * 0,05 = 107,88 W/block



4. Take the data sheet of the battery and look for the “Constant Power Discharge” table; (should be in W/block at 25°C) The calculated values for W/block from the previous point, must now be aligned with the values in that table.

5.

Figure 2-82: Battery Calculation – Constant Power Discharge Table of Battery Manufacturer

Data Sheet

How to find the values for the parameters? The target for finding parameter values is to align the “Constant Power Discharge” table values as close as possible to the calculated values for W/block. To do so, the combination of V/cell (VpC), discharge time and W/Block is crucial. The “problem” will be finding exact values. Which V/cell line should be taken, is based on the discharge time of the according W/block value. As a guideline, the following table can be used:

Time V/cell < 1 hour 1,65

>1 hour and < 3 hours 1,70 > 3 hours 1,75

What’s important?

For choosing the value “V/cell” it is important to know, what is the treatment philosophy of the planner/customer for the battery. The more values “V/cell” are aligned with 1,65V, the longer the backup time BUT the battery life duration will be shorter (due to deep discharge). (Or the other way around: the higher V/cell, the shorter the backup time BUT the battery life duration will be longer.)

This first value (100% load) must be chosen in that way, that the related time value is not smaller than 5 minutes. The value for 5% load (last value) must be chosen in that way, that the related time is not larger than 600 minutes. This is due to the fact, that the UPS firmware is designed to act within these values. Other values can not be handled by the UPS correctly.

The calculated value for 100% in the example is 2157 W/block. It is unlikely to find an exact value, therefore the next larger value can be taken … in this case 2255 W/block. Why? With a look to the table, it can be seen, that there are some values for



W/block higher than 2510. The appropriate discharge time values are all under 1 hour, therefore the V/cell must be 1,65. Keeping in mind that the time must be higher than 5 min, V/cell = 1,65 and W/block must be higher than 2510, there is only one value to chose: 2756 W/block. Note the values from the data sheet (like the following table).

Data Sheet values Load [%]

W/Block [W] (calculated)

W/Block [W]

Discharge Time [min.]

V min. [V/cell]

100 e.g. 2157,50 e.g. 2255 e.g. 5 e.g. 1,65 75 e.g. 1618,13 e.g. 1573 e.g. 10 e.g. 1,65 50 e.g. 1078,75 e.g. 972 e.g. 20 e.g. 1,65 25 e.g. 539,38 e.g. 513 e.g. 45 e.g. 1,65 5 e.g. 107,88 e.g. 108 e.g. 300 e.g. 1,80

To find the values for the other load values, deal with them in the same way like 100% load.

6. The values taken from the data sheet need to be “transformed” to the parameter values. The values for “Discharge Time” and “V min.” remain unchanged and become PNU 511 and PNU 513. The values for “W/Block” must be “transformed” to become PNU 510.

“W/block” [W] Power/Block = “No. of cells/block” * “No. of strings”

e.g. Power/Block = 2157/ 6 *2 = 360 PNU 510.5 = 360

PNU 1534 PNU 511/1535 PNU 513 Index Power/Block

[W/cell] Discharge Time [min.]

V min. [V/cell]

5 e.g. 360 e.g. 5 e.g. 1,65 4 e.g. 270 e.g. 10 e.g. 1,65 3 e.g. 180 e.g. 20 e.g. 1,65 2 e.g. 90 e.g. 45 e.g. 1,65 1 e.g. 18 e.g. 300 e.g. 1,80

Values for PNU 1536 can be taken from the already calculated “Total DC Power Full load” and from the “Discharge Time” at 100% load.

PNU 1536.1 = “Total DC Power Full load” KW PNU 1536.2 = “Discharge Time” at 100% load Min. PNU 626.2 Batt. Current Limit ≈ 10% of “Capacity in Ah” A

There is a Excel-Sheet to help calculating the battery parameter values. Which is also displaying the discharge curve as a diagram. Please ask your Chloride Service Center for it.



What’s important?

In the upper kVA-range of the 80-NET, it is pretty likely that the battery consists of more than one string. This is mainly the case to reduce the needed W/Block for the battery.

Parameter Number



Factorysetting

Battery Calculation active The battery calculation is calculating the remaining time and the available battery capacity. Default is 1, but is set to 0 in production if the unit is delivered without battery.

0 - 1 1 1433 (409)

CU1

Values: 0: Calculation is disabled Access

Level 3: URL, IBS 1: Calculation is enabled

Parameter



Factorysetting

Cell Number 1629 (605)

CU1

Amount of battery cells. 108-500 240


Parameter



Factorysetting

Power discharge characteristic This parameter defines the power values in W/Cell from the battery discharge characteristic. The values are given by the battery manufacturer.

0 – 65535 1534 (510)

CU1

Indices: i01: Power discharge point 1 (lowest power) 7 i02: Power discharge point 2 45 i03: Power discharge point 3 80 i04: Power discharge point 4 219 Access

Level 3: URL, IBS i05: Power discharge point 5 282

Parameter



Factorysetting

Time discharge characteristic This parameter contains the time values in min from the battery discharge characteristic. The values are given by the battery manufacturer.

0 – 65535 [min]

511/1535

Indices: i01: Time discharge point 1 (highest time) 600 i02: Time discharge point 2 60

i03: Time discharge point 3 30 i04: Time discharge point 4 10 Access

Level 3: URL, IBS i05: Time discharge point 5 5



Parameter Number



Factorysetting

Shutdown Voltage Table Together with PNU 511 “Time Discharge Characteristic”, this values describing a interpolation of the discharge time dependent deep discharge voltage.

0 – 2,9 [0,01V]

513

i01: Shutdown Voltage Discharge Point 1 (largest time) 1,8 i02: Shutdown Voltage Discharge Point 2 1,7 i03: Shutdown Voltage Discharge Point 3 1,67 i04: Shutdown Voltage Discharge Point 4 1,65 Access

Level 3: URL, IBS i05: Shutdown Voltage Discharge Point 5 1,65

Parameter



Factorysetting

Battery calibration values This parameter defines the battery back-up time at the indicated power, when the battery capacity is 100%. With version V2.2 and above, index 1 is preloaded depending on number of cell (PNU 1629) and discharge characteristic power per battery cell (PNU 1534.2), index 2 is set corresponding the associated discharge time value (PNU 1535.2). (CU2 PNU511 = CU1 PNU1535; they need to be set with same values;)

0 – 65535 1536 (512)

CU1

Indices: i01: Battery discharge power in 0,1KW 64 Access

Level 3: URL, IBS i02: Battery rest time in min. 60

2.5.1.1 Automatic recalibration of Discharging Characteristic During the life-cycle of the battery, the discharging characteristic is changing.

Figure 2-83: Battery re-calibration of discharging characteristics

Each time the following conditions are fulfilled, the 80-NET is recalculating the battery calculation values by itself:

• The battery capacity is > 95% • The load remains > 40% during the battery discharging and must stay within a

5% window • The “Minimal battery voltage” (PNU 1426.2 [402.2]) is reached

This can also be done manually by the trained service technician during e.g. maintenance. The battery test needs to be done until the end of the discharging of the battery to measure the time.



2.5.2 Battery Charging/Discharging Batteries are the energy source of the UPS during mains failure, therefore energy is taken from the batteries and, of course, energy needs to be put into the batteries again for the next mains failure. To charge batteries, 80-NET is giving a choice of four different methods. These methods including the involved parameters are described in the next chapter.

What’s important?

The recharge method depends on the battery type and battery manufacturer recommendation.

A proper setting of the parameters for charging is important, because if not done correctly, the batteries could become damaged. Settings are done with PPVIS.

There are two different possible thresholds to stop discharging at the end of battery energy:

- Voltage - Time

The UPS needs to know about the discharging characteristics of the battery. The following two parameters describe the “End-of-Discharge” curve for the battery. This curve represents the voltage-depending end of discharge for the battery. In combination with PNU 590 “Message Configuration” and PNU 591 “Delta Shutdown Imminent” a pre-warning delta can be defined. According warning messages (Warning 10 and 11) are issued. (More details under chapter “6.2 Warnings and Faults”)

Parameter Number



Factorysetting

Power discharge characteristic This parameter defines the power values in W/Cell from the battery discharge characteristic. The values are given by the battery manufacturer.

0 – 65535 1534 (510) CU1

Indices: i01: Power discharge point 1 (lowest power) 7 i02: Power discharge point 2 45 i03: Power discharge point 3 80 i04: Power discharge point 4 219 Access

Level 3: URL, IBS i05: Power discharge point 5 282

Parameter



Factorysetting

Time discharge characteristic This parameter contains the time values in [min] from the battery discharge characteristic. The values are given by the battery manufacturer.

0 – 65535 [min]

1535 (511) CU1






What’s important?

This value is also present on the CU2 board (PNU 511). Meaning that if the values of PNU 1535 will be changed also the values of PNU 511 MUST be changed manually.

Figure 2-84: Battery discharging characteristics

The time-depending end of discharge can also be selected with PNU 590 “Message Configuration”. If this possibility is chosen, discharging is stopped when “Battery hold-up time” PNU22 < PNU 117 “Battery stored energy time”. (More details under chapter “6.2 Warnings and Faults”)



2.5.2.1 Battery Charging Method As described in chapter “2.3.2 Booster/Charger (DC/DC IGBT Converter)” there are different methods to charge a battery with the 80-NET. Selection is done with PNU1617. There are also other parameters to define the charging method in more detail.

Parameter Number



Factorysetting

Charging Method Defines the used charging algorithm. 0 – 3 1

1617 (593) CU1 0: 1-stage charging with charging pause

1: 1-stage charging without charging pause 2: 2-stage charging with charging pause Access

Level 3: URL, IBS 3: 2-stage charging without charging pause

Charge Principle (0) – 1-stage with pause: After mains failure “Charging” mode is entered. If the “Charge Current” is almost not present any more, the “Post-Charging” phase is entered for a defined period (PNU 1578). Afterwards the “Pause” is entered, again for a defined period (PNU 1547). The battery is charged with “Float Charge” voltage (PNU1555).


Charge Principle (1) – 1-stage without pause: Charging is done at constant current (PNU 1554) up to the maximum “Float charge” voltage level (PNU 1555). Thereafter the voltage is kept at this constant level within narrow limits. Used for sealed, maintenance-free lead acid accumulators:




Charge Principle (2) – 2-stage with pause: If battery charging current is higher than “Current V2 V1” (PNU1625), the batteries will be charged with “Boost Charge” (PNU1622). The DC level will change to “Float Voltage” (PNU1555) when battery current falls below “Current V2 V1” (PNU1625) OR if the defined “Max. stage 2 time” (PNU1626) is expired. A post-charging phase is established, for a time period defined in “Battery recharge time” (PNU1578). After this period the UPS is going into charging pause for another defined period (PNU 1547). Used for sealed, low-maintenance lead acid accumulators or NiCd accumulators:


Charge Principle (3) – 2-stage without pause: If a mains failure occurs, the battery is recharged afterwards with “boost charge” voltage (PNU1622), as long as the battery current is higher than “Current V2 V1” (PNU1625) OR until the defined “Max. stage 2 time” (PNU1626) is expired. After one of the previous mentioned terms is fulfilled, the DC level will change to “Float Voltage” (PNU1555) for further charging of the battery. Before actually entering “Charge Stage 2” after mains failure, a test will be performed. The “Charge Current” must stay constant on “Max. charge current” level (PNU 1554) for a defined period (PNU 1624). If this is not the case, “Charge Stage 1” is entered right away.


The “Float Charge” voltage will be set with PNU1555 and the “Boost Charge” voltage with PNU1622.



Parameter Number



Factorysetting

Charging pause duration 1547 (523) CU1 Defines the amount of hours after which “Charge Battery” has to

be initiated; requires also that “Charge Battery” is enabled. 36 – 504

[h] 120


Parameter



Factorysetting

Max. Charge Current 1554 (530) CU1 Defines the maximal allowed charging current (Charging Current

Limit). 0 – 78 [0,1A]

6,5


Parameter



Factorysetting

Battery Recharge Time 1578 (554) CU1 Time, which specifies how long the battery is recharged after end

of charge for U phase was detected. 0 – 100

[h] 40


Parameter



Factorysetting

End-of-Charging Voltage 1 1555 (531) CU1 End-of-charging voltage per cell for one level charging or float

charge voltage (lower level) for two level charging. 0,5 – 2,9 [0,01V]

2,27

Access Level 3: URL, IBS,PRU, BYP, BTR

Parameter



Factorysetting

End-of-Charge Voltage 2 1622 (598) CU1 End-of-charge voltage per cell (higher level) for two level

charging. 0,5 – 2,9 [0,01V]

2,35


Parameter



Factorysetting

Battery Current Limit On-time 1624 (600) CU1 Time for which the battery current limitation must be active in order

to switch to the boost charge level. Only active for 2 step charging without charge pause.

1 – 600 [s]

60




Parameter Number



Factorysetting

Current V2 V1 1625 (601) CU1 Current under which the system switch from charge stage 2 to

charge stage 1, if the PNU1626 time was not reached. 1 – 800 [0,1 A]

1


Parameter Number



Factorysetting

Max. stage 2 time 1626 (602) CU1 Maximal charging time in stage 2. 1 – 100

[h] 10


Parameter Number



Factorysetting

Battery Cell Number Amount of battery cells (total). 108-500 240

1629 (605) CU1




2.5.2.2 Initial Charging The initial charging could be done, when a new battery is commissioned and the batteries need to be recharged after a longer storage. The “Initial Charging” needs to be activated by setting PNU 1618 “Initial Charge On” to “1”. While the “Initial Charging” is done, the batteries are charged with “Initial End-of-Charge Voltage” (PNU1620) for the “Initial Charge Duration” (PNU 1619). After the initial charging is done, the PNU1618 will reset itself to “no”, meaning that the initial charging is just done one time.

Figure 2-89: Initial Charging

What’s important?

Please be aware, that some battery manufacturer do NOT recommend a initial charging of their batteries. In any case, check the data sheet of the chosen battery type.

Parameter



Factorysetting

Initial Charge On 1618 (594) CU1 If a initial battery charging is wanted, this PNU needs to be set to

“YES” (1). For the initial charge, the battery is charged with the initial end-of-charge voltage (PNU1620) during the reselected time (PNU1619). After this period, this parameter will automatically be return to “no”.

0 – 1 0

0: no Access Level 3: URL, IBS 1: Yes (initial charge)

Parameter



Factorysetting

Initial Charge Duration 1619 (595) CU1 0 – 65535

[h] 12


Time during which the battery is charged with the initial end-of-charging voltage. During initial charging, the initial charging time is counted downwards.

Parameter Number



Factorysetting

Initial End-of-Charge Voltage 1620 (596) CU1 End-of-charge voltage per cell for initial charging. 0,5 – 2,9

[0,01V] 2,3




2.5.2.3 Battery Temperature Compensation The battery charger voltage is operated within narrow parameters. In order to ensure optimum battery charging, regulation is automatically adjusted to the ambient temperature.

Parameter Number



Factorysetting

Temperature Factor (Batt. Charging) 1540 (516) CU1 Increase of end-of-charge characteristic as a function of

temperature (mV/K). 0 – 0,01 [0,001V]

0,003


Parameter Number



Factorysetting

Battery Temperature Channel active Enabling or disabling the battery temperature channel. When disabled, the displayed temperature will always be 20°C!

0-1 1 1161 (137) CU1

value 0: Disabled Access

Level 3: URL, IBS 1: Enabled

The charging voltage is temperature-depending. The correction is based on the temperature factor, defined with PNU1540 (516), and proportional to a deviation from the default temperature (20°C).

Figure 2-90: Temperature-dependent charging voltage correction



2.5.3 Automatic Battery Test The automatic battery test is carried out by the CU1 board (enabled/disabled with PNU 1438.1) is carried out by the CU-Board at selectable intervals, e.g. weekly, fortnightly or monthly. A short-time discharge (selectable with PNU1438.2) of the battery will be made to confirm that all the battery blocks and connecting elements are in good working order. In order to prevent a faulty diagnosis the test will be launched 24 hours (factory setting PNU 1438.4) after the latest battery discharge at the earliest. The battery test is performed without any risk to the load, even if the battery is completely defective. Customer will be alerted about a detected battery. The battery test will not cause any degradation in terms of the battery system life expectancy. The test is done by decreasing the rectifier DC reference, as far as one of the following events occurs:

• Minimal battery voltage (PNU 1426)=< PNU513 – PNU511 curve, plus a fix threshold to avoid the inverter to stop before the rectifier starts

• A booster/charger warning or fault appears • A manual command to stop the autonomy test is given • Test Duration is expired (PNU 1438.2)

In online operation during battery test, energy is drawn from the battery. This takes place automatically every defined test interval (PNU 1438.3) following the last battery test or after switching the UPS on. The test lasts a defined duration (PNU 1438.2). However, the battery test will not be performed within the defined period “test inhibit time” (PNU 1438.4) and while:

- rectifier mains failure - mains switch QS1 open - battery discharge - bridge monitoring failure

This prevents the test being carried out on discharged batteries. The settings for that test is done with this parameter:

Parameter Number



Factorysetting

Automatic Battery Test Automatic battery test function settings. 0 – 65535

1438 (414) CU1 i01: Automatic Battery Test Enable 1

i02: Battery Test duration (s) 30 i03: Battery Test Interval Time (h) 330

Access Level 3: URL, IBS, PRU, BYP,BTR i04: Battery Test Inhibit Time (h) 24



Parameter Number



Factorysetting

Minimal Battery Voltage 1426 (402) CU1 Battery voltage in V/Cell that will

- Produce the warning 11 “Battery Undervoltage” - Determines the end of the autonomy test

0-10 [0,01V]

Indices: i01: Battery Undervoltage limit 1,6 Access

Level 3: URL, IBS i02: End of autonomy test battery voltage 1,7

If Fault 183 appears, then the battery voltage has fallen under the value of PNU1426.i02 during the Battery test.



2.5.4 Imminent Shutdown Curve There are different possible threshold to issue a Warning concerning upcoming respectively reached end of battery energy:

- Voltage - Time

Voltage dependent Warnings: The “End of Discharge” curve is representing the deep discharge curve of the battery, meaning no more energy for supporting the load can be taken from the battery without damaging them.

Therefore the Inverter will be turned OFF, when cell voltage is below that curve. (Load will be transferred to bypass, IF this is POSSIBLE. Meaning if there is a second mains within tolerance.)

Warning 11 Index 1 To activate a “Delta” before the “End of Discharge” message, PNU 590 needs to be set to “2” “Message battery voltage below shutdown imminent threshold”. With PNU 591 “Delta Shutdown Imminent”, the value of the “Delta” is defined.

The “Imminent Shutdown” curve is described with PNU 511 and PNU 513+591; If the battery voltage is below the “Imminent Shutdown” curve, Warning 10 Index 2 will be displayed.

Time dependent Warning: With PNU 590 “Message Configuration” = “1”, the time dependent warning is set (“Message battery backup time below”).

If the “Battery hold-up time” PNU 22 < PNU 117 “Battery stored energy time”, Warning 10 Index 1 will be displayed.

Figure 2-91: Imminent Shutdown Curve ↔ End of Discharge Curve



Parameter



Factorysetting

Time discharge characteristic This parameter contains time values in [min] from the battery discharge characteristic. The values are given by the battery manufacturer.

0 – 65535 [min]

511

CU2




What’s important?

This value is also present on the CU1 board (PNU 1535). Meaning that if the values of PNU 511 will be changed also the values of PNU 1535 MUST be changed manually.

Parameter



Factorysetting

Shutdown Voltage Table Together with PNU 511 “Time Discharge Characteristic”, this values describing a interpolation of the discharge time dependent deep discharge voltage.

0 – 2,9 [0,01V]

513

CU2

i01: Shutdown Voltage Discharge Point 1 (largest time) 1,8 i02: Shutdown Voltage Discharge Point 2 1,7 i03: Shutdown Voltage Discharge Point 3 1,67 i04: Shutdown Voltage Discharge Point 4 1,65 Access

Level 3: URL, IBS i05: Shutdown Voltage Discharge Point 5 1,65

Parameter



Factorysetting

Message Configuration Automatic battery test function settings. 0 – 3

590

CU2 1: No message for battery imminent message enabled 2: Message battery backup time below 3: Message battery voltage below shutdown imminent

threshold

Access Level 1: URL, IBS, BYP,BTR

4: Message battery backup time below OR shutdown imminent threshold

Parameter



Factorysetting

Delta Shutdown Imminent 591

CU2 Difference between deep discharge voltage and shutdown imminent voltage curve for defining the “pre”-warning (W10i2).

0 – 2 [0,01 V]

0,05

Access Level 3: URL, IBS, PRU, BYP,BTR


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 149/ 307Chapter: 2 Functional Description 2.6 Service Software PPVIS printed: 15.05.2007, 13:09

2.6 Service Software PPVIS A detailed description about the Service Software PPVIS can be found in one of the additional documents. The document is called “Technical Manual 80-NET PPVIS & PPGraph” and the document number is “10H52167TM01_PP”. PPVIS is a program for costumer and service purposes to show the UPS's state and to change configuration data. PPVIS communicates with the UPS by serial RS232 communication (interface X3), using the USS protocol. (Cable length should not extend 15 meters.) Together with a converter (RS485 to RS232) also an RS485 can be used, which has the advantage, that several units could be address with different slave addresses. (Cable length up to 1200 meters.) The functionality of the program embodies: • Visual UPS control panel • Status display • Battery Display • Oscilloscope for diagnostic purposes • Event memory • Parameter reading and writing • Data storage functions for visualisation with PPGraph • Life.net

What’s important?

To operate PPVIS with 80-NET one of the following versions or higher is necessary!!!

• 1.8.087 (Chloride version)

• 1.8.113 (Masterguard version)

CUdSMC, CUX Firmware on CUxx

Power circuits

RS232/RS485

display control - Actual value Acquisition (analog) - Analog outputs - CUdSMC, CUX - Digital input/output (e.g. IGBT firing)

PPVIS

Panel

Only used: for parallel operation


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 150/ 307Chapter: 2 Functional Description 2.7 Firmware printed: 15.05.2007, 13:09

2.7 Firmware The UPS has three different control units that require a specific software:

• “Rectifier CU-Board (CU1)”. This board controls the input stage of the UPS (pre-charge circuit, battery converter);

• “Inverter CU-Board (CU2). This board controls the output stage of the UPS (output inverter, automatic bypass switch);

• “Display board (LCDisplay)”. This board mainly collect data from the two CU-Board and shows all the information for the user through an LCDisplay and some function of the UPS can be controlled through a key pad.

All the three boards must be flashed before use of UPS. This is either already done (by factory) or must be done or redone by service personal in case of update or failure of UPS. If a LIFE station is present, please proceed in the following order to flash the CU boards:

1. Disconnect the telephone line or GSM modem connection 2. Flash the new firmware 3. Set, if lost, the parameter included power class PNU69 and LIFE 4. Connect the telephone line or GSM modem

In this way it is prevented that the parameter communication is not consistent, which could produce problem on LIFE station.

What’s important?

If a fault is present it is not possible to initialise the UPS.



2.7.1 CU1 Rectifier This firmware is responsible for rectifier and battery including all the related topic, e.g. battery calculation, calculation of back up time or input current limitation … The firmware number is: 10H01359 The firmware code and version can be found in PPVIS on the set “[19][CU1] Equipment Information”: PNU 1744.1 “SW Version (board slot 1 - CU)” Version e.g. 1.8 PNU 1745.1 “Software issue date (Year)” generating year e.g. 2005 PNU 1745.2 “Software issue date (Month)” generating month e.g. 10 PNU 1745.3 “Software issue date (Day)” generating day e.g. 25 PNU 1748.0 “CU1 Firmware Code” 10H01359

2.7.2 CU2 Inverter This firmware is responsible for the control of the inverter, booster/charger, bypass detection and overload measuring. The firmware number is: 10H01360 The firmware code and version can be found in PPVIS on the set “[1][CU2] Equipment Information”: PNU 720.1 “SW Version (board slot 1 - CU)” Version e.g. 1.8 PNU 721.1 “Software issue date (Year)” generating year e.g. 2005 PNU 721.2 “Software issue date (Month)” generating month e.g. 10 PNU 721.3 “Software issue date (Day)” generating day e.g. 28 PNU 724.0 “CU1 Firmware Code” 10H01360



2.7.3 LCDisplay (incl. menu) The figure below shows the structure of the LCD menu.

Actual valuesmenu

LIFEmenu

Display settingsmenu

UPS Settingswindows

UPS Settingschoose new value

UPS Settingsresult

Languagesettings

Contrastsettings

Warning/Fault Diagnostics

Main menuUPS Settings

menu

Manual commandsmenu

Statusmenu

Statuswindow for all

the stages

System block diagram(synoptic)

Warning Info/Fault InfoDiagnostics

Reset delayedcall

Manual callrequest

Set/ResetService mode

Manual commands

windows

Actual valueswindows

About...menu

1

2

3

4

5

6

7

8

9

10

11

12

13

14 15 16

17

18

19

20

21

22

Figure 2-92: LCD page structure

With the “About… menu” page it is possible to get the following system information: • UPS name (“80-NET” or “Series D”) • UPS rating (in kVA) [CU2-PNU 75.42] • Manufacturer [PNU 952] • LCD Firmware code, release and date • CU1 Firmware code, release and date [CU1-PNU 1748, 1744.1 and 1745.1-1745.3] • CU2 Firmware code, release and date [CU2-PNU 724, 720.1 and 721.1-721.3] • CU1 DSP Firmware code and date [CU1-PNU 1749.1 and 1749.2] • CU2 DSP Firmware code and date [CU2-PNU 725.1 and 725.2]



What’s important?

Freeze LCD function This function was established to speed up the serial communication between an external application, like PPVIS, and the CU2 (Inverter) through the LCD. To enable this function, simultaneously press the UP and DOWN key on the front panel for at least 2 seconds (only possible in the main synoptic window). While the function is active, the message “LCD frozen” will be displayed. When the function is activated, no diagnostics will be present on the LDC because communication with the CU has temporarily been suspended. If no request is sent through the service serial port (X3) towards the LCD, the function disables after 10 minutes. This function also can be disabled by simultaneously pressing the UP and DOWN keys again.

The following values are measured: Mains input V mains L1 (V) [PNU 1030] Mains failure no. [PNU 1584.1] V mains L2 (V) [PNU 1031] Mains fail time: d (days) [PNU 1585.1] V mains L3 (V) [PNU 1032] Mains fail time: h (hours) [PNU 1585.2] Frequency mains (Hz) [PNU 1042] Mains fail time: m (minutes) [PNU 1585.3] T inlet air (°C) [PNU 26.2] Mains fail time: s (seconds) [PNU 1585.4] Bypass input V bypass L1 (V) [PNU 6] Frequency bypass (Hz) [PNU 18] V bypass L2 (V) [PNU 7] V bypass L3 (V) [PNU 8] DC-Link Vdc (V) [PNU 1036] Vdc + (V) [PNU 1062.2] DC current (A) [PNU 31.12] Vdc – (V) [PNU 1062.1] UPS output V output L1 (V) [PNU 9] Out app power (kVA) [PNU 20.4] V output L2 (V) [PNU 10] Out app power L1 (kVA) [PNU 20.1] V output L3 (V) [PNU 11] Out app power L2 (kVA) [PNU 20.2] Frequency output (Hz) [PNU 17] Out app power L3 (kVA) [PNU 20.3] I output L1 (A) [PNU 14] Out real power (kW) [PNU 19.4] I output L2 (A) [PNU 15] Out real power L1 (kW) [PNU 19.1] I output L3 (A) [PNU 16] Out real power L2 (kW) [PNU 19.2] Time on inv.: d (days) [PNU 13.1] Out real power L3 (kW) [PNU 19.3] Time on inv.: h (hours) [PNU 13.2] Overload threshold (%) [PNU 565] Time on inv.: s (seconds) [PNU 13.3] Load (%) [PNU 566] Battery V Batt. Per cell (V/Cell) [PNU 24] Actual capacity (%) [PNU 1045] T Batt. (°C) [PNU 31.8] Hold up time (s) [PNU 1046] Batt. Current (A) [PNU 23]



Information available for each stage: Synchronisation stage (if external synchronisation is enabled) Synchron. Active Synchron. Inact. Rectifier stage Rectifier off Rect. hold off Rect. Precharge Rect. Walk in Rect. Current limit Rectifier on Battery stage Battery connected Batt. disconnected Inverter stage Inv. Running Inv. Turning on Inv. Turning off Inv. Not Running Bypass stage Bypass valid Bypass not valid Load stage Load on Bypass Load on Inverter Load on Man. Bypass Load on Sys. Bypass Load not supplied


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2.7.4 Flashing of a CU-Board It is necessary to put firmware on a CU-Board, otherwise the CU-Board does not know how to react in different situations. Therefore the CU-Board need’s to be flashed. With the process of flashing it is getting the “instructions”.

What’s important?

In a brand new UPS the CU-Board is already flashed from factory. Only in case of CU-Board replacement or Firmware updates, it is necessary to flash the CU-Board.

2.7.4.1 Software and Hardware Requirements Software required: C16Xflasher code 10H01301 rev 1.01 or higher. PC requirements: at least Pentium. Win 2000 and XP. Hardware: Serial cable to upload the firmware from PC to CU-Board

(PPVIS cable item code 6SU5932-0BA08) via the LCDisplay OR a cable for direct contact with the CU-Board (item code 10H55351P01)

2.7.4.2 How to flash a CU2-Board (Inverter)? Download respectively prepare all the necessary flashing-software and firmware-files before starting the flashing procedure. 1. Secure the Settings/Parameter of the UPS

Save important parameters for the UPS operation as well as customer settings. Close PPVIS after saving the needed parameters.

2. Switch off the UPS Switch off the UPS respectively safely transfer the load to maintenance bypass. Wait till the UPS inside is voltage free.

3. Connect cable There are three possibilities to connect the cable for flashing:

a) connect your PPVIS serial cable to the LCDisplay as shown below



b) use the X3 interface on the connectivity box to connect the PPVIS cable; in this case make sure that there is no connectivity (e.g. SNMP adapter) in the slot XS3 (just remove it, it is not necessary to change any parameters/settings)

c) connect the “direct connection cable” with X120 on the CU-Board directly 4. Remove/change jumpers

If you are connected via the LCDisplay with the CU-Board (cable connection 2.a) or via the X3 interface on the connectivity box (cable connection 2.b) than the jumpers CN11 on the LCDisplay board have to be changed from 1-3 and 2-4 to 6-4 and 5-3. This is necessary to speed up the communication between LCDisplay and CU-Board.

Jumper Settings for CN11 6 5 4 3

Standard operation

2 1

6 5 4 3

Flashing operation

2 1 In case you are connected directly with the X120 of the CU-Board (cable connection 2.c) the jumpers on the LCDisplay board do not have to be changed. The CU-Board is also equipped with jumpers X160, next to the interface X120. According to the jumper settings, the board is either in

- Standard Operation (normal running firmware), - Flashing Operation (upload of the firmware into the flash memory), - or Reset Operation (microprocessor reset)

In standard operation the two jumpers are set to 7-8 and 9-10; to set the flash mode, the two jumpers have to be set to 3-4 (responsible for starting the flashing operation after switching on the power supply) and 5-6 (responsible for a modified chip selection).

Figure 2-93: Flash Mode Setting – Jumper

Jumper Settings on CU-Board 10-9 8-7 6-5 4-3 2-1 Standard operation Flashing operation Change the jumpers X160 of the CU2 Board to 3-4 and 5-6.



5. Install the C16Xflasher (if not already existing on your notebook)

Start the “Setup.exe” and follow the instructions on your screen. After finishing the installation, start the program and click on “Settings”.

Figure 2-94: C16X Flasher

Enter the following settings:

- System clock 20 - Baud rate 38400 - Fix sector 1 erasure tick box - Sector erase enable

Figure 2-95: C16X Flasher Settings

Confirm with “OK”. Remove the plug X1 on AP7 “Bypass Control Board”, to make sure that the thyristors on the bypass do not fire.

6. Close QS2 (Before closing QS2, make sure the cable is properly set on both sides, the jumpers are changed and that you selected the correct file for flashing.)

7. Select the file Back on the main screen “C16Xflasher” you have to select the file you wish to flash into the CU-Board by clicking on “Select Image File” and choosing the appropriate file, e.g. cu01D.H86.



8. Click on the “Connect” button If the connection is ok, the buttons right beneath the button “Select Image File…” will be enabled.

9. Press the “Program device” button In the “Progress Bar” on the bottom of the window you can follow the progress of the flashing. Do not press the “Cancel” button in the “Abort”-Window. Please WAIT until the flashing is done. In case a error message appears: “Please reset board”, than turn off the UPS and start again from point 5. If “Flash programming done” appears in the “Status”-field (in the middle of the other text), the flashing procedure is successfully completed. To verify if the flashing was successful, press the “Verify Checksum” button. “Checksum ok” should appears in the “Status”-field.

10. Open switch QS2 again Wait till all “lights” got off and the UPS equipment (boards and so on) are discharged!

11. Connect plug X1 on AP7 Connect the plug X1 to the “Bypass Control Board” AP7 again.

12. Reset the jumpers and remove the PPVIS cable Put the jumpers CN11 from the LCDisplay back to the position 1-3 and 2-4 again and reset the jumpers X160 of the CU-Board to standard operation 7-8 and 9-10. Remove the PPVIS cable. (This is not necessary in case of using the direct connecting cable, because in that case the jumper were not changed.)

13. Re-Commissioning of the UPS Now you can start the UPS again. Start PPVIS. Reload the “CU2 Service initialisation” parameters. After setting the PNU52 back to “Return”, the CU is writing the information into the EEPROM. While this is done, no communication is present. This process could need some time. After this is done successfully, the best thing is to reset the UPS again before reloading the other saved parameters. For more details please see chapter “6.4 Replacing Procedures” “6.4.1 CU-Board”.



2.7.4.3 How to flash a CU1-Board (Rectifier)? Download respectively prepare all the necessary flashing-software and firmware-files before starting the flashing procedure. This is basically the same procedure like flashing the CU2-board (inverter). Merely the PPVIS cable needs to be connected to the X4 interface on the AP10 board. (Located in the connectivity box, access from the roof of the UPS; for more details please refer to the chapter “Connectivity Box”;) And there is NO need to change jumpers on the LCDisplay for faster connection. For more details on specific points, please, see previous chapter “How to flash the CU2-Board (Inverter)?” 1. Secure the Settings/Parameter of the UPS

Save important parameters for the UPS operation as well as customer settings. Close PPVIS after saving the needed parameters.

2. Switch off the UPS First of all, switch off the UPS respectively safely transfer the load to maintenance bypass.

3. Connect cable Connect the PPVIS cable to the X4 interface on AP10.

4. Jumper settings Change the jumpers X160 on the CU1 board to 3-4 and 5-6 for flash mode; standard mode/settings are 7-8 and 9-10;

5. Prepare C16Xflasher software Install the software (if not done yet).

6. Remove X1 on AP7 Remove the plug X1 on AP7 “Bypass Control Board”, to make sure that the thyristors on the bypass do not fire.

7. Close QS2 Warning 15 will appear. This is not important for flashing the CU1. Please continue flashing the CU2.

8. Select the file Select the appropriate file.

9. Click on the “Connect” button To set up a connection with the UPS.

10. Press the “Program device” button Start the flashing program. Wait till it is successfully done.

11. Open switch QS2 again Wait till the UPS is voltage free.



12. Connect plug X1 on AP7 Connect the plug X1 to the “Bypass Control Board” AP7 again.

13. Reset the jumpers and remove PPVIS cable Put the jumpers X160 back to 7-8 and 9-10. Remove the PPVIS cable

14. Re-Commissioning Re-commission the UPS. Restore the saved parameters.

2.7.4.4 Direct connecting cable for CU-Board flashing The direct connecting cable to the CU-Board can be ordered with item code 10H55351P01. But it is also possible to make one by yourself. You need:

• A cable with 3 wires, wire cross-section 24AWG, max. 300V and max. temperature 80°C; norm UL758

• For side A (connection X120 on CU-Board) a 44F block terminal • For side B (PC) a 9pol SUB D connector 4-40 UNC

Figure 2-96: 44F Block Terminal for interface X120 an CU-Board

Please connect the cable according to the following drawings.

Figure 2-97: Direct connecting cable from PC to X120 in CU-Board



Figure 2-98: Pin connection for the direct connecting cable from PC to X120 in CU-Board

Please pay attention to the correct wiring of the pins. Otherwise the cable will not work correctly.

What’s important?

Please be aware, that: - Not all PC’s /Notebook’s can be used with this cable, because the RS232 interface is not

providing the necessary nominal level. - There is no galvanic isolation between the signal common of the PC/Notebook and the

electronic of the UPS, meaning that in case of special failure the PC/Notebook could get damaged.



2.7.5 Flashing of a LCDisplay Download respectively prepare all the necessary flashing-software and firmware-files before starting the flashing procedure.

What’s important?

To flash the LCDisplay Board 710-01970, it is mandatory that the PPVIS Version 1.7.065 or higher is used.

If your computer is only equipped with a USB interface and you are using a adapter cable (USB interface on one side and a 9-pole D-type connector on the other side) it is very likely that the flashing procure will not work.

The LCDisplay Board 710-01970 is delivered with firmware 10H01362. Service engineers are requested to check and flash appropriate firmware before installing the board in the UPS.

2.7.5.1 How to flash LCDisplay? 1. Switch on the UPS

Make sure that the UPS is on. Transfer the load to maintenance bypass, in case the flashing procedure is failing. Remove all connectivity from XS3 and XS6!

2. Connect cable Connect the PC with the service port (X3 on LCDisplay board) using the PPVIS cable.

3. Set DIP switches The DIP switches SW1.2 and SW1.3 need to be set to ON. Set the SW1.1 DIP switch first to ON, wait 5 seconds and than switch to OFF again.

4. Install the Hitachi Flash Development Toolkit Start the “Setup.exe” file and follow the instructions on your screen until you reach the following window:

Figure 2-99: Hitachi Flash Development Toolkit Installation

Uncheck the other boxes, ONLY “H8” should be checked. Then keep following the instructions on your screen for further installation again.



5. Start the “Hitachi Flash Development Toolkit” and create a workspace

Figure 2-100: Hitachi Flash Development Toolkit

Figure 2-101: Hitachi Flash Development Toolkit – New Workspace

After entering a “Name”, choosing a “Location” and pressing the OK button you will receive a message: “You have created a new workspace. Would you like to run the Project Wizard to add a Project to the Workspace?”. Confirm with YES. Enter a “Project Name”:

Figure 2-102: Hitachi Flash Development Toolkit – Project Name



Select the device “H8/3064F”:

Figure 2-103: Hitachi Flash Development Toolkit – Choose Device

Choose Communication Port COM1:

Figure 2-104: Hitachi Flash Development Toolkit – Communication Port



Set the CPU crystal frequency to 19.66 MHz:

Figure 2-105: Hitachi Flash Development Toolkit – Device Settings

Check if the selected Connection is “Boot Mode”, the selected interface is “Direct Connection” and the box “Kernel already resident” is NOT checked:

Figure 2-106: Hitachi Flash Development Toolkit – Connection Type



Choose the protection “Automatic” and the messaging “Standard”:

Figure 2-107: Hitachi Flash Development Toolkit – Programming Options

Press Finish and you will receive this screen:

Figure 2-108: Hitachi Flash Development Screen



Now you need to add a new file to the project and select the firmware that you would like to flash to the LCDisplay, e.g. 10H01294R14.mot

Figure 2-109: Hitachi Flash Development Screen – Add Files to Project

Figure 2-110: Hitachi Flash Development Screen – Add Files to Project 2

Choose under “Tool” “Customise” folder “General” the dropdown “Would you like to perform a read-back verification after programming”; change it to “YES”. Open the “.mot” file you would like to flash into the LCDisplay with a double click.

Figure 2-111: Hitachi Flash Development Screen – Open .mot file



To connect with the device choose the menu “Device” “Connect to Device”

Figure 2-112: Hitachi Flash Development Screen – Connect to Device

After successfully connecting, choose “Image” “Download xxx.mot”. This operation will take about 2 minutes.

Figure 2-113: Hitachi Flash Development Screen – Download

6. Reset the DIP switches

Set the SW1.2 and SW1.3 DIP switch back to OFF and move the SW1.1 first to ON and than back to OFF again. The program should start now.

7. Check With the menu on the display you can check if your chosen software was flashed to the display all right. Go to the submenu “About”, there you can find all firmware and software versions. Verify if the “your” one is listed there.


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3 Installation

3.1 General For a detailed description of how to install the UPS and batteries, please refer to the User Manual. You will find the following information among other things in the User Manual:

• Safety concerning Batteries and UPS • Preparation for use of the UPS incl. transport, delivery and storage,

unpacking/re-packaging and so on… • How to install the UPS • External protection devices • Current and suggested cable sizes • Operation temperature and altitude

Cable entry is from the bottom or bottom-side of the cabinet.

What’s important?

Please be aware, that the 80-NET does have two supplies, the mains supply and the bypass supply. In case the customer has only one supply for the UPS, it is necessary to bridge the twosupplies of the UPS. If this is not done, warning 2 appears and the display may stay dark.

It is important to make sure that the mains, bypass and load connections are done as a correct phase rotation (right-handed field). If this is not done, warning 2 or/and warning 3 will appear.

The 80-NET needs a NEUTRAL!!!! Make sure it is connected. (Not only in the UPS, but also on site in the customers distribution.)

3.2 Placing the UPS & Battery Refer to the User Manual for more details on how to place the UPS and battery (e.g. wall-distance). Specially the operating temperature does have a effect on the UPS operation and battery. To high temperatures for example can cause battery failure. So keep in mind: The operating temperature range of the UPS is 0 °C to 35 °C (40°C for maximum 8 hours continuous operation). The ideal environmental temperature range is 15 °C to 25 °C. The battery life is defined at 20°C. Each increment of 10 °C above 25 °C reduces the expected life by 50%. Also the maximum operating altitude of the UPS is a point to consider: without derating it should not be higher than 1000 m. At higher altitudes the load must be reduced according to the user manual.


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3.3 Connecting the UPS & Battery While connecting the UPS and battery ensure that the live input source cannot accidentally be connected. Installation may only be carried out by qualified technicians and in conformity with the applicable safety standards. The PE safety conductor shall be connected before any other cables. Again, for information about this topic respectively for further details, refer to the user manual. E.g. questions concerning cable sizes, currents … This device is equipped with manual switches intended only for service bypass and internal service operations. It is, therefore, essential that the customer install external protection devices at the installation site. These must be installed near the unit and labelled as the mains separation device for the UPS. Batteries are a potential source of danger due to their electrical charge and chemical composition. Therefore observe the battery handling instructions of the manufacturer. These usually can be found in the material which accompanies the shipment. Make sure the correct polarity is present!


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4 Commissioning (Single Unit)

4.1 General

What’s important?

If the UPS device has not been used for a period of more than one year, the intermediate circuit capacitors must be reformed. If the UPS devices are commissioned within one year after delivery (check nameplate), this action is not necessary. Check chapter 6.3 “Trouble Locating & Testing” for details on how to reform the capacitors.

A adequate checklists for commissioning of the 80-NET could be found in the additional documentation to this Technical Manual 80-NET:

• Technical Manual 80-NET Checklists (10H52167TM01_CL)

What’s important?

Please be aware, that the 80-NET does have two supplies, the mains supply and the bypass supply. In case the customer has only one supply for the UPS, it is necessary to bridge the twosupplies of the UPS. If this is not done, warning 2 appears and the display may stay dark.

It is important to make sure that the mains, bypass and load connections are done as correct phase rotation (right-handed field). If this is not done, warning 2 or/and warning 3 will appear.

The 80-NET needs a NEUTRAL!!!! Make sure it is connected. (Not only in the UPS, but also on site in the customers distribution.)

Warning!

If the battery is connected to the intermediate circuit while the circuit is deenergised, the intermediate circuit capacitors could explode or the battery fuses may trip or become damaged. In this case, exchange the battery fuses as a precaution.



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4.1.1 Guided Procedures The feature “Guided Procedure” can be accessed via the main menu on the LCDisplay. The following guided procedures are available:

- for single unit Manual bypass Return form bypass Start up Shut down

- for distributed parallel units Manual bypass Return from bypass System start up System shut down

After entering one of the procedures, e.g. “manual bypass” this screen would appear:

Figure 4-1: Guided Procedure – Starting Screen for Procedure “Manual Bypass”

To indicate that a action must be performed,

- there are flashing switches in the diagram to indicate that the according switch must be opened/closed;

- there are two symbols for starting/stopping the inverter; these symbols are flashing, if the action is suggested;

Figure 4-2: Guided Procedure – Start and Stop Symbol

In the event of a fault, a warning message is displayed, exit the procedure, correct the fault condition and reset before proceeding. To exit the procedure, press the “Exit” button at any time.


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4.2 Start-up Procedure The following procedure will guide the commissioning engineer through the normal UPS start-up, allowing the LCD panel indications to be verified at each step. A detailed explanation of the LED and LCDisplay indications can be found in the user manual accompanying the UPS. 1. Ensure that external switches are in the OFF (0) position. 2. Ensure that external batteries are disconnected. 3. Check if UPS is connected according to the section “Installation” in the user

manual. Check conductor cross section and strain relief for the following cables:

- phases - neutral - earth

4. Check UPS and battery fuses with the mentioned values in the table of the user manual.

5. Check if earthing is connected, also for the battery cubicle. 6. Check if distribution at customer site is installed. 7. Specifically check if neutral is connected in the UPS AND all the way to and

through the customer site distribution! 8. Carry out a thorough inspection of the UPS

a. Check if UPS is accessible; b. Check if ventilation grills are NOT barred; c. Check if PCBs are fitted securely; d. Check if plugs of the boards are fitted correctly (they could got loose on the

transport); e. Check the assignment of XS3 and XS6;

9. Note the versions of the interface boards of rectifier (AP3) and inverter (AP4) 10. Battery temp. sensor XT1 installed at the battery? 11. Other external contacts/devices connected? Screened cables connected? 12. QS14 closed? 13. Make sure all switches are turned OFF 14. Turn on the mains separation device 15. Check if mains and bypass line do have correct phase rotation (right-hand field)?

If there is just one mains, check if mains and bypass line are bridged. 16. Check if voltage and frequency are in tolerance

U – N, V – N, W – N N – PE (must be 0V, for correct connection)

17. Put the connection field cover back on and connect PC with the UPS. Open PPVIS.

18. Close QS1 Warnings 2, 13, 22 and 32 appear

19. Save the factory settings (e.g. rectifier calibration) in PPVIS



20. Close QS2

Warning 2 disappears Before closing QS2, open the Set “UPS Actual Values” CU2 in PPVIS. You can check, if the bypass SCR are working properly, before turning on the inverter. (Defective bypass SCR and running inverter would cause Fault 39.) Monitor the values of bypass and output voltage immediately after closing QS2. The bypass voltage is appearing right away, the output voltage needs about 15 seconds until values are present, this is due to the necessary synchronisation of lines. If output voltage is showing a value right away, the SCR in the according phase is defective. If the output voltage is showing a strange or no value at all, it is likely that the “Bypass Control Board AP7” is defective. This would cause Fault 50 after about 15 seconds, because values are outside tolerance. (In case the output voltage stays at 0V, measure the actual bypass voltage to verify if it is really present, before replacing the AP7.)

21. Check the battery settings in PPVIS; correct if necessary; Initial charging wanted? (recommended by the battery manufacturer?)

22. Close QS9 (Battery fuses/circuit breaker still OPEN) Warning 13 disappears

23. Check whether the battery charge voltage on the UPS side of the battery isolator has the same polarity as the battery voltage on the battery side of the isolator.

24. Insert battery fuses 25. Measure the battery charging current and voltage.

Compare them with values of PPVIS (“Battery Display”) and adjust PNU 1440 if needed.

26. Check if the UPS clock is showing the correct time; 27. Close QS4

Warning 32 disappears 28. Turn on the inverter (push the button for 5 seconds)

Warning 22 disappears 29. Activated/set customer settings;

(Battery temp. sensor activated?) A complete reset can be necessary for setting certain parameters.

Be aware that if the above mentioned points are not adhered, problems may be experienced with the electrical supply.

Caution:

Unless otherwise stated, the UPS is shipped with the output voltage control set to the default value of 400V AC. Ensure that the load is not connected to the output of the UPS until the commissioning procedure has been completed.

To make commissioning on CU1 it is necessary to enter first in “H/W Init”-mode on CU2 in the classic way (i.e. inverter OFF and PNU52 = 2). Once the “H/W Init” on CU2



is activated it will turn off the rectifier and will allow to enter commissioning-mode on CU1 (PNU1076 [52] = 2). It will not be possible to make commissioning on CU1 independently to CU2. To re-establish normal operation exit from CU1 commissioning first and than from CU2 “H/W Init”. This will cause the automatic rectifier restart and then allow the inverter start. While CU1 is set to test mode (PNU1807 [783] = 1), the rectifier can be turned on and off independently to the CU1 status, if parameter PNU791 “Test rectifier On/Off manual” is set. This performance has been developed for service providing the possibility to maintain the rectifier OFF also after the unit has been switched OFF and ON.

4.3 Shut-down Procedure To shutdown the unit completely, follow this procedure: 1. Stop the inverter by pressing the inverter stop button for at least 5 seconds; 2. Open QS9; 3. Open QS4; 4. Open QS2; 5. Open QS1;

To transfer the load to maintenance bypass and to shutdown the unit, follow this procedure: 1. Press inverter OFF on LCDisplay for 5 seconds Normal mode (electronic

bypass); 2. Close QS3; 3. Open QS4; Service mode 4. Open QS1 and QS2; Maintenance bypass mode 5. Open QS9 (Disconnect the batteries) and any other external battery switch; 6. BEFORE continuing work,

measure the voltage at the battery terminal, the DC-link and at the mains input and wait until it has dropped to 0V. (This is to avoid electrical shocks.);


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5 Maintenance

5.1 General Although there is no need to substitute UPS internal components regularly as a preventative measure at any point during its design life, depending on environmental conditions, specific components, more subject to aging (e.g. electrolytic capacitors, backup batteries, fans etc.), may require replacement on an occasional basis. Therefore, CHLORIDE recommends that regular maintenance checks be carried out on site by an authorised customer service. The UPS indicates when the end of a fan’s lifetime has expired. A replacement fan is recommended. For maintenance or repair the UPS is equipped with a maintenance bypass switch (QS3), which enables transfer of the load to a bypass mains supply without any interruption in the supply to the load.

What’s important?

The transfer/retransfer of the load is achieved by synchronising the UPS automatically to the bypass mains supply, paralleling it with the inverter, then opening or closing the maintenance bypass switch. The switch configuration during maintenance bypass is as follows:

• QS1 = OPEN • QS2 = OPEN • QS3 = CLOSED • QS4 = OPEN • QS9 = OPEN


Warning!

During parallel operation of UPS units, the load switching function of the built-in service bypass must be carried out by an external switching device.

All internal subassemblies are accessible for typical and most frequent maintenance from the front of the unit via hinged doors. All checklists for maintenance of the 80-NET could be found in the additional documentation to this Technical Manual 80-NET:

• Technical Manual 80-NET Checklists (10H52167TM01_CL)


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5.2 Standard maintenance Before starting with any maintenance work on the UPS, a few points should be done with the UPS still in online mode.

when you enter the UPS and/or battery room notice if there is (1) a abnormal smell e.g. because of leaking batteries… (2) a abnormal sound e.g. because of faulty fan or transformer problem... (3) a abnormal amount of dirt (around the UPS and inside)

check temperatures and ventilation read out the event memory and the input “Mains Failure Total” (PNU 560) on

the PPVIS window “Status Display”. check XS3 and XS6 for existing connectivity

In the “checklist for preventive maintenance” (separate document) other respectively more detailed checks can be found. They can be documented with the checklist. However, the checklist is thought to be a kind of guideline, not a maintenance procedure. The condition of the UPS should be checked and documented. Important voltages and currents, condition of switches, condition of battery and certain functionalities should be checked and classified. Qualified personal may carry out maintenance work while observing the corresponding safety measures. To bring the UPS into a service state (transfer from online to maintenance bypass operation): 1. Press inverter OFF on LCDisplay for 5 seconds Normal mode (electronic

bypass); 2. Close QS3; 3. Open QS4; Service mode 4. Open QS1 and QS2; Maintenance bypass mode 5. Open QS9 (Disconnect the batteries) and any other external battery switch; 6. BEFORE continuing work,

measure the voltage at the battery terminal, the DC-link and at the mains input and wait until it has dropped to 0V. (This is to avoid electrical shocks.);

Qualified personal may now carry out maintenance work while observing the corresponding safety measures. If there is a external mains separation device for the UPS and the loads no longer need power, you may open that one too.

Parameter Number



Factorysetting

Mains Failure Total 1049 Total number of mains failure at bypass line. Only available in PPVIS.

0 – 65535 0

Access Level 1: never



Parameter



Factorysetting

Mains Failure Statistics Total number of mains failure and there duration since the commissioning of the unit at the rectifier input. Opening of QS1 will not be counted as mains failure. This parameter values will be shown on LCDisplay. This parameter can be reset by the service technician through PPVIS.

0 – 65535 1584

Indices: i01: Total number of mains failure 0 i02: Total duration of mains failure – seconds 0 Access

Level 4: URL i03: Total duration of mains failure – hours 0

Parameter Number



Factorysetting

Mains Failure Statistics Indicates the total duration of mains failure since the commissioning of the unit. Only mains failure on the rectifier input will be counted, opening of QS1 will not be counted. This parameter will automatically be reset, if PNU1584 will be reset.

0 – 65535 1585

Indices: i01: Days 0 i02: Hours 0 i03: Minutes 0 Access

Level 1: never i04: Seconds 0

5.3 Extended maintenance Which parts in the 80-NET should be changed in regular intervals: • Fan’s:

The UPS indicates when the end of the lifetime is reached. Replacing the fan’s is recommended.

• Batteries: Batteries in no proper state are highly recommended for replacement.

• Capacitors: DC as well as AC capacitors should be exchanged in defined intervals, depending on individual environmental conditions e.g. temperature, load, room air-conditioned and so on.



5.4 Battery maintenance Before you start any maintenance work on the battery, be sure that you followed the listed actions: • UPS is turned off. • Check if there is no voltage present on the battery contacts (open battery switch

if not already done.) • Disconnect the battery blocks, so that not more than five batteries are connected

in series. The voltage of a single block is not dangerous, however a number of such blocks, connected in series, can produce dangerous voltages.

• Since new batteries often do not provide full capacity after an initial charge it may be necessary to carry out a number of discharge/recharge cycles before optimum performance is achieved.

Please follow the instructions of the battery manufacturers concerning how to maintain the batteries.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 180/ 307Chapter: 6 Troubleshooting & Repair 6.1 General printed: 15.05.2007, 13:09

6 Troubleshooting & Repair

6.1 General The first step in troubleshooting is to get a detailed “picture” of the UPS situation. If you contact the responsible customer service representative, please have the following information ready:

• Device information: UPS series and type; Serial number (if possible also the order no.); Firmware versions;

• Exact warnings and faults shown on display; • Which messages are in the event storage? • Is the mains voltage present at the UPS input? • Measure the following:

Input voltage and frequency; Output voltage and frequency;

• Is the input fuse defective or have circuit breakers tripped? • Exact description of the problem

What loads are being operated? Does the problem occur regularly or sporadically? What has been done already?

What’s important?

Trained Engineers ONLY!!! Remember, only trained, Chloride authorised personal is allowed to carry out any work on the UPS!!!


Before starting any work in the UPS (e.g. changing boards…), make sure that you shutdown the UPS respectively that you transferred the load to maintenance bypass and that the 80-NET is voltage free.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 181/ 307Chapter: 6 Troubleshooting & Repair 6.2 Warnings and Faults printed: 15.05.2007, 13:09

6.2 Warnings and Faults During operation the UPS recognises and draws attention to a number of appearing events. These events are divided into “Warning” and “Faults” indications. Whether the message is a warning or fault can be determined from the number which appears in the warning/fault diagnosis page of the display, and the buzzer signals. Number CU Status 1 - 32 CU1 and CU2 Warning 33 - 99 CU2 (inverter) Fault 133 - 199 CU1 (rectifier) Fault

Buzzer The buzzer has different patterns, which indicate the active warning or fault.

- Pattern 1: long intervals This event is less serious. It is not essential that the cause must be corrected immediately, unless otherwise specified in table “Warning indicators”.

- Pattern 2: short intervals This a serious event. The cause should be rectified straight away to avoid a fault condition.

- Pattern 3: continuous tone This a serious event. The affected UPS component is always switched off and the UPS automatically switches to the best possible operating mode for supplying the loads.

The buzzer is silenced automatically as soon as the cause of the event is corrected. It can also be silenced manually by pressing the button TEST/RESET. If a warning appears, the UPS continues to operate. The yellow LED ALARM illuminates on the LCDisplay and a warning number is indicated. If a fault occurs, the red FAULT LED illuminates on the control panel. A number between 33 and 99 or between 133 and 199 appears in the diagnosis page of the display indicating the fault. Fault reset If a fault occurs:

- Firstly stop the buzzer by pressing the TEST/RESET button. - Secondly correct the fault. - Thirdly reset the fault by pressing the TEST/RESET button again.



6.2.1 Warnings Warnings: CU2- 10H01360 Rev 3.0 Warning configuration (Warning number: P4 bit#, Warning index P39.i0#, Warning info P39.i0#bit#)

Name (Shown on LCDisplay) W #

CU# Index Warning Info (Shown on LCD) Description

Notes / Action

Inverter, Neutral Booster stabiliser over-temperature W1i1 Inverter over-temperature Temp. above warning threshold defined by PNU152.2;

Check if fans are running correctly? Air supply/ventilation ok? Room temperature ok? Check actual value of temperature and verify with PPVIS value (Sensor ok?) Verify, if the measuring channel ST-S-OUT is ok? Cable ok? Contact to

Interface Board AP4 X83_1-3 ok? Reduce Load;

1

CU2

W1i2 Neutral-Booster stab. over-temp. Heavy non-linear load with DC content present; Temp. above warning threshold defined by PNU153.2; Like above ↑ (only measuring channel = ST-R; contacts AP3 X83_4-6);

Bypass mains warning W2i1 Bypass switch open Bypass input breaker QS2 closed?

If yes, measure if auxiliary contact is switching: on CU2 board X130_17-18 ; W2i2 Bypass supply failure Appears, when bypass voltage or frequency is out of tolerance for a time

period longer than defined in PNU110; Voltage tolerance: PNU106 (related to value of PNU71) Frequency tolerance: PNU104 (related to value of PNU72)

For the detection of this warning a average value of all three phases is used (no single phase consideration);

Measure if the actual values are within tolerance If yes, check AP4;

If there is just one power supply for mains and bypass of the UPS, than they are probably not connected;

Bypass line connection was not done as right-handed field;

2

CU2

W2i3 Parallel bypass not available Bypass failure signal from POB; Can only appear if UPS is in “Distributed Parallel System” configuration; Appears if one of the “other” UPSs is having W2i1 or W2i2 or F50; Verify on which UPS of the parallel system is showing W2i1/ i2 and correct it; Check connection between POB boards; Check POB boards (of the UPS with W2i1 or W2i2 first); Check AP4 boards (of the UPS with W2i1 or W2i2 first);




CU# Index Warning Info (Shown on LCD) Description Notes / Action

Primary supply warning W3i1 Primary mains switch open Mains input switch QS1 closed?

If yes, measure if auxiliary contact is switching: on CU1 board X130_13-14; Rectifier is not working;

W3i2 Primary mains power failure Set when AC voltage outside PNU1130 [106] i01 and i03 window (Factory setting V< -20% OR V> +15<%);

Set when Frequency outside PNU1128 [104] value (Factory setting Hz<0 -6% OR Hz < +6%);

Appears, when mains voltage or frequency is out of tolerance for a time period longer than defined in PNU1134 [110];

Rectifier is turning off automatically; UPS is running on batteries; Measure if the actual values are within tolerance

If yes, check AP3; If there is just one power supply for mains and bypass of the UPS, than they

are probably not connected; Mains connection was not done as right-handed field;

W3i3 Mains voltage low Set when AC voltage is inside a window defined with PNU1130 [106] i02-i03 (Factory setting -20% < Vac < -15% );

Mains voltage to low to charge the batteries; Battery charger is switched off; Check mains voltage;

W3i4 PK

3

CU1

W3i5 Out of Synchronisation

Inverter I2T 4

CU2

W4i1 Inverter I2T I2T over current detected on inverter output with DC CT TA9-TA11; Check the inverter output DC CTs TA9-TA11; Check the output AC CTs TA12-TA14; Check the output fuses FU4-FU6;

Pre-charge DC voltage monitoring Notice: When mains returns, while W5 is set, the inverter start is inhibited!!! W5i1 CU1 CU2

DC Voltage low DC-link voltage under threshold defined by PNU1159.2 (CU2) and by PNU101 (CU1);

If Booster is not working properly any more; If UPS is in Battery mode, than It appears when Battery is not ok any more;

W5i2 CU2

Precharge active Wait until precharge is done; Set while DC voltage < PNU101 Contactor KM3 is broken; Resistor R1/R2 is broken;

5

CU1 CU2

W5i3 CU2

Bypass disable for DC voltage low Active during precharge; Because there is no output contactor in this UPS, it is necessary to inhibited

the Static Bypass Switch to switching through, while the DC capacitors are not charged; If this is not done, the DC capacitors would be charged backwards from the output over the bypass line, what is not allowed; ((threshold √2 * RMS - 30V), delay 0,4sec);





Overload warning W6i1 90% overload capacity reached Inverter overload time counter has reached 90% of time-out threshold;

Load transferred to bypass if PNU567 Bit 2 = 1 is set (singe block only); Overload based on current value only; Temp. and time are taken in account for this overload warning; Overload monitored with AC CT TA12-TA14; For more details, please refer to the according subchapter of “6.2.3 Additional

Explanations for Warnings and Faults”; W6i2 Current limit Inverter current limitation active;

In case of peak currents (detected by TA9-TA11) on the inverter output, the bypass line will be used in parallel with the mains line, to reduce the current in the mains line; This is called dynamic line support;

6

CU2

W6i3 Overload Load % is above threshold defined by ambient temperature; Start of KW protection counter; Output overload incl. recovery time;

Phase sequence error warning W7i1 CU2

Bypass wrong phase rotation Bypass input phase error

Appears only when UPS is powered up, not while running; Check and if necessary change to a right-hand rotation; Maybe a one phase bypass mains failure is present;

7

CU1 CU2 W7i2

CU1 Primary mains wrong phase rotation Primary input phase error

Appears only when UPS is powered up, not while running; Check and if necessary change to a right-hand rotation; Maybe a one phase mains failure is present;

Manual /SBS bypass switch ON warning W8i1 Maintenance bypass switch closed Maintenance bypass QS3 is closed; Could it be opened? If yes, open;

QS3 open? If yes, measure if auxiliary contact is switching: on CU2 board X130_13-14;

8

CU2 W8i2 SBS bypass switch closed External SBS QS5 is closed (Input Function PNU93 i01=4); Check if the SBS

could be opened; If yes, open; Is QS5 of the SBS already open?

If yes, check the connection between X8 on the UPS and the SBS and the auxiliary contact on the SBS;

Output load supplied by battery 9

CU2

W9i1 Output load supplied by battery Set by CU2 when W3i2 "primary mains power failure" AND "inverter running"; Reset when mains power returns (rectifier ON) OR "inverter stop"; Also present, when rectifier has a problem; The battery is supplying the load;

Battery imminent end of autonomy warning W10i1 Imminent end of battery autonomy

time If PNU590 = 1 (CU2) (PNU gives a choice of 4 different states); Value of PNU22 “Battery hold up time” < PNU117 “Battery stored energy

time”; This warning is time dependent; For more details, please refer to the according subchapter of “6.2.3 Additional

Explanations for Warnings and Faults”;

10

CU2

W10i2 Battery shutdown imminent If PNU590 = 2 (CU2); Imminent shut down defined by battery voltage PNU24 < [PNU511&PNU513

curve+ PNU591] This warning is voltage dependent; For more details, please refer to the according subchapter of “6.2.3 Additional






Battery end of discharge warning W11i1 CU2

Battery end of discharge Set when battery voltage PNU24 < PNU511&PNU513 interpolation curve (“End of Discharge” curve);

Inverter stopped; Reset after [W5=0 AND inverter restart delay (PNU588) expired] Check the battery; Check the calculation settings; For more details, please refer to the according subchapter of “6.2.3 Additional


11

CU2 CU1

W11i2 CU1

Battery depleted Set when battery voltage PNU1048 < PNU1426.1 CU1 “Battery under voltage limit”: (default value 1.6 V/cell).

Booster stopped; Check the battery; Check the calculation settings;

Commissioning or test mode W12i1 CU2

Inverter H/W Init, Commissioning PNU52 = 2;

W12i2 CU2

Inverter test mode PNU783=1 or PNU125=1;

W12i3 Reserved W12i4 CU1

Rectifier H/W Init, Commissioning PNU1076 (52) = 2;

W12i5 CU1

Boost-charger test mode

12

CU1 CU2

W12i6 CU1

Control source is not CU2 PNU1078 (54) is not = 2;

Battery switch open 13

CU1

W13i1 Battery switch open Battery switch QS9 closed? If yes, measure if auxiliary contact is switching: on AP3 board X94_1-2;

Battery not available; Battery fuses ok? Battery ok? Check if battery loop is closed; XT2 closed? For a external battery it must be closed;

Connector closed? External battery switch closed?

Fan life exceeded 14

CU2

W14i1 Fan life exceeded Appears when PNU109 = 0. This parameter is counting down; Change the fans; For short term solution until the spare fans are available: “Reloading” the

PNU109 manually with a new fan life time. BUT make sure that the fans are able to endure the new set time. Otherwise the UPS could get damaged!

CU1 CU2 communication error 15

CU2

W15i1 CU1<->CU2 communication error CU1-CU2 communication stopped for more then 60s; Check cable between CU1 and CU2; Change CU1 and verify if communication is available again; Change CU2 and verify if communication is available again;

CPU time slice override (normally masked) W16i1 Inverter CU board time slice

overrun CU2 time slice skipped;

16 CU1 CU2

W16i2 Rectifier CU board time slice overrun

CU1 time slice skipped;





Reserved 17

Battery discharging or recharge inhibit W18i1 CU1

Battery discharging UPS is in battery mode; (Rectifier is signalising mains failure and the inverter is running;)

Set by CU1 if W3i2 “Primary mains power failure” and “Booster on”;

18

CU1 CU2 W18i2

CU2

Battery charger inhibited Batteries will not be charged; Command by CU2 when PNU93=1 or 18 active (Input function);

Battery temperature alarms W19i1 Temp. probe not responding Battery temp. sensor fault: Batt. temp T< -10°C or T>50°C;

Verify if temp. probe is working; measure the actual temp.; Temp. probe connected? Room temp. ok? Battery will not be charged;

W19i2 Batt. temp. out of range Battery temp. –10°C<T<PNU1557.i01 [533] or 40°C<T<50°C; Check air supply of batteries; Temp. probe working ok?

19

CU1

W19i3 High battery temperature Battery temp. user alarm: Batt. temp. P1557.i02<T<40°C; Check air supply of batteries; cooling ventilation must be implemented; Batteries ok? Batt. temp. value can be verified with PNU1050.2 (SET “Actual Values” CU1)

System warnings 1 W20i1 CU2

Inverter remotely stopped Set when PNU93.1 =19 (Input function) active

W20i2 CU1

Neutral switch open Neutral switch QS14 closed? If yes, measure if auxiliary contact is switching: on CU1 board X130_6-8; If not, shut down UPS before managing the QS14;

While warning is set, the closing of precharge contactor KM3 is inhibited and the rectifier stays off (CU1);

Start of the input inverter is inhibited (CU2); W20i3 CU2

Input air temp. sensor fault Temp. T< -10°C or T>50°C Verify, if the measuring channel ST-1 is ok? Cable ok? Contact to Interface

Board AP4 X82_3-4 ok? Should show –15°C in PPVIS; Check actual temperature; Check if sensor is defective;

W20i4 CU2

Input air temp. out of range Temp. –10C<T<PNU133.i01 or 40°C<T<50°C Air supply ok? Room temperature ok? Check actual value of temperature and verify with PPVIS value (Sensor ok?)

W20i5 CU2

Input air high temperature Temp. PNU133i02 <T<40°C Check air supply; cooling ventilation must be implemented;

20

CU1 CU2

W20i6 CU2

SBS output switch open QS6 PNU93.i1 Input function X8 = 22;

Battery temperature sensor fault W21i1 Battery voltage correction will be disabled, when warning appears;

21

CU1

Load Supply W22i1 Output load not supplied via the

secure bus Load not supplied through the secure bus;

W22i2 Inverter OFF Inverter off; Load supplied by bypass;

22

CU2

W22i3 Inverter inhibit DC low Inverter start inhibited; DC voltage < PNU135.i3 “UDC link min. voltage”;




CU# Index Warning Info (Shown on LCD)

Description Notes / Action

Reserved 23

Rectifier, Booster-Charger over temperature W24i1 Rectifier over-temperature Temp. above warning threshold defined by PNU1174i2

PNU1050.i3 “Temperatures – input converter” shows the PPVIS measured temp. value;

Check if fans are running correctly? Air supply ok? Room temperature ok? Check actual value of temperature and verify with PPVIS value (Sensor ok?) Verify, if the measuring channel ST-S-IN is ok? Cable ok? Contact to

Interface Board AP3 X83_1-3 ok? Reduce Load;

24

CU1

W24i2 Booster-charger over-temperature Like above ↑ (only measuring channel = ST-B; contacts AP3 X83_4-6); Temp. above warning threshold defined by PNU1175i2; PNU1050.i4 “Temperatures – booster/charger” shows the PPVIS measured

temp. value;

Reserved 25

Pending command W26i1 Inverter stop pending command Set in parallel operation when local command present but not global;

26

CU2 W26i2 Inverter start pending command Set in parallel operation when local command present but not global;

Battery autonomy test 27

CU1

W27i1 Battery autonomy test Warning during battery back-up time test;

Re-transfer inhibited 28

CU2

W28i1 Re-transfer inhibited Due to overload the transfer to inverter is inhibited (PNU567) BUT inverter is running and is waiting to take over;

Reduce load;

External synchronisation error 29

CU2

W29i1 External synchronisation error External synchronisation signal not correct; Check cable;

Switch closure monitoring W30i1 CU1

Do not insert battery Closure of QS9 battery switch disabled due to DC bus voltage low; (Set when W5 and W13 active; Reset when W5=0);

30

CU1 CU2 W30i2

CU2 Do not close output switch Closure of QS4 output switch disabled due to DC bus voltage low;

Reserved 31

Output switch open 32 W32i1 Output switch open Output switch QS4 closed?

If yes, measure if auxiliary contact is switching: on AP4 board X94_1-2; Inverter not running;



6.2.2 Faults Faults: CU2- 10H01360 Rev 3.0 Fault configuration (Fault number P947.i01-i04; Fault index P949.i0#; Fault info P949.i01-i04 =#)

Name (Shown on LCDisplay) F #

CU# Index Fault Info (Shown on LCD) Description Notes / Action

Inverter temperature faults Inverter faultF33i1 Inverter over-temperature Appears after W1 (W1 disappears when F33 appears);

Inverter turned off! Temp. above fault threshold defined by PNU152.3; Fans running? Air supply ok? Room temperature ok? Measure actual temp. value and verify with PPVIS value; Sensor ok? Verify, if the measuring channel ST-S-OUT is ok? Cable ok? Contact to

Interface Board AP4 X83_1-3 ok? Overload present? Reduce load;

F33i2 Inverter filter over-temperature Over temp. in choke L6-L8; Inverter turned off! Harmonics present? Not permitted load present on the UPS? Verify, if the measuring channel from choke to CU2 X130_15-16 is ok? Cable

ok? Contact on CU2 X130_15-16 ok? More see above ↑;

33

CU2

F33i3 Inverter temperature sensor fault Inverter turned off! Verify, if the measuring channel ST-S-OUT is ok? Cable ok? Contact to

Interface Board AP4 X83_1-3 ok? More see above ↑;

CU microcontroller error Inverter fault34

CU2

F34 Flash newest firmware onto the CU2 board; Exchange CU2; Inverter stopped;

Incorrect power class Other fault35

CU2

F35 Incorrect power class Power class not initialised; Select the correct power class;

Inverter contactor defective Inverter Fault36

CU2

F36i1 Inverter contactor defective Only, when a optional output contactor is installed; Check contactor coil; Check if the contactor is supplied with 24Vdc; Inverter contactor is off (feedback) AND inverter is in state “inverter operation”

AND test-mode not selected AND output contactor present (PNU651 =1);

Inverter start failed after n-consecutive times Inverter Fault37

CU2

F37i1 Multiple inv. cut-off due to DC undervoltage

Appears if inverter start failed after 4-consecutive attempts within 96s interval time because VDC < PNU101;

Check if under-voltage is present in the DC-link; Check the battery; Check the load; Check if rectifier and/or booster (Batt. mode) is working properly;

Reserved 38





Inverter DC overvoltage Inverter Fault39

CU2

F39 Inverter DC voltage high DC overvoltage. > ±450Vdc; Check SCR in bypass line and the “Bypass Control Board AP7”; Check the load; Backfeed/regeneration present? Is output contactor (if present) opening? Input transients present?

E.P.O. Inverter and Other fault40

CU2

F40 E.P.O. EPO X8 active (PNU93.1 = Input function 3); Reset contact respectively check it;

CU2 DSP error Inverter FaultF40i1 CU2 DSP program error If you have a newly flashed CU-Board, try a parameter reset;

Exchange CU2 board; F40i2 Wrong state of DSP state-machine Like above ↑ ; F40i3 Impermissible Interrupt Like above ↑ ;

41

CU2

F40i4 Wrong initialisation of data in DSP Like above ↑ ;

Inverter DC voltage low 42 F42i1 Inverter DC voltage low ;

Inverter desaturation Inverter FaultF43i1 DC/AC desaturation phase U Short circuit in the IGBT?

“IGBT Driver Board” AP15 defective? Inverter stopped; CU2 X109_B23;

F43i2 DC/AC desaturation phase V Short circuit in the IGBT? “IGBT Driver Board” AP16 defective? Inverter stopped; CU2 X109_A24;

43

CU2

F43i3 DC/AC desaturation phase W Short circuit in the IGBT? “IGBT Driver Board” AP17 defective? Inverter stopped; CU2 X109_B24;

Stop due to overcurrent Inverter Fault44

CU2

F44 Stop due to overcurrent Before F44 appears, W6 was already present; Set after 5 attempts within 1 min. of dynamic line support; Verify load; Verify output filter L6-L8; Dynamic line support is active, when current limit is lasting more than 3 ms.;

The bypass static switch will be turned on for 800 ms.;

Power supply feedback failure 45

CU2 F45i1 Power supply feedback failure ;





Secure bus voltage out of tolerance Inverter FaultF46i1 Output over-voltage Check the output current sense AC CT TA12-TA14;

Check if load is within UPS parameters (high engine load); F46i2 Output under-voltage Check output fuses FU4-FU6;

Check output contactor (if present); Check the output current sense AC CT TA12-TA14; Check if load is within UPS parameters (high engine load);

F46i3 Output frequency out of limits Check if load is within UPS parameters (high engine load); F46i4 Output short-circuit Short circuit present on the output;

Check output filters L6-L8; F46i5 DC component phase U Check DC-calibration of inverter;

Check inverter current sense TA9-TA11; F46i6 DC component phase V Check DC-calibration of inverter;

Check inverter current sense TA9-TA11;

46

CU2

F46i7 DC component phase W Check DC-calibration of inverter; Check inverter current sense TA9-TA11;

Inverter Overload I2T fault Inverter FaultF47i1 Inverter I2T phase U I2T fault on phase U;

Reduce load; Check the output current sense AC CT TA12-TA14;

F47i2 Inverter I2T phase V I2T fault on phase V; Reduce load; Check the output current sense AC CT TA12-TA14;

F47i3 Inverter I2T phase W I2T fault on phase W; Reduce load; Check the output current sense AC CT TA12-TA14;

47

CU2

F47i4 Inverter overload timeout Maximum of inverter output power exceeded (overload time counter has reached threshold);

Load transferred to bypass if PNU567 Bit 2 = 1 is set (single block only); Overload based on current value only; Temp. and time are taken in account for this overload fault; Overload monitored with AC CT TA12-TA14;

Backfeed protection active Inverter Fault48

CU2

F48 Backfeed protection active Backfeed fault detected by TA15-TA17 (bypass current sense); given to AP4 X61_1-6 and than to CU2 X109_B9 (output contact XT4 will get a signal from CU2 X109_B13 to signal a detected backfeed);

SW enabled by PNU142; Check bypass static switch; Check bypass current sense TA15-TA17;

Reserved 49

Bypass HW fault Bypass FaultF50i1 Reserved Bypass ready signal fault; F50i2 Reserved F50i3 Reserved F50i4 Reserved F50i5 Electronic fault ready

acknowledge is missing despite power supply OK

Check electronic components; Bypass static switch failure (X110 pin 3-4 "STS_GOOD" = OFF AND bypass

input OK);

50

CU2

F50i6 Incorrect state in bypass state-machine

Software fault;





Bypass failed during line support Bypass Fault51

CU2

F51 Bypass failed during line support Bypass line fault detected just at the end of dynamic line support period; Probably bypass fuse blown; Check electronic components;

Bypass overload timeout Bypass fault52

CU2

F52 Bypass overload timeout Bypass on AND overload time out counter reached; Verify load; Check the output current sense AC CT TA12-TA14; In PARALLEL system: check the bypass current distribution;

Bypass transformer protection Other Fault53

CU2

F53 Bypass transformer protection PNU93 (X8) input function = 24;

Fan system faulty Other Fault54

CU2

F54 Fan system faulty The signal for the fan test is sent from AP27/AP28 over AP4 X2_3-4 to CU2 X109_B10 ONLY when fans are running on high speed;

For the automatic fan test, the fans will be speed up to high speed; If the fans are running on high speed due to high temp. in the UPS, the fans

are constantly monitored; Check fans, and replace if necessary;

CU2 EEPROM error 1 - 10 Info list CU2 EEPROM error Other FaultF55i1 fault in write-operation - write verify not OK. F55i2 fault in write-operation - no ack. after slave address F55i3 fault in write-operation - no ack. after storage address F55i4 fault in write-operation - no ack after value address F55i5 fault in read-operation - no ack. after slave address F55i6 fault in read-operation - no ack. after storage address F55i7 fault in read-operation - no ack. after value address F55i8 no end of data signal after value read F55i9 invalid address at EEPROM - order

55

CU2

F55i10 invalid data type at EEPROM - order

CU2 error UART Other Fault56

CU2

F56 CU2 communication failure with CU1

Replace CU2 board;

CU2 EPROM checksum error Other Fault57

CU2

F57 CU2 EPROM checksum fault Re-flash the CU2 board with the corresponding firmware release;

Bypass output voltage fault Other FaultF58i1 Reserved

58

CU2 F58i2 Bypass output voltage fault Output voltage fault despite bypass input ok; Measure the actual bypass output voltage; Check output voltage sense (AP4 X4_1,3,5); Check bypass static switch; Check bypass control board AP7;

CU2 Dual Port RAM error Other Fault59

CU2

F59 CU2 fault accessing dual port RAM Fault set by "ready signal" missing coming from optional device connected to DPR;





Parallel bypass fault Other Fault60

CU2

F60 Parallel bypass fault Fault active only in parallel system when, after 5 attempt of dynamic mains support, the inverter is not able to support the load

One of the bypasses of a parallel UPS is not supporting, therefore the parallel system is not switching to bypass;

Check load distribution;

Parallel board signal failure Other Fault61

CU2

F61 Parallel board signal failure Check cable and cable connection of POB; Change the POB;

Ambient temperature sensor fault Other Fault62

CU2

F62 Ambient temperature sensor fault Should show –15°C in PPVIS; Check temperatures sensor connection and cable; Check actual temperature; Check if sensor is defective;

Reserved 63

- 71

Mains input transformer protection Other Fault72

CU2

F72 Mains input transformer protection PNU93 (X8) input function = 23;

Neutral booster protection Other FaultF73i1 Neutral booster choke over-

temperature Inductance over-temperature; Verify, if the measuring channel from choke to CU2 is ok? Cable and contact

ok? Booster stopped;

F73i2 Neutral booster over-temperature Temp. above fault threshold defined by PNU153.3; Booster stopped; Fans running? Air supply ok? Room temperature ok? Measure actual temp. value and verify with PPVIS value; Sensor ok? Verify, if the measuring channel is ok? Cable and contact on AP4 X83_4-6

ok? F73i3 Neutral booster desaturation Desaturation (input X109_B8);

Check IGBT; Check neutral booster CT;

73

CU2

F73i4 Neutral booster temperature sensor fault

Booster stopped; Verify, if the measuring channel ST-R-OUT is ok? Cable and contact on AP4

X83_4-6 ok? Measure actual temp. value and verify with PPVIS value; Sensor ok?

Reserved 74

- 82





Battery faults Other FaultF83i1 Battery fuse blown PNU93 (X8) input function 21. (Info transmitted on PZD 3 bit 1 "Battery fuse

open"); Check battery fuses; Check battery fuse monitoring;

83

CU2

F83i2 Battery insulation failure This option is sensing the lost battery insulation on CU1 X130_7-8 and is transmitted to CU2;

Reserved 84

- 99

Rectifier and boost faults Rectifier Fault101

CU1

F101 Rectifier and boost fault Special fault; Generated when rectifier and battery booster fault are present simultaneous

(because faults are mapped by the CU2, in the rectifier group, and therefore can not be handled independently.);

Rectifier temperature faults Rectifier FaultF133i1 Rectifier over-temperature Appears after W24 (W24 disappears when F133 appears);

Rectifier turned off! Temp. above fault threshold defined by PNU1174.3; Fans running? Air supply ok? Room temperature ok? Measure actual temp. value and verify with PPVIS value; Sensor ok? Verify, if the measuring channel ST-S-IN is ok? Cable ok? Contact to AP3

X83_1-3 ok? Overload present? Reduce load;

F133i2 Rectifier filter over-temperature Over temperature in choke L1-L3; Rectifier turned off! Verify, if the measuring channel to CU2 X130_15-16 is ok? Cable ok?

Contact CU2 X130_15-16 ok? More see above ↑

133

CU1

F133i3 Rectifier temperature sensor fault Rectifier turned off! Verify, if the measuring channel ST-S-IN is ok? Cable ok? Contact to

Interface Board AP3 X83_1-3 ok? More see above ↑

Reserved 134

- 138

Rectifier DC overvoltage Rectifier Fault139

CU1

F139 DC Over voltage DC overvoltage > ± 450Vdc; Check SCR in bypass line and the Bypass Control Board AP7; Check the load; Backfeed/regeneration present? Is output contactor (if present) opening? Input transients present?

E.P.O. Rectifier Fault140

CU1

F140 E.P.O. PNU93 (X8) input function 3. (Info transmitted over CU2 to CU1 PZD 1 bit 7);





CU1 DSP error Rectifier FaultF141i1 DSP couldn’t be stopped If you have a newly flashed CU board, try a parameter reset;

Exchange CU1 board; F141i2 Wrong state of DSP state-machine More see above ↑ ; F141i3 Not permitted Interrupt More see above ↑ ;

141

CU1

F141i4 Wrong initialisation of data in DSP More see above ↑ ;

Rectifier pre-charge failure Rectifier FaultF142i1 Precharge short circuit Precharge short circuit, because threshold PNU1159.1 [135.1] was not

reached within 1 sec.; F142i2 Precharge low VDC Precharge did not reach safe voltage despite mains OK;

(PNU1159.2 [135.2] +20V) Precharge resistor R1/R2 and capacitor C1-C3 ok? Precharge contactor KM3 ok? Fuses FU1-FU3 ok? KM1 ok?

F142i3 Precharge contactor feedback HW defective; Timeout for the feedback from the rectifier mains contactor KM1; KM1 ok?

142

CU1

F142i4 Precharge incorrect state Not allowed precharge state;

Rectifier desaturation Rectifier FaultF143i1 Rectifier desaturation phase U Short circuit in the IGBT?

“IGBT Driver Board” AP11 defective? Rectifier stopped; Phase U (CU1 X109_B23);

F143i2 Rectifier desaturation phase V Short circuit in the IGBT? “IGBT Driver Board” AP12 defective? Rectifier stopped; Phase V (CU1 X109_A24);

143

CU1

F143i3 Rectifier desaturation phase W Short circuit in the IGBT? “IGBT Driver Board” AP13 defective? Rectifier stopped; Phase W (CU1 X109_B24);

Reserved 144

Power supply feedback failure Other Fault145

CU1

F145 ;

Reserved 146

- 154

CU1 EEPROM error 1 - 10 Info list CU1 EEPROM error Other FaultF155i1 fault in write-operation - write verify not OK. F155i2 fault in write-operation - no ack. after slave address F155i3 fault in write-operation - no ack. after storage address F155i4 fault in write-operation - no ack after value address F155i5 fault in read-operation - no ack. after slave address F155i6 fault in read-operation - no ack. after storage address F155i7 fault in read-operation - no ack. after value address F155i8 no end of data signal after value read F155i9 invalid address at EEPROM - order

155

CU1

F155i10 invalid data type at EEPROM - order





CU1 error UART Other Fault156 F156 Serial interface: UART

communication Replace CU1 board;

CU1 EPROM checksum error Other Fault157

CU1

F157 CU1 EPROM checksum fault Re-flash CU1 board with the corresponding firmware release;

Reserved 158

CU1 dual port RAM error Other Fault159

CU1

F159 CU1 fault accessing dual port RAM Fault set by "ready signal" missing coming from optional device connected to DPR;

Reserved 160

-161

Battery temperature sensor fault Other Fault162

CU1 F162

Reserved 163

-172

Booster Charger protection Rectifier FaultF173i1 Booster-Charger filter over-

temperature Inductance over-temperature Verify, if the measuring channel from choke to CU1 X130_17-18 is ok? Cable

ok? Contact on CU1 X130_17-18 ok? Check the choke L4; Booster/Charger stopped;

F173i2 Booster-Charger over temperature Booster/Charger stopped; Temp. above fault threshold defined by PNU1175.i3; Fans / air supply / room temperature ok? Measure actual temp. value and verify with PPVIS value; Sensor ok? Verify, if the measuring channel ST-B is ok? Cable ok? Contact on AP3

X83_5-6 ok? F173i3 Booster-Charger Desaturation Desaturation (input X109_B8)

173

CU1

F173i4 Booster-Charger temperature sensor fault

Booster/Charger stopped; Verify, if the measuring channel ST-B is ok? Cable ok? Contact on AP3

X83_5-6 ok?

Reserved 174

-181

Rectifier DC closed loop fault Rectifier Fault182

CU1 F182i1 Rectifier DC closed loop fault Check rectifier;

Battery test fault Other Fault183

CU1

F183 Battery test fault Fault detected during a manual or automatic battery test. Set during battery test when Battery voltage < PNU1426.i2 “Min. Battery voltage”;

Reserved 184

-199



6.2.3 Additional Explanations for Warning and Faults

6.2.3.1 Warning 3 – Primary supply warning This warning contains a index which indicates reaching of “Mains voltage low” (W3i3). In contrary to a nonexistent indication of reaching a high mains voltage. This means, in case that the mains power falls below a first threshold, set with PNU 1130.i02, the UPS issues the warning W3i3 “mains voltage low” and battery charging is stopped. If the mains power is even getting lower and is falling below a second threshold (PNU 1130.i03) the rectifier will switch off and the UPS will run on batteries. warning W3i2 is indicating this situation. (Warning 9 is also issued for UPS running on batteries.) For a high mains power only one threshold is present (PNU 1130.i01). There is no warning threshold for a “pre” warning. If the threshold is exceeded, the UPS will turn of the rectifier and the unit is running on batteries. This will be indicated also with warning W3i2. (Warning 9 is also issued for UPS running on batteries.) In short… If W3i3 and W3i2 (and W9) is displayed, the rectifier turned of due to low mains voltage. If only W3i2 (and W9) is displayed, the rectifier turned of due to high mains voltage.

6.2.3.2 Warning 6 – Overload Warning While the inverter is running, the overload monitoring function is periodically executed. Depending on

- ambient temperature, - amount of overload and - period of overload

a counter is increased or decreased. After reaching certain counter values, actions are taken and Warning 6 or Fault 47 is issued. The overload is measured with the output current sense TA12-TA14 (AC CT). The overload capability of the UPS is depending on ambient temperature. The nominal apparent power (100%) is rated at 40°C. Meaning, in case of a lower ambient temperature than 40°C, the UPS is capable of providing a higher output power:

at 40°C 100% nominal apparent power at 30°C 105% of nominal apparent power at 40°C at 25°C 110% of nominal apparent power at 40°C at 0°C 115% of nominal apparent power at 40°C

For more details see either the “Technical Data Table” (1.3.2 Specification) or figure “Automatic Power Upgrade” (2.3.3 Inverter). This, on ambient temperature depending output power is causing for the same UPS (e.g. a 80-NET 100kVA) different thresholds for reaching the overload mark.

40°C … 80-NET 100kVA … output power for continuous operation … 100kVA 30°C … 80-NET 100kVA … output power for continuous operation … 105kVA



The overload capacity is furthermore depending on period and amount of overload. There are two main thresholds: (for describing the overload curve)

- 1min 150% and - 10min 125%.

125% and 150% are based on the nominal apparent power. If the counter has reached 90% of the time-out threshold, then the Warning 6 Index 1 will be issued.

Figure 6-1: Overload capacity

6.2.3.3 Warning 10 – Battery imminent end of autonomy warning There are different possible threshold to issue a warning concerning upcoming respectively reached end of battery energy:

- Voltage - Time

Warning 10 Index 1 is issued, when the “Battery hold-up time” PNU 22 < PNU 117 “Battery stored energy time”. This time dependent warning is only issued, when PNU 590 “Message Configuration” is set to “1”. The voltage depending Warning 10 Index 2 is issued, when the battery voltage is falling below the “Imminent Shutdown” curve.



The “Imminent Shutdown” curve is described with the “End of Discharge” curve (PNU 511 and PNU 513) plus a “Delta”, which is defined with PNU 591 “Delta Shutdown Imminent”. To activate this “Delta” before the “End of Discharge” message, PNU 590 “Message Configuration” needs to be set to “2” “Message battery voltage below shutdown imminent threshold”.

Figure 6-2: Imminent Shutdown Curve – End of Discharge Curve

More details for explaining this Warning 10 Index 1 and 2 in connection with Warning 11 Index 1 can be found in chapter “2.5.4 Imminent Shutdown Curve”.

6.2.3.4 Warning 11 – Battery end of discharge warning The voltage depending Warning 11 Index 1 will appear when the battery voltage is falling below the “End of Discharge” curve, described with PNU 511 and PNU 513. The inverter will be shut down, but the electronic of the UPS will still be supported by the battery voltage. Therefore, the battery discharging is not stopped. If the battery voltage is falling below the battery undervoltage threshold set with PNU 1426.1, Warning 11 Index 2 will appear and the booster/charger is stopped. Please, be aware that the battery is still connected, therefore the electronic of the UPS will be kept supported by the battery until it is totally depleted. To protect the battery from damage, it is suggested to open the battery switch QS9. More details for explaining this Warning 11 Index 1 in connection with Warning 10 Index 1 and 2 can be found in chapter “2.5.4 Imminent Shutdown Curve”.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 199/ 307Chapter: 6 Troubleshooting & Repair 6.3 Trouble Locating & Testing printed: 15.05.2007, 13:09

6.3 Trouble Locating & Testing To locate a problem it is essential to sum up the complete situation on site before acting to solve the trouble. PPVIS is a important part to judge the conditions of the UPS. Therefore a access to the UPS via PPVIS needs to be established (as far as this is possible, depending on the UPS condition). Here you may find a helpful guideline to locate the problem:

• Which warnings and fault are displayed by the UPS? Meaning? • Analyse the event memory. • Load dropped? • What kind of load is present? • Physical damage present? • Are there any external switches? • Mains supply ok? (within tolerance) • Where other warnings/faults displayed, before the service was called (reset

messages)? • What was done with the UPS before the problem occurred respectively before

the service arrived? Use the warning- and fault-list (chapter “6.2 Troubleshooting & Repair) from the previous chapter together with your picture of the situation on site to find a solution. Please keep in mind that, after troubleshooting, due to wrong connection of components, when the UPS is turned ON, it is possible that damages could occur to the UPS. To avoid any risk of damages a preliminary visual check is strongly required before the unit is supplied. As a start, find the main points in the list below:

• Input transient suppressor. In case of wrong connection the varistors may explode;

• Hall effect sensor current transformer (HCT). On the system schematics TA4, TA5, TA6, TA9, TA10, TA11. They must be correctly wired and with the right polarity;

• AC current transformer (CT). On the system schematics TA1, TA2, TA3, TA12, TA13, TA14. They must be correctly wired and with the right polarity;

• DC bus electrolytic capacitors. Check for the correct polarity; • Battery connector wired correctly; • KM1 coil connections. The driver signal of KM1 must be wired correctly to avoid

any possible wrong start up of the UPS;



Some actions for selected problems are given below here: Problem Possible cause Action

Mains switches turned off Switch on mains switch No mains voltage present Have mains inspected by qualified

electrician

No display No alarm (UPS switched of)

Input fuse defective or input circuit breaker tripped

Replace with fuse of same type or reset circuit breaker. If the problem persists, contact the responsible customer service representative.

Interruption of power to both, mains and bypass line present

A single differential breaker is installed upstream of the UPS and a fault in the installation earthing system caused a problem

Check the earthing system

Green “OK” LED does not illuminate, buzzer sounds at intervals

No mains voltage present UPS operation

Green “OK” LED does not illuminate when mains voltage present, buzzer sounds at intervals

Input fuse defective or input circuit breaker tripped

Replace with fuse of same type or reset circuit breaker. If the problem persists, contact the responsible customer service representative.

UPS error Verify the problem ALARM indicator illuminates, buzzer sounds continuously

Overheating Reduce ambient temperature

The fuse switch -of the battery extension(s)- is in “OPEN” position.

Move the fuse switch to the “ON” position.

Batteries are not completely charged

Verify the quality of the batteries; Charge batteries, and test backup time;

Batteries are defective Change the batteries

Backup time less than specified

Charging device is defective Replace the defective part. Wrong serial connection cable Check whether the correct cable

has been used (standard modem/null modem cables are not permissible)

Interface on the PC is being used by another process or is defective.

Check whether other software/ service is accessing the interface on the PC; try selecting a different serial interface.

No communication between UPS and PC

Interference on the data cable Lay cable differently Battery temperature shows always 20°C

The “Battery temperature channel” is not active.

Enable the battery temperature channel with PNU 1161 (137) on CU1

No backup time is shown while UPS in battery mode

Battery calculation disabled. Enable battery calculation PNU1433[409]



Problem Possible cause Action Message “Batt. low” is displayed, despite there should be quite a bit of backup time left.

Battery calculation disabled or not correctly set;

Check and/or enable the battery calculation

The oscillograph is showing missing half-waves at the inverter output.

Possible damage of the IGBT, “IGBT Driver Board” or “IGBT Interface Board” present.

Check IGBT and boards and exchange if necessary.

There was a indefinable inverter switch off

Is a MUN II adapter connected to X3 of the UPS? If yes, is the LCD firmware version lower than 2.00?

Update the LCD firmware to 2.00 or higher.



6.3.1 Rectifier examination Starting point for this test is a turned OFF rectifier. The bypass switch QS2 must remain open to avoid damages in case of phase rotations between the bypass line and the inverter line not yet checked. Start manually the rectifier using the test mode function. Check with a DVM that VDC_BUS_P and VDC_BUS_N reached the right value selected by the parameter. Test now the rectifier with the automatic start up. If a calibration is necessary use the DC calibration function on PPVIS (CU1 side). The two values measured using a DVM must be ±365V ± 2V. Verify with PPVIS and LCD the correct actual values.

6.3.2 Inverter examination (Power Circuit Test) The purpose of this test is to start the inverter in a controlled way and to be able to measure the important measures in value and polarity with a DVM and a oscillograph. With only a “low” inverter output voltage present, measurements can be done without any danger to the inverter itself, but it still can be seen if e.g. voltage in each phase is present, or all half-waves are present. After replacing inverter components, this test is also a good possibility to check if everything is working properly again. Starting point are fully charged capacitors and inverter is turned off. Connect your Notebook to the 80-NET service port X3 with a serial cable and start your PPVIS version for 80-NET. (at least 1.8.087 CHL/ 1.8.113 MG) 1. Connect a DVM between fuse FU4 and neutral N; 2. Remove the POB from the unit if present; 3. Close QS1; 4. Select the parameter input SET “[CU2] Power Circuit Test”; 5. Wait until all parameters from the UPS are loaded; 6. Change the “Target” to “RAM”;

(This is not possible with the Chloride version of PPVIS, only Masterguard version;) 7. Change PNU 51 “Access Level CU” to Expert and PNU 799 “Superservice” to

“SF4”;



8. Change/set/enter the parameters as shown and send them:

Figure 6-3: Power Circuit Test (CU2) – Parameters for Test

The PNU 125.0 “UPS operat. in manual byp.” needs to be set to “Yes”, only then the inverter will start by pressing the “Inverter start button”. PNU 783 “Test Operation” needs to be set to “On” to start the power circuit test. PNU 786.0 “Test voltage” stands for the nominal output voltage (which complies to the value 71.0 “Line voltage”), while a value of “16384” means 400Vac and “1638” means 40Vac.

9. Make sure that the switches are in the following positions: a. QS1 = closed b. QS2 = open c. QS4 = open d. QS9 = open

10. Press the “Inverter ON” button on the UPS; 11. In addition to the shown values of the PPVIS status display, measure the output

voltage L1/L2/L3 to neutral with a DVM and compare the result .



12. You can see the changes within the “Status Display” of PPVIS;

Figure 6-4: Power Circuit Test (CU2) – Status Display

13. Now you can perform your tests. E.g. slowly increase the value of parameter 786.0 “1638” “2638” or “3000” and so on. While you do so, please monitor the values on the “Status Display” and on your DVM. The three phases need to be symmetric (within tolerance of course).

14. After being done with your tests, turn off the inverter on the LCDisplay and additionally by setting the PNU125 back to “No”. Also set the PNU 783 “Test Operation” to “OFF” Don’t forget to exit the “Testmode”, to reset all PNU, to change the “Target” back to “EEPROM” and to built-in the POB again, if present.

Figure 6-5: Power Circuit Test (CU2) – Reset after Test

Note: Any appearing warning or fault message are normal, because the system is in an abnormal state.



Parameter Number



Factorysetting

UPS Operation in Manual Bypass 125 This parameter determines whether it is possible to switch on the inverter (for test purposes) even if the manual bypass is in the ON position; the “Run-in operation” warning signal is issued.

0 – 1 0

0: No Access Level 3: URL, IBS, PRU, BYP, BTR

1: Yes

Parameter



Factorysetting

Test Operation 783 Test operation (controlled operation) is conducted with no evaluation of the actual values of the mains, secure bus and inverter contactors return signal; Further, the bypass is regarded as not in place (regardless of the parameterization); the operating mode is intended for run-in operation and will trigger a warning signal; the test operation can be effectively stopped only if the inverter is switched off; at restart of the inverter, the warning signal is cancelled.

0 – 1 0

0: Off Access Level 4: URL, IBS, PRU, BYP, BTR

1: On

Parameter



Factorysetting

Test Voltage 786 Only in test operation (PNU783 = 1 “ON”) this parameter is used to change the output voltage for test purposes. 4000Hex = 16384 is equivalent to nominal value (=230V or 120V, depending on the UPS series)

0 – 18000 16384




6.3.3 IGBT examination In case of power problems within the 80-NET, it is likely that the IGBTs got damaged. Therefore one of the important actions to solve the problem, is to check and eventually replace the IGBTs.

6.3.3.1 How to check the IGBTs? “Dual-pack” IGBTs are used in the 80-NET:

Figure 6-6: IGBT dual-pack internal circuit

Figure 6-7: IGBT dual-pack layout schematic

The values given below may vary slightly from the values measured while testing an IGBT. 1. Ensure that the UPS is shut down and the battery is disconnected 2. Wait until the DC-Link capacitors discharged: verify that the bus voltage is zero

before proceeding 3. Disconnect the cables from the IGBT to be tested 4. With reference to the below table, carry out a check of the impedances across the

IGBT terminals using a DVM set to the “Diode” range 5. If the indicated values are different to those shown, or if the device fails to switch

ON/OFF then it must be regarded as unserviceable and needs to be replaced.



What to do DVM +ve connector

DVM -ve connector

DVM (mV)indication Summary

Checking IGBT1 Connect DVM across the Emitter-Collector junction

E2 C1 0L IGBT switched off in a serviceable condition

Reverse the DVM connector to check internal diode

C1 E2 0,388 Diode Forward Resistance

Reconnect DVM to original polarity

E2 C1 0L

Connect the +ve DVM connector to the gate

G1 E1 The device should turn ON

Recheck the Emitter-Collector junction

E2 C1 0,64 This low reading indicates that the device is turned on (Note it will remain ON under the present circumstances due to its internal Cge capacitance

Turn the device OFF by shorting G1 and E1

E2 C1 0L High resistance indicates that the device is OFF

Checking IGBT2 Connect DVM across the Emitter-Collector junction

C2 E1 E2 0L IGBT switched off in a serviceable condition

Reverse the DVM connector to check internal diode

E2 C2 E1 0,322 Diode Forward Resistance

Reconnect DVM to original polarity

C2 E1 E2 0L

Connect the +ve DVM connector to the gate

G2 E2 The device should turn ON

Recheck the Emitter-Collector junction

C2 E1 E2 0,445 This low reading indicates that the device is turned on (Note it will remain ON under the present circumstances due to its internal Cge capacitance

Turn the device OFF by shorting G2 and E2

C2 E1 E2 0L High resistance indicates that the device is OFF



6.3.3.2 Changing the IGBTs When you change the IGBTs please be aware of the ESD handling instructions: IGBT modules are devices sensitive to electrostatic discharge on the gates. To avoid electrostatic discharge on the gate which could destroy the IGBT-MOS gate, the module is delivered with a conductive material connecting gates and emitters electrically. This connection should be kept intact until the driver has been connected. Take precautions for conductive grounded working, while handling the IGBT. Mounting instructions

A) Demounting the old IGBT modules Before mounting the new IGBT modules, the old ones need to be removed. Be careful with demounting the IGBT interface as well as the “IGBT Driver Boards” on top of the IGBT modules. Make sure the UPS is voltage free before you start working on it. Apply safety instructions.

B) Thermal contact In order to ensure the necessary thermal contact and to obtain the thermal contact resistance values, the contact surface of the heat sink must be clean and free from dust particles. Before assembly onto the heat sink, the module base plate or the contact surface of the heat sink is to be evenly coated with a thin layer (approx. 50 μm) of a heat-conductive paste. For even distribution we recommend using a hard rubber roller or a silk screen process.

What’s important?

A IGBT module is not a ideal switch and therefore power losses occur during operation. To reduce power losses the IGBT is mounted onto a heat sink in order to dissipate the generated heat. Due to unevenness, there are little air gaps between the module base and the heat sink. These air gaps prevent the heat flow from the IGBT module to the heat sink. To avoid these air gaps the thermal paste is applied as a interface between the module and the heat sink. Its function is to flow along the shape of the interface, allowing a metal-to-metal contact where it is possible and filling the remaining gaps. Through the filled gaps, a correct heat flow is granted. Although thermal paste is more effective for transferring heat than air, it is less effective than metal components. Therefore only a thin layer - for a optimum thickness - of thermal paste must be applied to allow the metal to metal contact.

C) Module screw joint & fixation

To secure the IGBT modules, we strongly recommend using either M6 steel screws (DIN, property class 4.8) in combination with suitable washers and spring lock washers or combination screws. The mounting torque to the heat sink Ms has to be kept in accordance to the specified data sheet values. The screws must be tightened in diagonal order (crosswise) with equal torque in several steps (starting with 0,5Nm) until the specified torque value Ms has been reached. We further recommend that the screws are retightened according to the given torque value following a period of a few hours, as part of the heat-conductive paste may spread under the mounting pressure.



For power screw driver we recommend in any case to use an electric power screw driver. The specified screw parameters are better adjustable and especially the final torque will be reached more smoothly. With pneumatic systems a shock and a higher torque overshoot by reaching the final torque due to the behaviour of the clutch can be seen.

6.3.4 Capacitor Reforming If the UPS was not used for more than a year, it is necessary to reform the intermediate circuit capacitors. To reform the capacitors on the 80-NET there are two possible ways described hereafter, which could be used: A 1. The unit is connected to the distribution and is still off; 2. Remove all 6 fuses of the “Supply Interface Board” AP6; 3. Remove/open Q1; 4. Insert a DVM on the inputs of fuse FU5 and FU6; 5. Close QS1 and reopen QS1 without any delay; This should be done as quickly as

possible; 6. Wait until the capacitors are discharged again (until the voltage dropped to 0V

again); 7. Repeat step 5 and 6 about 10 times per year of not use of the UPS;

E.g. the UPS was standing 1,5 years on stock procedure should be repeated about 15 times

8. Again repeat steps 5 and 6 for the same amount of times; BUT this time, after closing QS1, wait a little bit until reopening QS1 again; Suggested time is about 2 sec., the voltage on the DVM should not rise above 600V; Also wait until the voltage dropped to 0V between each closing of QS1;

9. Insert the fuses on AP6 again and Q1; 10. A normal commissioning procedure can now be done; B 1. The unit is connected to the distribution and is still off; 2. Remove all 6 fuses of the “Supply Interface Board” AP6; 3. Remove/open Q1; 4. Insert a megohmmeter on the inputs of fuse FU5 and FU6;

This should be set to 500V 5. Close QS1 and slowly increase the voltage due to the megohmmeter; 6. Open QS1 again and wait till the voltage dropped to 0V;

Insert the fuses on AP6 again and Q1; 7. A normal commissioning procedure can now be done; Please keep in mind that this procedure of reforming the capacitors is no guarantee, that the capacitors will be ok. After such a long period of not using the unit, there is still a possibility that the capacitors could get respectively are damaged.



6.3.5 Backfeed protection

What’s important?

This function is required by the UPS safety standard. A proper test must be done. With the UPS in normal mode supplying some load (i.e.75%) and the bypass input switch open, short circuit each thyristor on the bypass line (one at a time) and verify that the status of XT4 changes to the active position.

6.3.6 EPO in & out With the UPS running in normal mode, activate the EPO command and verify the complete shut down of the machine. Verify the correct status of XT3 “EPO out”.

6.3.7 Automatic bypass test

What’s important?

This test must only be carried out with the DC-bus capacitors fully charged. Suggested load 20% - 30% of the nominal resistive load. With the main input switch QS1 already closed, close the bypass input switch QS2. After a delay of a few seconds the UPS supplies the load through the bypass line SCR. • To verify that the bypass is working correctly and there is not any phase rotation

inside the UPS, using a DVM, measure the input and output voltage of each phase vs. neutral and verify that: U1-U2 = 0V + 1V V1-V2 = 0V + 1V W1-W2 = 0V + 1V.

• Input AC bypass voltage: compare the three input voltages, measured with a DVM, with the PPVIS/LCD readings (CU2). The differences between the DVM and the PPVIS/LCD measures must be within a range of + 1%.

• Output AC voltage: compare the three input voltages, measured with a DVM, with the PPVIS/LCD readings (CU2). The differences between the DVM and the PPVIS/LCD measures must be within a range of + 1%.



6.3.8 Automatic transfer inverter to bypass and bypass to inverter The CU-Board must not close the bypass static switch, if the DC capacitors are not fully charged. Suggested sequence:

• UPS off; all switches open; • Input bypass switch QS2 and output switch QS4 closed. Logic circuits supplied,

static bypass switch open. Verify that the LCD shows the correct information; • Mains input switch QS1 closed. Precharge of the DC-link capacitors and start

up of rectifier. The output voltage must be present now. Verify that LCD shows the correct information.

• Open the bypass switch QS2 to avoid the risk of bypass/inverter commutation out of synch. Turn the inverter ON and supply the load (i.e. 50%);

• Close now the input bypass switch QS2 and wait for the synchronization of inverter to bypass;

• Check, using an external scope, the synchronization between inverter and bypass. Phase delay must be < 100µsec.

• Repeat the same test for all three phases; • Transfer the nominal load to the bypass line turning off the inverter; • Verify that the commutation has been done without any interruption and the DC

bus remains within the tolerance; • Retransfer the nominal load to inverter turning it on. • Repeat the same control as before;

6.3.9 Verify maintenance bypass switch QS3 and neutral switch QS14 • Apply the nominal power. • Turn off inverter. Load on bypass. • Close the manual bypass switch QS3. • Open the output switch QS4. • Check if bypass input voltage = output voltage; • Check with PPVIS if indicated “load on manual bypass”; • Open mains input switch QS1 and bypass switch QS2 to turn off the UPS; • Open the service neutral switch QS14; • Close the mains input switch QS1. The UPS must not precharge the DC

capacitors and a proper warning is displayed on the LCD. Open the mains input switch QS1 and close the neutral switch QS14.

• Close the mains input switch QS1 and bypass switch QS2 and wait for the complete precharge of the DC capacitors and the enabling of the bypass line;

• Close the output switch QS4; • Open the manual bypass switch QS3; • Turn on the inverter; • During all this test the load must be supplied without any interruption.



6.3.10 Temperature sensors Using the temperature function in PPVIS verify that all temperature probes are working correctly. Connect an external sensor to the input battery temperature channel. All the temperature values must be compared with a reference thermal probe.

Figure 6-8: Overview Temperature Ranges for Ambient, Battery, Rectifier, Booster/Charger, Inverter

and Neutral Booster



6.3.11 DC-Link Calibration The DC-Link voltage for the 60-200kVA must be adjusted to ± 365V. For a new UPS this is done by the factory, but after troubleshooting it may be necessary to do this. Nominal DC-Link voltage: ± 365V

Measuring point: Supply interface board AP6 For DC-Link pos. Fuse F5 to N For DC-Link neg. Fuse F6 to N

Order of calibration: 1) CU1 rectifier 2) CU2 inverter

Actual values: CU1 VDC link neg. PNU 1062.1 CU1 VDC link pos. PNU 1062.2 CU2 VDC link neg. PNU 38.1 CU2 VDC link pos. PNU 38.2 A) Procedure – scaling of measured and shown DC-Link voltage (CU1): 1. Starting point should be a UPS, which was running in online-mode for about 15

minutes with a test load of about 50%; (if test load is not available, do it in open-circuit operation)

2. Connect PPVIS and select SET “CU1 DC-Calibration”. (With this, the rectifier will be calibrated in booster mode.)

3. Set PNU 1075 “Access Level” to “Expert” and PNU 1823 “Superservice” to “Superservice 4”.

4. Measure the neg. DC-Link voltage and align the DVM reading with the value of PNU1100.19 (“VDC Link – “) to –365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about ± 1V should be adhered.

5. Measure the pos. DC-Link voltage and align the DVM reading with the value of PNU1100.20(“VDC Link + “) to +365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about ± 1V should be adhered.

6. Go back to “Superservice” = “SF 0” and “Access Level” = “Normal Operation” B) Procedure – scaling of measured and shown DC-Link voltage (CU2): 1. Starting point like CU1. 2. Connect PPVIS and select SET “CU2 DC-Calibration”. 3. Set PNU 51 “Access Level” to “Expert” and PNU 799 “Superservice” to

“Superservice 4”. 4. Measure the neg. DC-Link voltage using PPVIS PNU38.1 and align that PPVIS

reading with the value of PNU76.19 (“VDC Link – “) to –365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about ± 1V should be adhered.

5. Measure the pos. DC-Link voltage using PPVIS PNU38.2 and align that PPVIS reading with the value of PNU76.20 (“VDC Link + “) to +365V. With increasing the PNU value e.g. at about 50, the DC-Link voltage should drop at about 1,5V. A accuracy of about ± 1V should be adhered.

6. Go back to “Superservice” = “SF 0” and “Access Level” = “Normal Operation”



C) Procedure for minimizing the DC-offset at the inverter output: 1. Select SET “CU2 DC-Calibration”. 2. Set PNU 51 “Access Level” to “Expert” and PNU 799 “Superservice” to

“Superservice 4”. 3. Take the DC-offset measuring tool and connect it to L1, L2,L3 and N at the

inverter output. (Not the UPS output.) 4. Measure the DC-offset with the DVM at the measuring tool, per phase to N.

A positive offset will be cancelled with a positive entry into the PNU 76.21, 76.22 and 76.23 for “VDC out L1”, …L2” and “..L3”. (Max. steps of hundred) A accuracy of about ± 0,15V should be adhered.

5. Go back to “Superservice” = “SF 0” and “Access Level” = “Normal Operation” If the input THD is not like specified, it is possible to try to calibrate the offset of the rectifier input current. (Only if absolutely necessary!) D) Calibration of the rectifier input current offset 1. Turn off the rectifier by transferring the load on maintenance bypass and setting

“Function selection CU” (PNU 52) on CU2 to “H/W_Init URL”. 2. Connect PPVIS directly to the CU1 board via the X4 interface on the AP10

(access on the UPS roof). 3. Verify the rectifier input currents per phase with the PPVIS oscilloscope.

(Measured with TA4-TA6 to verify the DC-Offset.) (Settings: Trace Mode: Medium, Trigger Control: Single Shot) With the “Numerical View” it is possible to calculate the average of the deviation (e.g. L1= -150, L2= -16, L3= -78)

4. Connect PPVIS on the X3 interface again and select the SET “CU1 DC-Calibration”.

5. Set PNU 1075 “Access Level” to “Expert” and PNU 1823 “Superservice” to “SF 4”.6. Insert the calculated average deviation values into the corresponding PNU

1100.24, 1100.25 and 1100.26 “VEC_I_INV_OFFSET_L1”, “…L2” and “…L3” 7. Go back to “Superservice” = “SF 0” and “Access Level” = “Normal Operation”. 8. Turn on the rectifier:

Return the “Function selection CU” (PNU 52) to “Return”. 9. These value correction will be used for the rectifier control only. It is not possible

to measure the corrections, because you can not change the mains. You can only vary how the rectifier control is changing the mains. (A direct improvement can only be seen by the current harmonic distortion and it is fluctuating quite a bit.)



6.3.12 Incident Scenario Analysis – Troubleshooting

6.3.12.1 Case 1: Blown overvoltage protection on AP7 and AP33 Failure picture As soon as the inverter is starting, the overvoltage protection on AP7 “Bypass Control Board” and AP33 “Filter Board” (output) will blow. Performed tests for finding the cause Inverter power circuit test was started. Even with a low voltage set, the unit went in overvoltage on line 2. (Line 2 is a example for this case.) The “Filter Board” AP33 (output) was disconnected to ensure no more damage due to overvoltage and the overvoltage protection on the “Bypass Control Board” AP7 was also disconnected for the testing purpose. The “IGBT Interface Board” AP25, the “IGBT Driver Board” AP16 and the IGBT itself were replaced with new ones but as soon as the testing was started again the same problem reappeared on the system and the overvoltage was present on line 2 again. The “CU2-Board” AP2 and the “Interface Board” AP4 for the inverter were replaced to ensure that the signal for the inverter was not corrupt and sending the wrong firing signal to the IGBT. But again, the overvoltage on line 2 was present when starting the power circuit test.

The only other possibility was that the output choke was damaged, which is not visible.

Failure clearing The cover of the chokes L6-L8 was removed. The cable from the choke to the output fuse was damaged. A cause for this could be a loosened connection (e.g. due to transportation of the unit) which would cause overheating in the cable due to a higher resistance and therefore melting of insulation. This in turn would cause the inverter to turn up the energy due to the higher resistance and therefore cause an overvoltage on the output. After replacing the cable and making sure that all connections are done properly, the problem was cleared. Summarisation of the situation If a problem is experienced on the inverter and the IGBT is looking to be in a operating state and the IGBT driver as well as the IGBT interface board have been swapped to a another line for testing but still the fault stays present on the original line it can also be that there is something wrong with the choke, which is not visible unless the covers of the chokes are removed on one side to have a look at the chokes.



Figure 6-9: Output filter board AP33 with damage on line 2

Figure 6-10: Bypass Control Board with a damaged overvoltage protection on line 2

Figure 6-11: Damaged cable due to overheating



Figure 6-12: Output chokes with removed side cover and visible damage on the second choke

Figure 6-13: Closer look to the melted isolation



6.3.12.2 Case 2: Rectifier is not starting – Frequency 60 Hz Failure picture The unit is working within a 60Hz network. The rectifier is not starting, as well as the bypass and the inverter, despite everything seems to be ok. Performed tests for finding the cause Check if PNU 1096 (CU1) “Mains Frequency” is set to value “1” (60Hz). Do NOT set the parameter to “autodefault”. This is necessary because otherwise the mains frequency is outside tolerance and the rectifier will not start. (This should be indicated with W3i2.) Check the setting on PNU 72 (CU2) “Mains Frequency”. This value can either be set to value “4” (autodefault) or also to value “1” for 60Hz. Are the “Fan Speed Control Boards” set to 60 Hz? There is a jumper JP1 on each board that need to be set for 60Hz use of the unit. (A soldering iron is needed to set these jumpers.) Failure clearing The jumpers JP1 on the each “Fan Speed Control Board” needs to be set. The PNU 1096 “Mains Frequency” on CU1 need to be set to value “1”. The PNU 72 on CU2 can be set/left on “autodefault” (value 4) or “60Hz” (value1). (The inverter CU-board is detecting the chosen frequency from the rectifier.) Summarisation of the situation The unit will operate with 60Hz after certain settings are done.


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6.4 Replacing Procedures Enclosed you will find only a short description of replacing some parts of the 80-NET. In general the replacing of parts is described in AIF documents (Adjustment in Field). These AIF documents are supplied with the delivered board/parts. List of AIF for 80-NET (Version 10.05.2007): AIF no. Description Issue date Rev.108 15B10853G1 Interface Board 10.11.2005 1



6.4.1 CU-Board Before replacing the CU-Board please download the following pages from the original CU-Board by using PPVIS:

• Service Initialisation of CU1 and CU2 • Service Commissioning of CU1 and CU2 • DC Calibration of CU1 and CU2 • Contacts of CU2 • Service Battery Commissioning of CU1

If you need more than the mentioned parameters, download them as well. Now replace the original CU2-Board with a new one, having the firmware already flashed. The board needs to be initialised: 1. Open PPVIS and go to set “CU2 SERVICE INITIALISATION”.

Wait till all parameters are read! 2. Prepare the upload of the saved parameters:

Menu “Parameter” “Load Values” select the file DO NOT send the parameters yet! Wait till all parameters are read!

3. Select appropriate access level for the following parameters, even if these values are already set (and visible under “Actual Values”). “[ 51. 0] Access level CU4” = “Experts (3)”, “[799. 0] SF - Superservice” = “SF4 (Superservice) (4)”, “[ 52. 0] Function selection CU4” = “HW Initialisation (2)”

4. To send all the values select: Menu “Parameters” Select “Send all set values”

5. Verifying that all parameters are passed onto ‘actual value’ column. 6. Change “[ 52. 0] Function selection CU4” back to “Return (0)”;

With this, all the information will be written to the EEPROM; It can last quite a few minutes until communication will resume.

7. Change “[ 52. 0] Function selection CU4” to “Parameter Reset (1)”; With this, it is assured that all the default values for the flashed firmware are loaded.

Repeat this steps for CU1-Board, if needed. 7. Perform a power reset (switch UPS off and on again). 8. Load all the remaining pages previously saved. In case you replaced or flashed both CU-Boards, repeat steps 1. – 6. for CU1 before presuming with step 7. If the old CU-Board is dead, you have to replace the board without downloading the parameters before. After building in the new CU-Board the UPS needs to be adjusted again, for this you might take the downloaded parameter sets from the commissioning or a later service assignment of the UPS.



6.4.2 Fans Forced redundant air cooling will ensure that all the components are operated within their specification. Airflow is controlled according to load demand. The UPS is also capable of preserving normal operations even with one cooling fan stopped (due to a failure) with 70% of the output nominal load @ 25°C ambient temperature. If these conditions are not met (with one fan failed), the UPS is supplying the load through the static bypass if an overheating of the converters occurs. The failed fan condition will be immediately notified by the UPS through all the user interfaces and through the LIFE.net service. The cooling air entry is in the base and the air exit at the top of the device. The enclosure is installed with at least 500 mm of free space between the device and roof of the enclosure in order to allow cooling air to exit unhindered. To test the replaced fans, supply the load through the bypass line. The fans must run. Check for the correct rotation of all fans.

What’s important?

The double speed control must be done with the inverter ON. To check the double speed control circuit it is necessary to change the temperature threshold. Don’t forget to reset the temperature threshold to the normal/regular value.

Replacement procedure: 1.) To replace the fans, please remove the screws of the fan grid

Figure 6-14: Fan replacement –1–



2.) Remove the two screws, holding the middle plate, then remove the plate.


3.) Slowly lift up the fan grid and fan, disconnect the supply connector and remove

fan. (The cable connections of the fan are not very long, therefore be careful not to rip or break the cable plugs.) Fan can now be replaced.



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6.5 Battery Initial checks after battery connection Before connecting the external battery again, verify if the polarity before and after the external battery switch is the same. This is done by measuring the UPS battery input residual DC voltage greater than 50Vdc, and the polarity of the external battery cabinet. The battery current measured by PPVIS/LCD must be 0A. Check of battery mode Suggested load applied to the output should be 20% - 30% of nominal. Shut down mains input and compare the following measures with respect to the correspondent on PPVIS/LCD:

• battery voltage • battery current • DC bus voltage.

Repeat the test with nominal load. Recharge mode Following the previous test, with the UPS supplying nominal load, reconnect the mains input. The UPS has to switch from battery mode to normal mode without any interruption of the output voltage. Verify with a DVM the battery recharging current with respect to the correspondent value on PPVIS/LCD. The difference between those two values must be within + 5% of the tolerance range. External battery switch Remove the jumper on XT2 and verify if the warning 13 “Battery switch open” is present.

What’s important?

Please note, that the real life time of a battery is a interaction of: - the number of discharge cycles to which the battery is subjected - the average operating temperature

Therefore the mentioned life-cycle of the battery (e.g. 10 years according to EUROBAT) can vary from the real life time of the battery.



6.5.1 Battery Current Limit Setting Procedure 1. Starting point should be a connected PC and a started PPVIS. Select SET

“RECT- Service Battery Commissioning” from “Parameter Input”. 2. Check the value of parameter 1554; This value will be used to calibrate the

measurement; 3. Close QS1 – rectifier starts – and close QS9;

After a few seconds the charger will start; 4. Measure the actual battery charging current on the positive cable of the battery

with an external clip-on ammeter; Make a note; 5. Back in PPVIS on SET “RECT- Service Battery Commissioning”:

Set PNU 51 “Access Level” to “Expert” and PNU 799 “Superservice” to “Superservice 4” as well as PNU 52 “Function Selection” to “HW-Init”.

6. “Correct” PNU 1440.1 “Battery Current Display Calibration” with the result of the following: PNU1440.1 = – (Value of PNU 1554 – Measured value); e.g. PNU1440.1 = – (6,5A – 6,9A) = – ( – 0,4A)= 0,4A

7. Go back to “Function Selection” = “Return”, “Superservice” = “SF 0” and “Access Level” = “Normal Operation”;

Parameter Number


value range

Dimension

Factorysetting

Battery Current Display Calibration 1440 With this parameter a OFFSET can be added to the battery current

measurement , in order to calibrate the display measure. -10 - +10

[0,1 A]

value i01: Charging current measurement calibration 0 Access:

Level 3 URL, IBS, BYP, BTR

i02: Discharging current measurement calibration 0

Parameter



Factorysetting

Max. Charge Current 1554 With this command it is possible to change rectifier parameters. 0-78

[0,1 A] 6,5

Access: Level 3 URL, IBS, PRU, BYP, BTR



6.5.2 Removing one battery block If a defected battery block was found on the 80-NET battery system, you can remove this block and modify the charger voltage settings until you get a new battery block to replace the defective one. (Should be done as soon as possible.) But keep in mind, that the 80-NET is running on a minimum of 240 cells. Do not remove more than 1 block (6 cells), if running on 240 cells. 1. Disconnect the battery system from the UPS;

Remove the defective battery block; Reconnect the battery system to the UPS;

2. Connected your PC and a started PPVIS; Turn on QS2; Select SET “Service Battery Commissioning” from “Parameter Input”;

3. Set PNU 1075 “Access Level” to “Expert” and PNU 1823 “Superservice” to “Superservice 4” as well as PNU 1076 “Function Selection” to “HW-Init”;

4. With PNU 1629 “Battery Cell Number” you have to set the new value for cells. (usually it is the nominal number of cells minus 6 cells) “Send”;

5. Go back to “Function Selection” = “Return”, “Superservice” = “SF 0” and “Access Level” = “Normal Operation”;

6. Restart the unit;

Parameter Number



Factorysetting

Battery Cell Number 605 Amount of battery cells. 108-500 240



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7 Parallel Systems

7.1 General The 80-NET is connectable in parallel for multi-module systems (up to 8 units with same rating). The parallel connection improves reliability and/or the total output power. For the mentioned configuration a Parallel-Kit is needed, which is available as option, that could be added on at a later time. The option consists among other parts of one subassembly POB (Parallel Operation Board) and a shielded 25 conductor communication cables to the neighbouring UPS modules (closed loop ring bus). A parallel system is controlled and monitored automatically via the controller of the individual UPS blocks. These control is shared among the units (no master/slave architecture). The distribution of the load is divided equally between the individual UPS systems. This is achieved with a tolerance of less than 5% at any system load fraction (0 - 100%). The loop ring bus allow the parallel configuration to share the system load also with an interruption in the data cable (first failure proof system). When planning the system and during installation, power cables, having the same length, are to be used between the input distribution and the input terminals for the bypass and rectifier (U, V, W, - U1, V1, W1, N), as well as from the UPS outputs (U2, V2, W2, N) to the parallel connection point on the load side. Differences of 20% are allowed for power cable lengths of up to 20 m. For larger distances, cable lengths may not vary by more than 10%. Each UPS in the parallel system must have an input and output disconnector, to deenergise the UPS for maintenance work. Equally important is installation of a external manual bypass to switch off the UPSs without interrupting the mains supply for the load. It is advisable to include in planning, a connection for a test load, so that the system can be tested under (test) load. It is possible to increase the power of the system using a non-redundant parallel configuration. In this case all connected UPS units deliver the rated power and, in the event of a unit failure or overload, the system transfer the load to bypass. There are two types of parallel configuration:

• Distributed (n-times UPS + S.B.S. or just n-times UPS) mostly to increase power output;

• Centralized (n-times UPS + C.O.C.) mostly to enhance reliability not used on 80-NET!!!;


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Figure 7-1: Distributed parallel systems (modular)

Parallel UPS - Start Inverter To switch ON the inverters of the UPS in a parallel system, press and hold the inverter start button on each UPS control panel, one by one. With starting the last inverter, all the inverters in the system will switch ON and the load is supplied from the inverters. Until all the inverters have switched to ON, the process of turning on can be stopped by pressing and holding the inverter stop button on the control panel for a minimum of five seconds. Parallel UPS - Normal operation - Stop inverter To switch off the inverters of the UPS in a parallel system, press, and hold, the inverter stop button on each UPS control panel, one by one. The inverter continues to supply the load until the last inverter stop button has been pressed for five seconds, then all the inverters in the system switch off and the load is transferred to the bypass supply. Until all the inverters have switched off and the load is transferred to the bypass, the process of turning off may be reset on any, or all, of the UPS, by pressing the inverter start button on the control panel for a minimum of five seconds.


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7.2 POB Connection Before installing the POB board and any other equipment, be sure that the UPS is voltage-free to work inside. Consider the safety instructions of the technical manual. Built in the POB board and connect the board with each other: The POB needs to be placed into the electronic box slot 2 (right one). Connect the interface X110 (CU-Board) with the interface X120 (POB) of the SAME unit! … for each unit… e.g.

block 1 – CU-Board X110 ↔ block 1 – POB X120

block 2 – CU-Board X110 ↔ block 2 – POB X120 And than connect also the interface X130 (POB) with the interface X140 (POB) of the NEXT unit. e.g.

block 1 – POB X130 ↔ block 2 – POB X140

block 2 – POB X130 ↔ block n – POB X140

block n – POB X130 ↔ block 1 – POB X140 Check if the PNU 95 is still set to value “0”; this is done under “Parameter Input” Set “Optional Modules”.

Parameter Number



Factorysetting

Optional Modules Slot 2 Settings for the use of slot 2 in the Electronic Box. 0-1 0 value 0: No optional board or POB

95

CU2 Access: Level 3 URL 1: CB1 or CBP (Communication board via Profibus DP)


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7.3 S.B.S. (System Bypass Switch) A system bypass switch is available as an option for the modular parallel configuration. For parallel systems including more than two UPS, a system bypass switch must be provided within the installation, including two power disconnect switches.

Figure 7-2: SBS for Modular Parallel Configuration

A contact from the SBS needs to be connected to the EPO contact X8 of each UPS in the parallel configuration. In addition the parameter 93.1 “Input Function Contact” on the CU2 board of each UPS needs to be set to value 4 “Manual bypass switch report” and a second input contact PNU93.2 needs to be set to value 22 “System output switch open”. This must be done because the UPSs necessarily need to know if the QS5 is still closed, otherwise the inverters will not start if this would be the fact. The S.B.S. is available with the following data:

Rating: Height (mm) Width (mm) Depth (mm) Weight (kg) 400A 1780 620 858 300 800A 1780 620 858 400

1600A 1780 1020 858 500 2500A 1780 1020 858 600

Depth including front door handle; without handle 830 mm;


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7.4 Installation Before commissioning the UPSs, verify the following:

• Check that the UPSs are connected according to chapter 8 user manual “Parallel operation”. The UPSs need 3 phases and a neutral!

• Ensure that the ventilation grilles are NOT barred. • Ensure the earth connection is in place. • Ensure that the NEUTRAL connection is in place. • Ensure that the phase sequence of each UPS is connected as right-hand field. • Ensure that any external switches are in the OFF (0) position. • Ensure that any external batteries are disconnected. • Ensure the polarity of the DC voltage on the battery side is the same as that on

the UPS side. • Check the connected devices (load), if they might cause overload when the

UPS is turned on. • Ensure that the load is isolated from the output of the UPS • Carry out a thorough internal inspection

◊ Check if the internal wire connections and ribbon cables are secured ◊ Check if the PCBs are fitted securely

In addition, verify if the following installations are done for the parallel system:

• Is the POB installed in each unit on the electronic box slot 2 (right one)? • Are the POB signal cables installed/changed? Verify if correct. • Is the SBS connected with the interface X8 of each unit? (PNU 93.1

reconfigured to value 4?) • PNU 578 set to “1” for each unit? • On distributed parallel system PNU 73 need to stay on factory setting “1”.

Only for centralized parallel systems, the bypass line of the UPSs would be disabled (PNU 73 = 0).

For centralised parallel systems, disable the bypass line of the UPSs.

Parameter Number



Factorysetting

Bypass installed Bypass in place 0-1 1

73 CU2

value

0: No Access: Level 3 URL, IBS 1: Yes

Parameter



Factorysetting

System Bypass Switch installed A system bypass switch is installed. 0-1 0

578

Values: 0: No Access:

Level 3 URL, IBS 1: Yes


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7.5 Commissioning Please keep in mind that all the measuring and testing, which is done while commissioning a single unit, should also be applied here. It is recommended to commission each unit in the parallel configuration firstly as a single block, to make sure each unit is ok. For more details please refer to chapter “4 Commissioning (Single Unit)”. Commissioning for distributed parallel system with external switches:

1. Starting point: All switches/disconnector in OFF position; load is supplied via the external manual bypass (SBS QS5 is closed).

2. Close the external mains switches for each UPS. Close QS1 of each UPS.

Load is still supplied via the SBS. Rectifiers are now running.

3. Verify if each UPS is recognising the POB; (PNU 129 value must be set to “YES”) If not check if the POB is fitted correctly, check cable connections;

4. Measure the DC-link voltage of each UPS respectively check the values in the display menu under “Actual Values”. Is it within tolerance? (nominal should be +/- 365Vdc)



5. Close the external bypass switches of each UPS. Close QS2 of each UPS. Wait till the bypass SCR are switching through.

Load is still supplied via the external manual bypass (SBS). Warning 13, 22 and 32 are present. Warning 8 might be present, depending if the signal of the SBS is given to the UPS (via X8 EPO).

6. Check if the input voltage on each UPS input is the same. U (UPS1) U (UPS2) ≈ 0V (max. about 2% of nominal voltage) …

7. Before closing QS4, check if the output is voltage-free. (U2 N ≈ 0V, …) Close QS4 and the related external output switch of UPS 1. Measure if the voltage and polarity before and after QS4 of UPS 2 is the same. (To make sure there are no faulty phase connection.) If yes, close ONLY the external output switch QS4 of the UPS 2. Repeat this for the other UPSs in the parallel system… one by one.



7a. The inverter output voltage of each UPS

need to be calibrated as close as possible to 230V per phase. Open all external output switches! Turn ON the inverter of each UPS ( W26i2 appears on that UPS), after pressing the last inverter start button for 5 seconds, all the inverters will start. ( W26i2 disappears) Recalibration is done with PNU118. Calculate the average voltage value of all three phases per unit:

VL1-N + VL2-N + VL3-N Cal1 = 3 Cal1 needs to be adjusted as close as possible to 230V; What is done via entering a % into PNU118; Smallest adjustment possible is 0,1%; Range from –10% to +10%; This must be done for each unit; After all unit have been calibrated, a power reset must be done. (inv. stop QS1+QS2 off

wait a few seconds QS1+QS2 on inv. start)

Check if calibration was successful. If not, recalibrate the specific unit again; …power reset … check again …

8. Inverter still on; Close the external output switches;

Measure if there are no output currents per phase present. (If yes, recalibrate to zero.)

Measure the DC-link voltage or/and check it with the menu “Actual Values”. (nominal should be +/- 365Vdc)

9. If checks are ok, turn the inverters OFF again.



10. Before closing QS6, measure before and after the switch, if the voltage is the same. If yes, close QS6. Open QS5.

11. Measure the output currents again. (per phase, per UPS) Current splitting should be equal for each UPS.

12. Turn ON the inverters again.

Measure the output currents again. (per phase and UPS)

13. Check if the battery voltage on the UPS side of the battery switch QS9 is the same polarity as the battery voltage on the battery side of the switch QS9. (For each UPS) If ok, close QS9 of each UPS (Warning 13 disappears.) If a external battery switch is present:

Close QS9 first! Measure the battery voltage polarity before and after the still open external battery switch. If ok, than close the external battery switch.


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7.6 Maintenance While the unit is isolated from the parallel system for maintenance, but specially while returning one unit to the parallel distributed system, feel free to proceed any test, which is done while commissioning a single unit, to make sure that the unit is working properly. One unit shutdown To shutdown one unit of the parallel system for maintenance, proceed as follows: (The load will be supported by the other UPSs in the parallel distributed system.) 1. Connect your PC to the UPS and run software PPVIS; 2. Click on parameter input; 3. Select page '[CU2] Function Parallel switch-off'; 4. Press button “Target” to save the parameter changes to the RAM;

(not the EEPROM); 5. Set parameter '[ 51. 0] Access level CU' to 'expert (3)'; 6. Set parameter '[132. 0] Inverter forced ON/OFF' to 'possible (1)'; 7. Press 'Inverter Stop' on the unit to be shut down;

warning 22i2 appear; 8. Open the external output switch and open QS4 on the unit to be shut down;

in addition warning 22i1 and warning 32 appear; 9. Unplug the Parallel POB cables on that unit and link the ends together.

Fault 61 appears on the other units; reset it; 10. Open all the other switches (QS9, QS1, QS2 and QS14);

For QS14, please wait till the UPS is voltage-free; DO NOT CLOSE QS3;

11. Open the external battery fuses; (for the battery of that single unit) 12. Open the other external switches of this unit for mains and bypass input; 13. Unit is now OFF and load is supplied from remaining live units; 14. BEFORE continuing work,

measure the voltage at the battery terminal, the DC-link and at the mains input and wait until it has dropped to 0V. (This is to avoid electrical shocks.) Apply safety measures;

Parameter Number



Factorysetting

Inverter Forced ON/OFF 132

CU2 This parameter allows the inverter to be switched on/off by the “Inverter Stop” or “Inverter Start” button, when this parameter is set to 1.

0-1 0

value 0: Forced switch ON/OFF not possible

Access: Level 3 URL, IBS, PRU, BYP, BTR 1: Forced switch ON/OFF possible


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Returning one unit to ONLINE (while rest of system is supplying load) 1. Close QS14); 2. Close the external switches for mains and bypass input; 3. Close switches QS1 & QS2;

warning 13, 22 and 32 appear; 4. Wait for block diagram to appear on LCD; 5. Close QS9; warning 13 disappears;

Make sure that the external battery fuses are OPEN! 6. Close the external battery fuses; 7. Close QS4 switch; (DO NOT close the external output switch)

Test the UPS: Press the inverter start button bypass static switch is turning off!

if this is the case, turn off the inverter bypass static switch is turning on again;

Check with PPVIS if PNU129 “Parallel Operation” (on Set “Service Commissioning” is set to “YES”;

8. Unplug the linked POB cables and connect them to the corresponding plugs on the POB;

Fault 61 appears on the other units; reset it; Bypass static switch is turning off;

9. Close external output switches; 10. Press 'Inverter Start' button for 5 seconds; 11. After few seconds the unit should go online;

Parameter Number



Factorysetting

Parallel Operation This parameter is used to determine whether the requirements for parallel operation are satisfied (POB and connection cables in place).

0-1 0 129

CU2

value 0: No Access:

Level 1 never 1: Yes

Shutdown of the whole parallel distributed system 1. Press the inverter stop button on each UPS for at least 5 seconds;

after the last button, all the inverters should shutdown; 2. Close QS5 (SBS); 3. Open QS6 (SBS); 4. Shutdown each UPS like a single unit; 5. Open all external switches, if not already done;


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8 Frequency Converter 80-NET may be programmed for use as a frequency converter (50Hz in -60Hz out or 60Hz in -50Hz out), with or without a battery connected. The bypass input will be disabled and the warnings and faults, which are not appropriate for use of 80-NET as a Frequency Converter will be masked. The LCD cancels the bypass and battery symbol. In this operational mode, the data shown in the “Technical Data Table” may vary (e.g. output overload capability). Please contact Chloride Technical Support for details. If the UPS will run on 60Hz, it is necessary to set the jumper JP1 on the “Fan Speed Control Board” (AP27, AP28, AP29) accordingly.

JP1 50Hz No 60Hz Yes


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 238/ 307Chapter: 9 Optional Equipment 9.1 LIFE printed: 15.05.2007, 13:09

9 Optional Equipment Some of the options listed in this section may modify the data in the standard technical data tables (see chapter “Specification”). It may not be possible to use certain options simultaneously on the same UPS.

9.1 LIFE In order to increase the overall reliability of the system, 80-NET will be delivered with the LIFE.net communication kit, providing connection to Chloride’s LIFE.net monitoring service. LIFE.net allows the remote monitoring of the UPS through telephone lines or GSM link in order to ensure maximum reliability of the UPS throughout its operational life. The monitoring is a real 24-hour, 365 day service. The UPS is automatically dialling up the service center at defined intervals (by the customer) to provide detailed information that are analysed from the service center in order to predict near term problems. In addition, it is possible to control the UPS remotely, if this is selected. The communication of UPS data to the Chloride LIFE command center is transmitted via the integrated modem. There are 4 different kinds of UPS CALL’s to the LIFE center (the received UPS information will be collected in a database and allocated to the corresponding UPS. And if needed acted upon. The database includes all information about the UPS and end-user data, e.g. like address, contact person and so on.): • Routine Call:

The UPS calls the LIFE center at predefined intervals and is transmitting the “Event Storage”.

• Manual Call: By pressing a combination of LCDisplay keys, a manual call is activated. This possibility allows the end-user to check a valid communication with the LIFE center and also to send UPS information whenever he likes to the LIFE center.

• Buffer Full Call: In case the “Event Storage” is full with not yet (to the LIFE center) delivered events, and new space is needed for more “events”, the UPS can call the LIFE center to “drop” these information of.

• Alarm Call: In case the events indicate a immediate attention of service staff, the UPS will call the LIFE center. LIFE center staff can log into the UPS and undertake necessary analysis as well as appropriate actions to correct the anomalous UPS function.

During the call the command center shall:

• Identify the UPS connected • Request the data stored in the UPS memory since the last connection • Request real-time information from the UPS (selectable)



The service center analyses historical data and issue a regular detailed report to the customer informing him of the UPS operational condition and any critical states. The LIFE.net center allows the possibility of activating the LIFE-SMS delivery system option, where the customer may receive SMS notification which will be activated in the event of one of the following:

• Mains power failure (time period >3 minutes; configurable from 3 to 60 minutes) • Mains power recovery (fixed time of 10 minutes) • Bypass line failure (time period >10 minutes; configurable from 10 to 60

minutes) • Load supplied by bypass (fixed time of 15 minutes)

Example for a SMS:

LIFE-SMS INFO: 80NET B123456 09 – Apr – 2005 11:00:05 Mains Failure

Security is obeyed due to restrictions which allow only a user with valid PC hardware key, USER-ID and password to access data of the LIFE.net center respectively to send remote control commands to the UPS. It is also possible to parameterise the UPS, so that no remote control commands can be send to the UPS respectively will be accepted by the UPS. In case the end-user wishes to execute commands only on the LCDisplay of the UPS.

9.1.1 Installation and Configuration For a detailed description, please read the LIFE user manual and/or other technical documentations. The LIFE.net Adapter is a standard of 80-NET, therefore delivered with the 80-NET. Configuration and installation of the adapter is therefore not needed. Only a few finishing touches.

What’s important?

A connection to the UPS via PPVIS (version > 1.7) is needed for a check of the LIFE settings and further detailed UPS information.

The XS6 slot is internally connected with the X6 interface, due to this, no extra connection/cable is needed. The LIFE.net adapter is powered through the XS6 slot. A connection (telephone cable with RJ11 plug terminal) from the LIFE.net adapter to the telephone socket must be set up.



For parallel units a additional connection between the adapters must be set up using a CAT 5 shielded cable. The “MUX-In” of UPS 1 to the “MUX-OUT” of UPS 2 and so on…

Figure 9-1: LIFE connection between parallel UPSs

To check any LIFE settings, connect the notebook to service port X3 and start PPVIS. • Check if the communication setup is correct:

Menu SETUP COMMUNICATION; They should be … Baud Rate = 9600, Parity = None and Port = COM1; press ok.

• Check the clock settings: Menu SETUP OPTIONS; On the tab “General” the question “UPS Clock check?” should be answered “YES” and the “Maximum tolerable time …” should be set to “5 min”.

• Switch on the UPS. • Close and restart PPVIS. • Open the “Control Panel” of the UPS and check if a message “Correct the UPS

clock?” appears, confirm with “YES”. • Check if COM1 is setup for LIFE.net via the parameter menu “Parameter Input”

“Service Commissioning” (SET field) Look for the parameters: a) Baud rate X6 Modem/Multi RS232 – 684.1 9600 Baud b) Ser. Protocol X6 Modem/Multi RS232 – 688 LIFE c) Bus address X6 Modem/Multi RS232 – 683.1 0 (for single UPS) d) Parity Settings X6 Modem/Multi RS232 – 690 No Parity (For parallel UPSs, the bus address of the 1. UPS is “0”, of the 2. UPS is “1”, of the 3. UPS is “2” and so on…) If necessary change the parameters to the mentioned values and switch the UPS OFF and then ON again. (While changing the parameters, UPS must be in bypass mode; return to normal operation after switching the UPS on again.)

• Disable the serial communication between LCD and CU-Board; (PNU 53 “Enable parameterisation” on CU2 and PNU 1077 on CU1; set to “serial 1 + serial 2”) Because both, LCD and PPVIS, access the same LIFE data, it is necessary to disable the serial communication between LCD and CU-Board to avoid unexpected LIFE settings throughout LIFE configuration and monitoring. (Note: - Do not switch off the UPS while the LCD communication with the CU-Board is disabled. - The message “CU communication lost” will appear on the LCD.)



• Open the parameter-set “LIFE.net” from the “UPS Main Menu” and select the tab “LIFE.net configuration”. Wait for the window to update and than check/change (if necessary) the values according to this table: (confirm these values by clicking on “Update Configuration”.) Parameter Value LIFE.net “Enabled”; Serial number UPS serial number; Answer mode “Enabled”, if the telephone line is dedicated to the UPS;

“Disabled”, if the telephone line is shared with other users; Call interval To be set in accordance with the LIFE.net Watch Station

Operator; usually 1 or 2 days; Com. trials number

“5” for the maximum number of non successful calls before rescheduling the call to the next routine call date;

Modem type “User defined” for the Slot modem; First User String: E0V0Q0X0&D0&R1&K0&Y0 Second User String: \NO%C0&W0

External line prefix

“T” if the telephone is directly connected to a outside line/exchange line; “T”+ “number to connect to a exchange line” for not directly connected telephones; If dialling pauses are necessary, use a comma for each 2 seconds pause; e.g. T0, 0 to get a exchange line, 2 sec. Wait;

Preferred phone number

Type the full telephone number of the LIFE.net Watch Station to which the UPS is to be connected;

Backup phone number

Number of additional LIFE.net Watch Station telephone numbers;

Backup phone numbers (1, 2 …7)

Additional full telephone numbers of LIFE.net Watch Station; This number will only be used if the first call using the preferred number was not successful;

• Change to the tab “LIFE status” and set up the time and date of the next call and confirm with pressing the “Modify next call date”-button.

• There are 4 events that will cause the LIFE center to send out a SMS to the customer, if present and set up. These events are - Load on Bypass - Bypass failure - Mains Power Failure - Mains Power restored Each event must be enabled and the event delay time (time period of the event been present on the UPS) must be defined. To do so, select in “Parameter Input” the set “LIFE SMS Events”. Change the “LIFE parameter function” to “LIFE SMS (25)” and press “send”. The current LIFE SMS settings will be displayed. To change them, set the parameter “Setting LIFE” to “true” (and send) and change the events like you wish. (Delay time must be entered in seconds.)

• Check the installation: Press the “Manual call” button on the tab “LIFE status” of the LIFE.net submenu of the UPS Main menu. (The following status change should appear (on the left side of the “LIFE status” tab – see picture below – the respective status is green): UPS not connected UPS wait to be connected Sending LIFE date in progress – stage 1 Sending



LIFE date in progress – stage 2 Term data in progress [only if the operator has requested an online session from the LIFE Center] Master close in progress)

• Ensure the UPS does not got to “Delayed call” state, while terminating the connection. (“Delay call in” field must remain at 0:00:00) (Note: a delayed call means that LIFE data transfer has not been completed; the UPS will repeat the call after a pre-established period (minimum 5 minutes)).

• Check with the LIFE Center if all information, which were sent by the UPS were received.

• Check if the “Next scheduled call” data is correct. (Should have updated itself.) • Check if the “Routine call” is working; set the call time to one minute after the

actual LIFE date/time and wait till the UPS is calling the LIFE center; verify if the connection is passing through the states mentioned under “Manual call” earlier and also verify with the LIFE center if the call was accepted.

• Check if the “Service mode active” is set to “No” again. • Restore the serial communication between LCD and CU-Board

Figure 9-2: PPVIS – LIFE.net – UPS Main Menu – LIFE status screen



Figure 9-3: PPVIS – LIFE.net – UPS Main Menu – LIFE configuration

General notes: • The CAT5 cable may be up to 100m long • On a MUX board, the yellow LED illuminates ONLY if there is a valid INPUT signal

from another MUX board • The CAT5 cable also carries the power supply; this means, as long as one UPS is

still ON (in parallel systems) this MUX board is able to communicate with the LIFE center.

• The UPS clock is handled by the LIFE center server and therefore the UPS date and time will be synchronised with the LIFE center server and can hence be different from the PC clock were PPVIS is started.

• The execution of several actions can take several seconds. E.g. modifying the next call date, reset delayed call…



9.1.2 Troubleshooting Malfunction Cause Check/Action

The number of the LIFE center is unavailable

Call the LIFE center with a analogue telephone via the same line the UPS should use. Is the number correct? Is a prefix needed? Are dialling pauses needed (use comma for each 2 second pause)?

Modem is switched off Switch the modem on

No calls initiated by the UPS

Incorrect LIFE center number inserted

Check whether the correct prefix and telephone number including dialling pauses (commas) is inserted in the LIFE.net configuration of PPVIS.

The LIFE center does not recognise the UPS

Check if the serial number of the UPS and the one registered at the LIFE center is the same.

The LIFE.net data (in PPVIS) memorised by the UPS are corrupt

Set the timekeeper ahead by one second in order to reset the LIFE.net events; the UPS should switch to service mode automatically; Deactivate the service mode and repeat the data transfer test.

The UPS calls the LIFE center but does not transfer data

Interference on the telephone line

To decrease interference, coil the telephone connecting cable in a toroid with at least 10 turns.

The UPS does not initiate routine calls

LIFE.net time is not synchronised with the time of the timekeeper

To resynchronise the LIFE.net clock with the timekeeper it is necessary to reset LIFE.net completely; press the “Reset LIFE.net” button in the LIFE.net configuration and than reconfigure LIFE.net.

The UPS is not configured to receive calls

Ensure that the UPS is configured to receive calls; (PPVIS LIFE.net configuration: “Answer enabled”)

The telephone line is shared with other users

Ensure that other user, which may be connected in parallel with the UPS telephone line, do not respond to calls from the LIFE center.

The UPS may be busy programming the modem

Wait 10 seconds, then repeat the call from the LIFE center.

The UPS does not respond to calls initiated by the LIFE center

The UPS may be in some other “not connected” state

Wait 2 minutes, then repeat the call from the LIFE center.

The LIFE settings displayed on PPVIS do not match the operator input OR the LIFE settings reading in PPVIS are extremely slow

The communication between LCD and CU-Board has not been disabled

Make sure the parameter 53 “Enable Parameterisation” (included in set “Service Commissioning”) is set to 3.



9.1.3 PPVIS Parameters for LIFE Communication setup:

Parameter Number



Factorysetting

Bus address Bus address will be set to the selected serial interface. 0-31

683

CU2 Value: i01: Interface 1 (X3, X5) 0

i03: Interface 2 (X2) 0 i04: Interface to the rectifier (RS485) 30 Access:

Level 2 URL, IBS, PRU i05: CAN interface 0

Parameter



Factorysetting

Baud rate Setting of the Baud rate for the relevant serial interface. 0-8 value i01: Interface 1 (X3, X5) 6 i02: Charger interface 6 i03: Interface 2 (X2) 6

684

CU2

i04: BAC interface 6 PWE:

1: 300 bauds 2: 600 bauds 3: 1200 bauds 4: 2400 bauds 5: 4800 bauds 6: 9600 bauds 7: 19200 bauds Access:

Level 2 URL, IBS, PRU 8: 38400 bauds

Parameter



Factorysetting

Serial protocol X2

Selecting the required protocol at customer interface (serial interface 2); Caution: Re-parameterisation requires resetting the CU-board! *Switching between these two protocols is possible during normal UPS operation. Starting point is the protocol in the EEPROM. A change is possible for RAM only or RAM and EEPROM.

0-2 2 688

CU2

Value: 0: PPVIS (USS)* 1: PPNET/MopUPS (SNMP)

Access: Level 3 URL, IBS,PRU, BYP, BTR 2: LIFE*



Parameter



Factorysetting

Parity settings X2 (serial 2) 690

CU2 This parameter determines whether recognition of the transfer protocol (USS) at the service interface is to be modem-compatible (without parity) or modem-incompatible.

0-1 1

value 0: With parity

Access: Level 3 URL, IBS,PRU, BYP, BTR 1: Without parity

For enabling the communication between LCD and CU-Board:

Parameter Number



Factorysetting

Enabling Parameterisation Authorises the source from where parameterisation can be carried out.

0-164 163

value i0: Non i1: Serial 1 (X3+X5) i2: Serial 2 (X2)

53

CU2

i3: Serial 1 (X3+X5) + serial 2 (X2) i33: Serial 1 (X3+X5) + Profibus i34: Serial 2 (X2) + Profibus i35: Serial 1 (X3+X5) + serial 2 (X2) + Profibus i129: Serial 1 (X3+X5) + CAN i130: Serial 2 (X2) + CAN i131: Serial 1 (X3+X5) + serial 2 (X2) + CAN i161: Serial 1 (X3+X5) + Profibus + CAN i162: Serial 2 (X2) + Profibus + CAN

Access: Level 3 URL, IBS,PRU, BYP, BTR i163: Serial 1 (X3+X5) + serial 2 (X2) + Profibus + CAN

Parameter Number



Factorysetting

Enabling Parameterisation Authorises the source from where parameterisation can be carried out.

0-255 227

value Bit 0: Serial 1 (X3+X5) Bit 1: Serial 2 (X2) Bit 2: Reserved (PMU)

1077

CU1

Bit 3: Reserved (SCB) Bit 4: Reserved (PTX)

Bit 5: Profibus Bit 6: Serial 3 (Inverter CU2)

Access: Level 3 URL, IBS,PRU, BYP, BTR Bit 7: CAN


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9.2 ManageUPS NET Adapter II MUN = ManageUPS NET This option can be ordered as a package (which includes a MUN adapter, DCU software CD, serial cable and documentation; the external MUN adapter package includes also a external power supply) to ensure monitoring and control of the networked UPS through TCP/IP protocol. The adapter permits:

• UPS monitoring from NMS via SNMP • UPS monitoring from PC via a Web browser • Dispatch of different message types on occurrence of events

ManageUPS NET Adapter II, in conjunction with Software MopUPS, shall also permit safe shutdown of the operating systems. The ManageUPS NET Adapter II offers an open approach to network power management by delivering a complete set of manageability options including WEB, Telnet, and Out-Of-Band accessibility, in addition to the full featured, embedded SNMP agent. Event messages are offered as E-Mail as well as SNMP Traps. For details, see http://connectivity.chloridepower.com/ Features are:

1. DHCP Network Configuration Supports automatic configuration of IP settings using the DHCP protocol. DHCP server must be located and routable in the same LAN or WAN network as the ManageUPS NET Adapter II.

2. Multiple Network Access Methods Site power and UPS status information can be accessed securely from any computer on the customer network. View UPS system status in real time for situational decision support. Access via Telnet, SNMP, or Web Browser.

3. Network Shutdown ManageUPS includes a UPS status server and a network shutdown controller to ensure safe shutdown of multiple servers, workstations or PCs in TCP/IP network environments. ManageUPS II Network Shutdown Controller calls shutdown of computers running MopUPS NSA or RCCMD. Multiple schedules allow for sophisticated load shedding during extended outages to preserve battery autonomy for the most critical loads. ManageUPS II UPS Status Server allows computers running MopUPS Professional or MopUPS P/R to share UPS status information. This allows server group administrators to tailor their own automated power-fail- response scenarios. Both methods can be used simultaneously, and in various combinations to allow complete flexibility in tailoring sophisticated power-fail-response plans for a wide range of operating systems.

4. Security Telnet, Web, FTP, and SNMP servers can be individually disabled. SNMP server uses communities to restrict access. Web, Telnet and FTP servers have username and password access control. Web server uses basic HTTP authentication.

http://connectivity.chloridepower.com/



5. Serviceability Allows firmware or configuration files to be updated over the network for simple maintenance. Use ManageUPS DCU for simplified updating and version management.

6. Event and Data Logging ManageUPS II keeps a log file of UPS events and environment data. On-board log file viewer lets you filter records for easy analysis.

The requirements for this adapter are:

• Network connection is 10/100 BaseT (Low Power version is 10BaseT only) • Web interface requires a W3C standards compliant web browser • Automatic network configuration requires a DHCP Server • Email requires SMTP Server • SNMP trap requires SNMP trap receiver • Log functions work best with access to NTP (network time) server.

The MUN adapter is speaking the UPS internal protocol language “USS” with the UPS, this means:

if the MUN is used in slot XS3, the protocol language is set correctly, because slot XS3 is only available with USS protocol

if the MUN is used in slot XS6, the protocol language needs to be changed to USS, because the default setting for XS6 is “Life”. (PNU 688)

What is a DHCP Server?

It might be possible that your network is containing a so called DHCP server. This server is administering free IP addresses within the network. If a device within the network is requesting/requiring a IP address, the DHCP server will provide a temporary one. It also supplies the device with all the necessary information such as IP address, subnet mask, gateway, DNS server etc. This means, for installing a MUN adapter, if such a DHCP server is present, it will assign a free IP Address to your adapter. This again is excellent for a first configuration but the IP address should be changed during setup to a fixed/static IP address by the user or the person who configures it. This should be done because the provided IP address is only assigned for a limited time to the MUN adapter. Therefore it is likely that after a while for e.g. programs, connected to the adapter, point to the wrong IP address which will lead to an error.

9.2.1 ManageUPS NET Adapter II installation Hardware installation external MUN:

1. Use the green wire provided with MUN adapter to connect the earth reference screw on the MUN chassis to a chassis cover screw on the UPS secure MUN ESD grounding (earth shielding) connection to UPS.

2. Connect the “UPS Port” on ManageUPS to the RS232 UPS serial port X3 using the cable 9-pin serial cable CA-5A10S-10

3. Connect the AC/DC power supply included to an AC source (100-240Vac – 50-60Hz) that is powered by the UPS output. Connect the DC output cable from the power supply to the DC Input port on ManageUPS.



Hardware installation internal MUN:

1. Put the internal adapter into XS3 or alternatively into XS6, but remember to change the protocol language to “USS”. Install screws to secure ManageUPS ESD grounding (earth shielding) connection to UPS chassis.

Configuration: A. Connect the network with a shielded cable (Cat 5) to the 10/100Base-T connector

of the MUN adapter. Two flashing lights can be seen (orange = connection; green = data-flow) (if not, check cabling and power supply)

B. Configuring Network settings: If your network does not have a BootP server, use the serial configuration cable (CA-2A00S-02) to connect a PC/terminal (9600,8,N,1 – send Line Ends with Line Feed), to ManageUPS “Terminal Port” (TERM) to configure network and other settings. Type “CONSOLE” to access the configuration menu. See your ManageUPS user documentation for further details . Default username = “admin” Default password = “admin”

OR A. Connect the network with a shielded cable (Cat. 5) to the 10/100Base-T connector

of the MUN adapter. Two flashing lights can be seen (orange = connection; green = data-flow) (if not, check cabling and power supply)

B. Install the included DCU software either from the CD or download it from the Chloride connectivity webpage for a comfortable configuration over the network.

C. Start the DCU software and configure the new found MUN adapters via that software. See also the following chapter. More details can be found in the installation manual, application note or user manual.

Note: external MUN

If your are using both MopUPS shutdown software and ManageUPS NET Adapter II, connect the ManageUPS “UPS Port” to RS232 port on the UPS. Connect the MopUPS computer serial port to the “Terminal Port” on ManageUPS for serial communication. For network communications choose “MOPNET communications” option when installing MopUPS.

Note: internal MUN

For network communications choose “MOPNET communications” option when installing MopUPS.



9.2.2 MUN Configuration via DCU 1. When you start the program DCU, you will automatically find all discovered MUN

adapter within your network. These are shown in the left navigation tree.

Figure 9-4: MUN configuration via DCU – 1

The serial number of the MUN adapter can also be seen. This helps to identify the correct adapter, while installing more than one adapter. (Serial number can also be found on a sticker on the adapter.)

2. Click on the adapter you want to configure. Normally you should receive the following picture:


DCU is trying to access the DHCP assigned IP address of the MUN adapter. The IP address can be seen in the left bottom corner. The default username and password are both “admin”.



2b. In case the screen under 2. will not appear:

Move your mouse over the adapter you would like to configurate in the left tree. (It is not necessary to click onto the adapter.) A small yellow window will appear with the IP address of the adapter.


As the access you have from your local computer is limited due to TCP/IP regulations, there might be the need of changing the address of your computer for initial setup.

- Please make a click with the “right” mouse button onto the “Network Surroundings” symbol on your desktop and got to properties

- Please make a click with the “right” mouse button on the “LAN Connection” and go to properties

- Please click on the “Internet Protocol (TCP/IP)” and than on the button “Properties”

- Please click on “Use the following IP address” and type in a free IP address from range that can be accessed by the adapter

- Press “OK”, “OK”, “OK” … you should be back at the beginning Please change back to DCU and try to access the adapter again. Enter “admin” / “admin” for login and password.

3. The first access over the adapter to the UPS may need some time. The following screen must appear.

Figure 9-7: MUN configuration via DCU – “ManageUPS NET page”

4. The MUN adapter can be configured now. Details can be found in the user manual.



9.2.3 Environmental Sensor The environment sensor can be purchased together with a ManageUPS NET Adapter II. This bundle “ManageUPS II + E” includes a ManageUPS NET Adapter II, a auxiliary BLUE BUS connector, 1 environment sensor module and 5 meter BLUE BUS cable.

Figure 9-8: Environmental Sensor

Environment monitoring sensor provides:

• Temperature • Humidity • 3 input signals (volt free relay contacts) • 1 output signal control relay (30V / 1A)

Environment Monitoring - benefits

• Early Warning System: Detection of environment conditions that can lead to equipment failure and

downtime if left uncorrected; Sending of notifications via email and/or SNMP trap to the appropriate

destination; • Flexibility:

Three (3) input contact sensors provide for monitoring of volt-free contact status indicators provided on 3rd party devices. (Example, room or enclosure door sensors, IR sensors, water sensors, process control sensors etc. …)

One (1) output relay can be used to switch warning lights, audible horns or other signal control functions.

The environment sensor can be extended by connecting up to 15 further sensors in serial. To add more sensor modules or other BLUE BUS accessories, connect the BLUE BUS OUT to the BLUE BUS IN of the next module. Set a BLUE BUS address between 32-47 using dip switches 2-5 on the side of the sensor. Dip 1 is Terminator for last module on the bus.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 253/ 307Chapter: 8 Optional Equipment 8.3 MopUPS Shutdown and Monitoring SW printed: 15.05.2007, 13:09

9.3 Software There are different versions of software tools available for shutdown, messaging, monitoring and configuration:

MopUPS Professional MopUPS P/R for Parallel/Redundant System MopUPS NSA (Network Shutdown Agent) RCCMD (Network Shutdown Agent) ManageUPS CIO ManageUPS DCU

Figure 9-9: Principal Software Application

Definitions:

A “system” is normally composed of one or more UPS, whom act in the same way (together) upon events. According to this, if e.g. two single units on site are instructed to react differently in case of the same event or e.g. supply different sections of the customer load, they would count as two systems, because they do not work together.

(This definition is mainly for MopUPS P/R) Figure 9-10: Definition “system” (Software)

A “server” (host) is a computer system that provides services to other computing systems—called clients—over a network. In our application it is used to operate the main software for monitoring, messaging and shutdown. (That would be “MopUPS Professional” and “MopUPS P/R”.)

A “client” is a computer system that accesses other (remote) services on another computer (server) over the network. In our application, this will be the computers on which “MopUPS NSA” or “RCCMD” will be installed. These two software tools will shutdown the computers whom they are installed on, on request of the server.



A “service” is one of the two layers which compose the software MopUPS Professional and MopUPS P/R. The service layer is working in the background even if the correspondent GUI (second layer) is not open. In the background the “service” is monitoring the UPS status, it logs events, it initiates system shutdown and it sends messages in response to various situations reported by the UPS.

A “GUI” (graphical user interface) is the second layer which composes the software MopUPS Professional and MopUPS P/R. This application program starts when the user wants to view UPS status in real time, view the data or event logs for trend analysis or configure events response or communications settings for the MopUPS service. This means, that this visual part of the program (the GUI) must not be open all the time to have a operating software. Data will be collected even with a closed GUI. (“Collecting” is the job of the “service”.)

For details, see http://connectivity.chloridepower.com/ or refer to the User Manuals of these products. For installation and setup of MopUPS Professional and MopUPS P/R, please refer to the “User’s Guide and Reference”. Before starting to install MopUPS, you should prepare some data among others:

• License Key – shipped with the CD or sent via email. • IP address of each ManageUPS NET Adapter on your network – each UPS

module monitored by MopUPS will be represented by a ManageUPS NET Adapter.

• Name of the SMTP server on your network - for email alert messaging functions.

• Email address – who should receive an email alert. • Phone number and PIN number of the intended pager recipients – for pager

alert. • Correct spelling of the network names of the computers targeted for remote

shutdown and also when to shutdown – for enabling network shutdown functions.

• UPS information (output power, battery autonomy, redundancy, and so on…)

http://connectivity.chloridepower.com/



MopUPS Professional

MopUPS P/R

ManageUPS CIO

ManageUPS II /II+E MopNSA RCCMD

Messaging Yes Yes Yes Yes - - Management Yes Yes Yes Yes - - Shutdown Yes Yes No Yes - - Local Shutdown Yes Yes No - - - Remote Shutdown via MopNSA Yes Yes No Yes - -

Remote Shutdown via RCCMD Yes Yes No Yes - -

Parallel UPS / multiple UPSs No Yes Yes No - -

Single UPS Yes Yes Yes Yes - - Serial Connection Yes No No No - - Network Connection Yes Yes Yes Yes - -

Windows Yes Yes Yes No Yes Yes Unix Yes Yes No No Yes Yes Linux Yes Yes No No Yes Yes Novell Yes No No No Yes Yes



9.3.1 MopUPS Professional There are two ways of using the software in connection with a PC:

via serial connection for local shutdown via network connection for network shutdown

The main feature of the software “MopUPS Professional” is

a safe system shutdown and a useful power management.

MopUPS Professional is providing the following advantages:

network shutdown scheduled shutdown and restart event messaging event logging data logging real time viewing UPS diagnostics remote access

Features are:

1. Remote Management From any computer on your IP base network, real time information about site power, UPS status, event history and voltage logs can be viewed. Access is based on user authentication with 128bit, MD5 encryption.

2. Remote Messaging This keeps you informed anywhere. Fault and recovery messages are sent via pager, email, network or SNMP trap. A quick link back to the UPS web page (via URL) is included in the email body. Many pager systems will forward a email to your wireless pager so you can be informed anywhere.

3. Network Shutdown Networked computers on a shared power source often need a coordinated policy for emergency shutdown (e.g. the sequence for shutdown of servers is important). MopUPS Professional provides several shutdown architectures.

4. System Shutdown (Local shutdown) MopUPS Professional monitors the UPS for power fail, low battery or other events that jeopardize computer power, and initiates a controlled system shutdown.

The requirements for this software are:

• For installation a user account with Administrator rights (root login)! • For email messaging a network SMTP server on non Unix/Linux systems • For serial UPS monitoring a dedicated computer serial port • For network monitoring a TCP/IP Ethernet connection and ManageUPS NET

Adapter • X-Windows required for Unix and Linux installations.

This software supports all Chloride, Masterguard and ONEAC UPS systems. It is use in stand alone or multiple server environments with a single UPS. Therefore can be used with 80-NET.



While it is always possible to use a serial connection, it is recommended to use a ManageUPS NET Adapter II (SNMP adapter) for the communication connection between MopUPS Professional and the 80-NET, so that multiple Server Systems can communicate over Ethernet with the UPS.

Figure 9-11: MopUPS Professional Edition – Screen Host Level View

Figure 9-12: MopUPS Professional Edition – Screen “Event Options”



9.3.2 MopUPS for Parallel/Redundant Systems (MopUPS P/R) This software is designed to serve applications with particularly high availability requirements that are powered by parallel, redundant or other multi-module power systems. While 80-NET in redundant parallel configuration, MopUPS P/R monitors all connected 80-NET UPS simultaneously. Power loading, autonomy estimates, and other measures are collected from individual modules and aggregated appropriately for series or parallel redundant systems as well as centralized or distributed parallel systems configured (with or without redundancy). MopUPS P/R, which requires a ManageUPS Net Adapter II, can analyze module-specific conditions and report situations that may impact redundancy or power margin. It also serves as a central management console for multiple power systems in a facility, campus, or enterprise network environment. A ManageUPS NET Adapter II is required for MopUPS P/R, because this software can not be connected via a serial cable. Only a network connection is possible. Features are:

1. Power Management A centralized viewing utility is monitoring MopUPS services and network shutdown agents on remote systems. Easy navigation between module, system and host level provides convenient real time status viewing for situational decision support. Intuitive viewing utility graphically display power data and sort event history, log entries by date/time, event origin, or event type for simplified trend analysis.

2. Remote Messaging This keeps you informed anywhere. Fault and recovery messages are sent via pager, email or network popup. You decide which events will trigger messages for specific recipients, and how the message will be sent.

3. Network Shutdown Networked computers on a shared power source often need a coordinated policy for emergency shutdown (e.g. the sequence for shutdown of servers is important). MopUPS P/R provides several shutdown architectures.

4. Scalability Network license mechanism lets you add licensed services as needed – add modules as needed, add systems as needed. Adjust system redundancy settings from N+0 to N+N. Manage multiple dependencies when servers depend on remote storage or other network infrastructure elements powered by separate UPS.

5. System Security The security level is defined with username/password, port selection and IP filtering options, to secure remote access from the GUI or network shutdown service.



The requirements for this software are: • For installation a user account with administrator rights (root login)! • For email messaging a network SMTP server on non Unix/Linux systems • For UPS monitoring a TCP/IP Ethernet connection and a ManageUPS NET

Adapter on each UPS module that is routable from the IP of the MopUPS host system.

• X-Windows required for Unix and Linux installation.

Figure 9-13: MopUPS P/R Edition – Screen “System”

All events are logged in the event log file and messaged to the host administrator. Any event can become a “Trigger” for an “event response”. The “event response controller” manages default and user-determined event response actions. Event response settings can be viewed and configured from the “Event Settings” tab (System Level View).



9.3.3 CIO (Critical Infrastructure Overseer) The software ManageUPS CIO is the central management solution for

• Remote Site UPS • Distributed UPS • Alarm Management • Asset Management

This software is not executing any shutdown procedures/scenarios. ManageUPS CIO:

• Monitors all agents • Displays all current alarms (client) • Network navigation to all agents • Central event archive & report • HLM (higher lever manager) integration module

Infrastructure Management Tool

• Monitor UPS and related premise infrastructure devices via TCP/IP network • Centralize alarm management for many devices – many buildings – many sites • Streamline asset management tasks with standard reports of current status and

activity history • Simplify integration with higher-order management systems via „Open“ protocols

Software Application – Windows 2000/XP

• Monitors all Chloride UPS over ethernet via Chloride protocol • Monitors other devices via SNMP • Auto-discover and network search functions simplify configuration and set-up

tasks • Easy organization of UPS inventory via drag and drop folders & smart folders • Display UPS inventory via list-tree view (folders) and “Map” view custom maps /

blueprints / floor plan drawings / photos - imported as JPG files



• Displays current alarms for acknowledgement by CMS operator • CIO redundancy module verifies status and synchronized configuration of “sister”

system • Central archive of UPS event histories retrieved from agent layer. • HLM integration modules support standard protocols: Modbus over IP, SNMP • HLM integration modules offer HLM watchdog function

Figure 9-14: ManageUPS CIO – Service Information

Figure 9-15: ManageUPS CIO – Pin Map



Figure 9-16: ManageUPS CIO – Alarm View

9.3.4 Remote Shutdown Clients There are different possible ways to perform a shutdown, which cover nearly all required client/server possibilities.

9.3.4.1 MopUPS Network Shutdown Agent (NSA) A remote shutdown command to a MopUPS NSA client can only be issued from either:

• ManageUPS NET Adapter II or • MopUPS P/R.

One of these two applications monitors the UPS if a defined event occurs e.g. UPS is getting towards the “end of autonomy”. In case of a event, different server/computers can be shutdown. To shutdown these servers/computes a “Remote Shutdown Client” in this case MopUPS NSA needs to be installed on each of them. Only when this is done, the shutdown agent “MopUPS NSA” provides secure shutdown for the applications, when the server issues a signal. MopUPS NSA can be used on any routable computer on your LAN or WAN. MopUPS NSA is not UPS dependent. MopUPS NSA is a light version of the MopUPS service, which is not monitoring a UPS but listening for shutdown commands from a password authenticated remote MopUPS service. MopUPS NSA can be configured to call a script on its host computer before executing OS shutdown. The requirements for this software are:

• For installation a user account with administrator rights (root login)! • X-Windows required for Unix and Linux installation.



9.3.4.2 Remote Control Command (RCCMD) The Remote Control Command software package is a simple shutdown application used in situations where MopUPS and MopNSA are not available on that particular operating system. RCCMD listens for a signal from a defined "master" and executes a user defined shutdown sequence (typically a batch file or shell script). RCCMD can be used to shutdown an unlimited number of network routable computer systems and it covers older operating systems currently not supported by MopUPS or MopNSA. The signal sent from a "server" to a "client" is very small, and only sent once. There is no active polling or monitoring between the "client" and the "server", so no network stress is noticeable. The RCCMD software does not monitor a UPS directly. RCCMD monitors a specific TCP/IP port for a signal from a "master" device such as MopUPS software or ManageUPS NET Adapter II. UPS support is defined by the product that directly monitors the UPS, not RCCMD.


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9.3.5 Hardware Configuration Software

9.3.5.1 ManageUPS Discovery and Configuration Utility (DCU) A tool to simplify installation and configuration of ManageUPS NET Adapter II via the TCP/IP network from your MopUPS computer. ManageUPS DCU software will auto detect your ManageUPS NET Adapter II and can also search for routable ManageUPS NET Adapter II. A bookmark list of available ManageUPS II (and legacy ManageUPS) adapters can be kept for quick access to the web interface.

• Auto-find local net • Discover – search routable nets • Provides 1-click navigation to key ManageUPS configuration menus • Configure one, save settings… then upload to many • Simplifies firmware update via net

Figure 9-17: ManageUPS DCU


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9.4 Connectivity The following tables give details of the various combinations of connectivity solutions which can be used in association with 80-NET. Only one combination A-D can be used at the same time, other combinations may be possible. For port numbers, please refer to chapter “Connectivity box”. For further information please refer to CHLORIDE connectivity solutions specifications. X3 and XS3 uses USS protocol, X6 and XS6 can be set to USS or LIFE.net protocol:

Combination Connectivity Solution

Possible common connection board

interfaces Protocol A B C D

ManageUPS II Slot 1 (XS6) and Slot 2 (XS3) USS XS3 XS3 XS6 XS3 and

XS6 Slot Modem Card Slot 1 (XS6) Life.net MUX for Slot Modem Card Slot 1 (XS6) Life.net

XS6 - not available

not available

Application on Serial Interface 1 (e.g. MopUPS)

X3 (also available when ManageUPS Card fitted in XS3)

USS available available available available

Application on Serial Interface 2 (e.g. MopUPS)

X6 (not available when Slot Modem/MUX fitted in XS6)

USS not available available available available

Profibus CU-Board Box Profibus DP V1 yes yes yes yes

AS400 X7 Dry contact yes yes yes yes


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9.5 Remote alarm unit (R.A.U.) A remote alarm unit is a panel which displays the four most important messages from the UPS. It is also possible to display the summary alarm of four UPS systems instead of four single messages of one unit. You can change the messages by changing the parameterisation of the UPS output contacts on X7. (Don’t forget to rename the massage description on the panel of the R.A.U.) The connecting cable must not exceed 300m. A acoustic alarm is also present and will be activated any time an alarm situation is present. It is possible to silence the acoustic alarm by pressing the button indicated under number 8. The acoustic alarm can be deactivated completely by pressing the buttons indicated under number 7 and 8 simultaneously. To reverse this action press again. If the acoustic alarm is deactivated, alarms are not acoustically signalised. To install a R.A.U. you need the following materials:

• Remote alarm unit (supplied) • D-type male 9-pin (screw-type) connector (supplied) • Data cable from UPS to R.A.U. (5-strand, 0,5 mm²) (provided by customer) • External power supply (provided by customer)

Figure 9-18: Remote Alarm Unit (R.A.U.)

Legend 1 LED for “System normal” 8 Button “Alarm mute” 2 LED for “UPS alarm” 3 LED for “Shutdown imminent” 4 LED for “Mains failure” 5 LED for “Load on bypass”

9 LED indication of: ON OFF Acoustic alarm off

6 Free 10 Brand name 7 Button for LED test



Figure 9-19: Remote Alarm Unit - Panel

Remote alarm unit indication Indication LED

colour Single system Parallel system

System normal Green Load supplied by inverter Load supplied by the UPS UPS alarm Red Alarm status Alarm status Shutdown imminent

Red Battery at end of autonomy At least one UPS has battery at end of autonomy

Mains failure Red Primary mains failure or outside limits

At least one UPS has primary mains failed or outside limits, or the UPS stopped

Load on bypass Red Load supplied by bypass Load supplied by bypass



9.5.1 Connecting the R.A.U. The R.A.U. needs to be connected as shown in the following table. The cables (for power supply as well as for signalling) are not supplied with the R.A.U. or UPS, they need to be provided by the customer. Cable specification like described afterwards. Insert the power cable through the left opening and connect the grounding, the phase and the neutral phase to the terminal. (Be aware of the safety instructions.) For linking the signals/signal cable you need a 5-stand 0,5mm² cable. The length depends on the requirements of the customer. The one end will be connected to the M1-terminal of the R.A.U., the other end has to be connected with a D-type male 9-pin (screw-type) connector as mentioned in the table under “UPS connector X7”. This connector needs to be connected with the interface X7 on the UPS.

RAU Terminal M1 – pin

UPS Connector X7 Function

1 6 Load on Bypass 2 9 Mains failure 3 7 Imminent shutdown 4 8 System Normal / Summary Alarm 5 5 GND connection with relay common point 6 - -

Figure 9-20: Remote Alarm Unit – inside


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9.6 External Battery Circuit Breaker This option consists of a fully-rated circuit breaker, with an auxiliary contact which allows the UPS to monitor its status via a dedicated input contact. The circuit breaker is housed in a wall-mounted box and designed for use with rack-mounted battery systems. The circuit breaker also serves to protect the power cables connecting the battery to the UPS.

Figure 9-21: Battery Circuit Breaker – Electrical Drawing


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9.7 MBSM External Synchronisation This Multi Bus Synchronisation Module (MBSM) is a wall-mounted device, which generates a reference frequency that follows either the bypass supply (bypass supply within tolerance) or a quartz crystal oscillator generated signal (bypass supply out of tolerance). A normal behaviour of each UPS is to synchronise internally with the bypass supply. This is necessary to ensure a gapless switching from inverter mode to bypass mode. If not synchronised, the load could be lost, due to a short circuit or a gap while switching. So, if a UPS is working individually, no MBSM is needed, because the synchronisation of this one UPS is done by the UPS itself. If there is more than one UPS supplying the load (parallel units), than every UPS is synchronising with itself, but not with the “other” UPS(s). As long as the bypass supply is the same for each parallel UPS and there is no problem with the bypass supply, everything is still synchronised, because all parallel UPSs are individually synchronised to their own bypass supply, which is the same for all UPSs. As long as the bypass supply is within tolerance and the connected UPSs do not have any failures concerning their supplies (bypass supply, mains UPS1, mains UPS2 and so on), each UPS is behaving normal, the MBSM is not active (would not been needed). BUT if there is a problem with the bypass supply of one UPS (e.g. fuse blown), than this UPS is starting to synchronise to it’s own internal quartz crystal oscillator (and not to the bypass supply any more). As a consequence, not all the UPSs of the parallel connection are synchronised to each other any more. In case of a mains failure it is not possible (or highly unlikely) that the unsynchronised UPS switches without gap and therefore the load will be dropped. To prevent that, a MBSM is needed. The task of the MBSM is to take care that, every UPS in the parallel system is synchronised to either the bypass supply (if within tolerance) or to the quartz crystal oscillator signal of the MBSM itself (if bypass supply is out of tolerance). In case of a problem (e.g. fuse blown of one bypass line or bypass supply out of tolerance), which would cause the parallel UPSs to be unsynchronised to each other, the MBSM is forcing each UPS (via the parallel control software) to follow it’s external reference frequency to maintain synchronicity. (The UPS software control is ONLY capable of forcing the external frequency operation when the bypass supply is out of limits and the connection is active.) In case there is a failure on the MBSM or on the connection to the UPS (e.g. external frequency is not accepted or the cable is disconnected), the affected UPS will state a warning “Synchronisation Fault” on the LCDisplay of the UPS (Warning 29 in PPVIS).



Each of the connected UPSs is indicating the status of the connection on it’s LCDisplay:

• ACTIVE: means synchronisation source by external signal

• NOT ACTIVE: means synchronisation source by bypass line

• SYNCHRONISATION FAULT: means external frequency signal failure or cable disconnected

There are also two indicators on the front of the MBSM. The yellow one (L1) is indicating “SYSTEM OK” while normal operation. The red one (L2) shows if a fault is present (“SYSTEM FAULT”). A terminal block XT2 is provided, which may be used for remote indication.

9.7.1 Connecting the MBSM For more information about safety and details on installing the MBSM, please refer to the user handbook of the MBSM (10H52150PUMC). MBSM connection with up to 6 UPSs and bypass supply:

• From each UPS the AP1 (interface board) is connected with the MBSM AP1 (SSC board) via a RJ45 cable. (Synchronisation signal from MBSM to UPS)

• From each UPS the output is connected with the MBSM XT1; starting with the contacts 5/6 of the MBSM XT1 terminal for the first UPS; 7/8 for the second UPS, 9/10 for the third UPS and so on. The connection is done with a min. 1,5 mm² cable. (Output of each UPS to MBSM)

• The bypass supply is connected to the MBSM terminal XT1 (contacts 1, 2, 3 and 4) at a point where it is common to all units in the system. The connection should be done, using min. 1,5 mm² wire. (Input/ mains of each UPS to MBSM; reference signal for synchronisation)



Figure 9-22: MBSM – PCB layout

TM1 – TM6 Isolation transformer F1 – F12 Fuses F13 – F15 Fuses XT1 – Input contacts XT2 – Output contacts

AP1 To MBSM – from UPS XP1 RJ45 cable from UPS 1 to XP1 (comes from AP1 [interface board] of UPS 1) XP2 RJ45 cable from UPS 2 to XP2 (comes from AP1 [interface board] of UPS 2) XP3 RJ45 cable from UPS 3 to XP3 (comes from AP1 [interface board] of UPS 3) XP4 RJ45 cable from UPS 4 to XP4 (comes from AP1 [interface board] of UPS 4) XP5 RJ45 cable from UPS 5 to XP5 (comes from AP1 [interface board] of UPS 5) XP6 RJ45 cable from UPS 6 to XP6 (comes from AP1 [interface board] of UPS 6)

XT1 To MBSM – from UPS (mains) and a “common” bypass point 1 From Bypass Supply U Input Line 380/415V 50/60Hz 2 From Bypass Supply V Input Line 380/415V 50/60Hz 3 From Bypass Supply W Input Line 380/415V 50/60Hz 4 From Bypass Supply N Input Line 380/415V 50/60Hz 5 From UPS 1 output – L System Sync. Con. Supply 220/240V 50/60Hz 6 From UPS 1 output – N System Sync. Con. Supply 220/240V 50/60Hz 7 From UPS 2 output – L System Sync. Con. Supply 220/240V 50/60Hz 8 From UPS 2 output – N System Sync. Con. Supply 220/240V 50/60Hz 9 From UPS 3 output – L System Sync. Con. Supply 220/240V 50/60Hz 10 From UPS 3 output – N System Sync. Con. Supply 220/240V 50/60Hz 11 From UPS 4 output – L System Sync. Con. Supply 220/240V 50/60Hz 12 From UPS 4 output – N System Sync. Con. Supply 220/240V 50/60Hz 13 From UPS 5 output – L System Sync. Con. Supply 220/240V 50/60Hz 14 From UPS 5 output – N System Sync. Con. Supply 220/240V 50/60Hz 15 From UPS 6 output – L System Sync. Con. Supply 220/240V 50/60Hz 16 From UPS 6 output – N System Sync. Con. Supply 220/240V 50/60Hz



XT2 MBSM output

1 Bypass Failure K1 2 Bypass Failure K1 3 Bypass Failure K1 4 Bypass Failure K2 5 Bypass Failure K2 6 Bypass Failure K2 7 Frequency Out of Limit K3 8 Frequency Out of Limit K3 9 Frequency Out of Limit K3 10 PCB supply OK 11 PCB supply OK 12 PCB supply OK

Figure 9-23: MBSM – Connection of AP1 board



9.7.2 Configuration of the MBSM & UPS To enable the synchronisation on the UPS, parameter PNU 579 and PNU 67.1, 67.2, 67.3 and 67.4 have to changed/configured as below (darker blue/grey):

Parameter Number



Factorysetting

579 External Synchronisation enable The synchronisation with an external synchronisation signal in case

of bypass mains failure or SGS operation is enabled (corresponding parameterisation of PNU123 Backup generator provided).

0 - 1 0

Value: 0: No synchronisation with external frequency Access:

Level 3 URL, IBS 1: Synchronisation with external frequency enabled 1

Parameter Number



Factorysetting

67 External Synchronisation Settings 0-65535 value i01: PHI_OFFSET 0 i02: EXT_SYN_F_LIM 1024 i03: EXT_SYN_PHI_LIM 1024 Access:

Level 3 URL, IBS i04: DELTA_F_GAIN 4096

Offset compensation tuning The parameter PNU 67.1 has been designed to compensate the phase error between the bypass input and the inverter output signal. The value to be inserted to compensate the error is calculated applying one of the following formula: HEX input: PNU 67.1 [hex] = phase-error [°] * 0x10000 / 360 (0x10000 is 10000 in Hex format.) Decimal input: PNU 67.1 [dec] = phase-error [°] * 65536 / 360 To carry out the procedure it is necessary to use an oscilloscope between bypass input and inverter output.


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9.8 JBUS More details, installation and operation instructions can be found in the user manual. The JBUS option enables the 80-NET to be connected to a standard RS485 compatible JBUS network for a bi-directional communication between numerous devises connected to that network. The JBUS adapter is acting as communication protocol converter between the UPS and the JBUS master HOST. The 80-NET serial port is RS232 compatible and therefore an adaptor RS232/RS485 (item code 15B10518G1) is necessary. Which must be configured like follows: • J1 = 2 • SW1 = DTE • J2 = J3 = OPEN

Figure 9-24: JBUS – Details

For a trouble-free communication it is necessary to carry out the following: • cable must be twisted and shielded (e.g. 24AWG wire); • transmission line must be terminated with a 120 Ohm resistance; the terminations

should be located at the two extremes, or most distant points, of the line; • shield shall be connected to the connector chassis at one end of cable only;



Figure 9-25: JBUS

The JBUS protocol enables the master unit to communicate with the slave units (connected in the network). Communication is always initiated by the master, he is sending a request frame to which only the addressed slave will reply. The master can read or write one or more bits or words within the address range of the devices. (JBUS is supporting only N-word commands (command 3) and RTU (Remote Terminal Unit) mode but no ASCII mode. Characteristics: Baud rate 9600 (settable) Start bit 1 Data length 8 Stop bit 1 Parity None Flow control None Terminal emulation VT-100

On the MULTICOM JBUS adapter you will find 4 interfaces, COM1, COM2, COM3 and COM4 with the following signals: Pin Signal Explanation

1 DCD Carrier detect 2 RX Receive data 3 TX Transmit data 4 DTR Data terminal 5 GND Digital ground 6 DSR Data set ready 7 RTS Request to send 8 CTS Clear to send 9 RI Ring indicator

The serial cable connected to each serial port should not be longer than 10 meters.



9.8.1 Installation Set the DIP switches (on the rear panel of the MULTICOM JBUS adapter) as follows:

Switch Position Description 1 ON Don’t care 2 OFF Don’t care 3 OFF Don’t care 4 OFF Normal operation

(ON would mean “Board testing mode active”) Connect the power supply cable and switch the adapter ON using the switch present at the rear panel. Connect a PC with a serial RS232 cable to COM4 of the adapter. Use HYPERTERMINAL on your PC to configure the “F5 serial parameters” of the adapter:

• UPS type • UPS address (must match the address set in the UPS) • JBUS address (must match the JBUS slave address assigned by the JBUS

master) • UPS * COM1 baud rate (must match the baud rate set in the UPS … normally

9600) • UPS * COM2 baud rate (must match the baud rate defined by the JBUS master

… normally 9600) Connect the RS232/RS485 converter via the serial cable to the COM2 of the adapter. Connect the COM1 of the JBUS adapter via serial cable to COM port X3 of the UPS. Verify if the UPS is turned ON. Verify with PPVIS if X3 is using the USS protocol. Verify if the BUS address of the USS protocol is available at X3. Verify if the same BUS address is entered into the JBUS adapter. Verify with the terminal emulation software if the JBUS adapter and the UPS are regularly communicating.



9.8.2 Troubleshooting Malfunction Cause Check/Action

Check the power supply cable

Check if the power supply cable is really connected and verify if the input voltage is within tolerance.

Check the fuses In case the fuse is blown, replace it.

The light at the rear panel is turned off.

Check the power supply switch position

In case it is set to 0, switch it to 1

Check the connection with the UPS

The UPS must be connected to the communication port COM1. This modality must NOT be set during the normal operation. In case the DIP switch 4 is in ON position, set it to OFF position and then switch the MULITCOM JBUS adapter off and on again.

The MULTICOM JBUS adapter could be in test mode

Verify if the terminal page “Serial parameters” of the terminal emulation is the same like the UPS data.

The MULTICOM JBUS adapter cannot communicate with the UPS

Serial parameters settings are incorrect

Verify in the terminal page “Serial parameters” of the terminal emulation, if the JBUS address is correct.

Verify the JBUS address Verify if the terminal page “Serial parameters” of the terminal emulation, if the JBUS address is correct.

Verify the cabling Verify all the cabling of the JBUS kit.

The JBUS host cannot talk to the MULTICOM JBUS adapter.

Verify the communication protocol

Every UPS in JBUS has a specific structure of information, verify if the JBUS host is communicating using the same data structure definition.


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9.9 Profibus 80-NET can be connected to higher level automatic systems by installing a Profibus interface card CBP2 as option in the CU-Board technical box of the inverter (CU2). This Profibus allows communication between devices of different manufacturers without any special interface adjustment. It can be used for both high-speed time critical applications and complex communication tasks. The Profibus card is compatible to a Profibus DP V1 bus system and allows a very fast, cyclical data exchange between higher level systems such as Simatic S5, S7, Symadyn D, PC/PG and units in the field. The following information can be transmitted by the UPS:

• Status of the unit • Alarm information, information on faults • UPS output voltage levels • Control information

9.9.1 Installation Please be aware of the safety instruction given in this manual before installing the Profibus. The Profibus is only communicating with the CU2-Board (inverter), therefore it must be installed in that electronic box.

The 80-NET must be switched off. Open the front cover to access the electronic box. Put the smaller Profibus CBP2 card onto the adapter card. (The position of the

card – upper or lower mounting place – has no preference.) There are 3 slots in the electronic box of the CU2-Board (inverter):

• SLOT1 is the LEFT slot and is reserved for the CU-board. • SLOT2 is the RIGHT slot and can be used for the POB or Profibus interface

card CBP2. • SLOT3 is the MIDDLE slot and is only used for the Profibus interface card

CBP2 when slot2 is used for POB. (If not already installed, the inverter electronic box must be equipped with the

included back plane to allow communication between the installed optional boards. for details please refer to the installation manual of the Profibus.)

Connect your notebook to the service port X3 and start PPVIS. It is necessary to set parameters to make the CU-board recognize the Profibus card. Select the SET “Optional Module” under “Parameter Input”.

Switch to access level “Experts” and function selection “H/W init” Depending on the slot where you installed the Profibus card, change the settings

of “Module on Place 2” or “Module on Place 3” from “no module [or POB] (0)” to “CB1 or CBP (1)”.

With the fields “Profibus PZD5 … PDZ9 content” you can change/choose customer specified settings.

Switch to access level “Return” and function selection “Normal operation” Make a power reset.

The three LED on the front of the Profibus interface card CBP2 indicate the status of the board.



LED Status Diagnostic information Red Flashing CBP board operating; voltage supply on; Yellow Flashing Fault-free data exchange with the UPS; Green Flashing Fault-free useful data transfer via the Profibus;

What’s important?

During normal operation, all 3 LED’s repeatedly flash at the same time for the same length of time. If this is not the case, there is an exceptional condition. Please refer to the troubleshooting section of this chapter.

When the UPS is parameterised correctly, then the red and yellow LED are blinking simultaneously. If only the Red is blinking, then the UPS is not correctly configured.

Parameter



Factorysetting

CB Process Data Selection (Profibus) Defines the contents of process data produced in the Profibus message. Certain values can be selected according to customer specifications.

0 - 23

Indices: i01: PDZ5 content 1 i02: PDZ6 content 2 i03: PDZ7 content 3 i04: PDZ8 content 4

921

i05: PDZ9 content 5 Values: 0: NO Value 1: V Mains L1 [V] 2: V Mains L2 [V] 3: V Mains L3 [V] 4: V intermediate circuit [V] 5: V Output L1 [V] 6: V Output L2 [V] 7: V Output L3 [V] 8: I Output L1 [0,1 A] 9: I Output L2 [0,1 A] 10: I Output L3 [0,1 A] 11: Frequency Output [0,1 Hz] 12: Frequency Mains [0,1 Hz] 13: Output real power L1 [0,1 kW] 14: Output real power L2 [0,1 kW] 15: Output real power L3 [0,1 kW] 16: Output real power total [0,1 kW] 17: Output apparent power L1 [0,1 kVA] 18: Output apparent power L2 [0,1 kVA] 19: Output apparent power L3 [0,1 kVA] 20: Output apparent power total [0,1 kVA]

21: Batt. Hold-up time [s] 22: Batt. Current [0,1 A] Access:

Level 2 URL 23: V Batt./Cell [0,01 V]



9.9.2 Troubleshooting If one or more LEDs are constantly lit, then a fault has occurred. Malfunction Cause Check/Action ONLY red LED is flashing

UPS is not correctly configured.

Parameterise the UPS; Go back to the installation chapter and change the set “Optional Module” from “Parameter Input” accordingly;

Red LED is Off or On

No voltage supply for CBP present;

Replace the CBP or back plane board

Check the parameterisation; Yellow LED is Off or On

Data exchange with the UPS is not possible; Replace the CBP or back plane board

Profibus cable not connected; Green LED is Off or On

Transfer of useful data via Profibus is not possible; Profibus master is not initialised;

Nothing happens Wrong slot Change the slot; If you do not use a POB board, the slot for the Profibus must be SLOT2 (right one);


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 282/ 307Chapter: 9 Optional Equipment 9.10 Battery Management Modules printed: 15.05.2007, 13:09

9.10 Battery management modules With these modules connected to the battery blocks, the following enhanced battery management features are available:

• Separate “Battery Voltage Measuring Modules” (BVM) monitor the condition of each individual battery block.

• Each battery block is analysed by measuring its minimum and maximum voltage.

9.11 Dust filters This option improves the air inlet protection level from IP20 to IP40 for specific applications such as dusty environments. The filter is housed in the UPS cubicle (IP20).


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 283/ 307Chapter: 9 Optional Equipment 9.12 Special – Input Choke printed: 15.05.2007, 13:09

9.12 Special – Input Choke

9.12.1 Input Choke for 80kVA Order number: SU66510AA000AA0 Additional schematic diagrams: 10H72884

Figure 9-26: Special – Input Choke for 80kVA


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 284/ 307Chapter: 9 Optional Equipment 9.12 Special – Input Choke printed: 15.05.2007, 13:09

9.12.2 Input Choke for 120kVA Order number: SU66510BA000AA0 Additional schematic diagrams: 10H72884

Figure 9-27: Special – Input Choke for 120kVA


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 285/ 307Chapter: 10 List of Components printed: 15.05.2007, 13:09

10 List of Components

List of Component: Version from 24.01.2007. This list will not be updated!!! Please check the partner web site for the newest version.

Rating (kVA): … amount per unit …

Mod

ule*

Material description Function kVA rating

Drawing number Item code

60/80 100/120 160 200 RE IN CU-Board (CUX) AP1,

AP2 451909988311 1 1

1 1

1 1

1 1

RE IN Interface board AP3,

AP4 15H50547 15B10853G1 1 1

1 1

1 1

1 1

SMPS board AP5 15H50860 15B10860G1 1 1 1 1 Supply Interface board AP6 15H70837 15B10848G1 1 1 1 1 Bypass Control board AP7 15H70848 15B10859G1 1 1 1 1 LCDisplay AP8 15H70825 710-01970 1 1 1 1 Connectivity board AP9 15H70838 15B10849G1 1 1 1 1 In/Out board AP10 15H70844 15B10854G1 1 1 1 1

RE CB IN

IGBT Driver board AP11-AP13, AP14, AP15-AP17

15H70841 15B10851G1 3 1 3

3 1 3

3 1 3

3 1 3

RE CB IN RE CB IN RE CB IN RE

CB IN

IGBT Interface board

60/80: AP19-21, AP22-23, AP24-26

100/120: AP19-21, AP40-42AP22-23, AP43 AP24-26, AP44-46

160: AP19-21, AP40-42AP22-23, AP43,47AP24-26, AP44-46

200: AP19-21, AP40-42, AP48-50 AP22-23, AP43,47,AP24-26, AP44-46, AP51-53

15H70842 15B10857G1

3 2 3

6 3 6

6 4 6

9

4 9

Fan Speed Control board

60/80: AP27, AP28 100/120: AP27-AP29 160: AP27-AP30 200: AP27-AP30, AP54

15H70845 15B10855G1

2

3

4

5 I B O

Filter board RFI AP31 AP32 AP33

15H70849 15B10861G1 1 1 1

1 1 1

1 1 1

1 1 1

I B Varistor board AP36

AP37 15B70681 15B10671G5 1 1

1 1

1 1

1 1

DC Modem LIFE.NET AP38 15B10840G1 1 1 1 1 RE IN CB

VT1 300A 1200V IGBT 100/120: V1-3, V1'-3',

V9-11, V9'-V11' 160: V4,V4’,V4’’,V4’’’

10B44112P3412 6 6

4

RE CB IN CB RE IN RE

CB IN

VT2 400A 1200V IGBT

60/80: V1-V3, V4, V4', V9-V11,

100/120: V4, V4', V4'' 160: V1-V3, V1'-V3',

V9-11, V9'-V11' 200: V1-V3, V1'-V3', V1’’-

V3’’ V4,V4’ V4’’,V4’’’ V9-11, V9'-V11', V9’’’-V11’’’

10B44112P4312

3 2 3

3

6 6

9

4 9

BY V2 130A 1600V SCR V5, V6, V7 00B44095PT016 3 BY V2 160A 1600V SCR V5, V6, V7 00B44095PT116 3 BY V2 250A 1600V SCR V5, V6, V7 00B44095PT416 3 3





Mod

ule*

Material description Function KVA rating


60/80 100/120 160 200 DC C 4700µF 450Vdc Electr. C6,C7 10B42052P04 8 12 16 22

I B O I

B

O I

B

O I

B

O

C 100µF 275Vac

60/80: C1-C3, C1’-C3’,,C4-C5, C4’-C5’,C8-C10, C8’-C10’

100/120: C1-C3,C1’-C3’,C1’’-C3’’, C4-C5,C4’-C5’,C4’’-C5’’, C8-C10,C8’-C10’, C8’’-C10’’

160: C1-C3,C1’-C3’, C1’’-C3’’, C1’’’-C3’’’,C4-C5,C4’-C5’, C4’’-C5’’,C4’’’-C5’’’, C8-C10, C8’-C10’,C8’’-C10’’,C8’’’-C10’’’

200: C1-C3, C1’-C3’,C1’’-C3’’, C1’’’-C3’’’,C1’’’’-C3’’’’, C4-C5, C4’-C5’,C4’’-C5’’, C4’’’-C5’’’,C4’’’’-C5’’’’, C8-C10, C8’-C10’,C8’’-C10’’, C8’’’-C10’’’, C8’’’’-C10’’’’

10H42088P01

6 4 6

9

6

9

12

8

12

15

10

15

B C 30µF 470Vac C11,C12,C13 00B42004P0219 3 3 3 3 I O

DC B

DC B

DC B I O

DC B I O

C 1µF 2000Vdc

60/80: C21-C23, C24-C26, C27-C29, C32 C30, C31

100/120: C27, C30, C31

160: C27, C30,C31,C40-C41C20,C33-C35 C36-C39

200: C27, C30,C31,C40-C41C20,C33-C35 C36-C39

10B42018P2

3 3 4 2

1 2

1 4 4 4

1 4 4 4

C 330nF 1200Vdc polypropyl. 10B42059P33D1 8 15 16 22 I B

O

QS3 125A

QS1, QS2, QS3, QS4

10B46426P13C

1 1 1 1

I B

O

QS3 250A

QS1, QS2, QS3, QS4

10B46426P07C

1 1 1 1

1 1 1 1

I B

O

QS3 400A

QS1, QS2, QS3, QS4

10B46426P59C

1 1 1 1

Y

QS4 125A

60/80: QS9, QS14

100/120: QS14 160: QS14

10B46426P54C

1 1

1

1

Y QS4 160A 100/120: QS9 200: QS14 10B46426P56C 1 1

Y QS4 200A QS9 10B46426P68C 1 1





Mod

ule*



60/80 100/120 160 200 Cont. Aux (NO) 10B48317P66 1 2 2 3 I KM5 24Vdc 20A/9A KM3 10B48317P71 1 1 1 1

I KM3 230Vac 125A/80A

60/80: KM1 100/120: KM1, KM1' 160: KM1, KM1' 200: KM1,KM1',KM1’’

10B48317P72

1

2

2

3

EV1 230V 200W 1520R 50-60Hz

60/80: EV1,EV2 100/120: EV1-EV3 160: EV1-EV4 200: EV1-EV5

10B48250P2

2

3

4

5 I O

FU 200A 500V Extra Quick Blow

FU1-FU3 FU4-FU6 00B46117PC200 3

3

I O


FU1-FU3 FU4-FU6 10H46741PC250 3

3

I O


FU1-FU3 FU4-FU6 10H46117PC350 3

3

I O


FU1-FU3 FU4-FU6 10H46117PC500 3

3

B FU 250A 700V Extra Quick Blow FU7, FU8 00B46117PE250 2




FU 2A 500V Slow Blow 6.3x32

60/80: Q1, Q4-Q9 100/120: Q1, Q1', Q4-Q10 160: Q1, Q1', Q4-Q11 200: Q1, Q1', Q1’’,

Q4-Q12

10B46209P05R

7

9

10

3 9

Fuse Holder 6.3x32 switchable

60/80: for Q8, Q9, Q1 100/120: for Q8-Q10… 160: for Q8-Q11… 200: for Q8-Q11…

10B46389P01

3

5

6

8 Fuse Holder 6.3x32 tube plug for Q4-Q7 10B46347P01 4 4 4 4 I O B

TA 200A/200mA TA1-TA3, TA12-TA14, TA15-TA17

00B48018P10 3 3 3

I O B

TA 600A/200mA TA1-TA3, TA12-TA14, TA15-TA17

00B48018P30 3 3 3

3 3 3

3 3 3

I TA 200Adc TA4-TA6 10B48279P1 3 Y O I Y O

TA 200Adc

60/80: TA7, TA9-TA11

100/120: TA4-TA6, TA7, TA9-TA11

10B48279P12

1 3

3 1 3

I Y O

TA 400Adc TA4-TA6, TA7, TA9-TA11

10B48279P13 3 1 3

3 1 3



List of Component: Version from 24.01.2007. This list will not be updated!!!

Please check the partner web site for the newest version. Rating (kVA):

… amount per unit …

Mod

ule*



60/80 100/120 160 200 I O I O

L1 250µH 120A

60/80: L1-L3, L6-L8

160: L1-L3, L1’-L3’, L6-L8, L6’-L8’

10H48572P01

3 3

6 6

I O L1 170µH 180A L1-L3,

L6-L8 10H48572P02 3 3

DC L1 250µH 160A 60/80: L4 160: L4, L4’ 10H48573P01 1 2

DC L1 170µH 240A L4 10H48573P02 1

DC L1 200µH 150A L1-L3, L1’-L3’ L6-L8, L6’-L8’ 10H48572P03 12

DC L1 200µH 200A L4, L4’ 10H48573P03 2 ST 2k NTC ST1 10H46738P02 6 6 6 6 I R 8R2 125W 10% R1, R2 10H40037 10H40037P01 2 2 2 2 Mat. Filt. General Filter A30 OPTION “dust filter” 10H46746PC1 0,333 0,479 L3 ca. 0,3mH 125A OPTION “input choke” 10H48581P9008 1 L3 ca. 0,2mH 180A OPTION “input choke” 10H48581P9012 1 POB OPTION “parallel system” 451909987000 1 1 1 1

* Module explanation: BY = Bypass I = Mains Input RE = Rectifier B = Bypass Input IN = Inverter O = Output (after Inverter and Bypass) CB = Charger/Booster Y = Battery (between DC-Link and battery input contacts DC = DC-Link


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 289/ 307Chapter: 11 Circuit Diagrams printed: 15.05.2007, 13:09

11 Circuit Diagrams All relevant circuit diagrams were put into a separate document for easier handling concerning updates and file-size. The document is called “Technical Manual 80-NET Circuit Diagrams” and the document number is “10H52167TM01_CD”. You will find the following schematic diagrams in that separate manual: (drawing no. 10H72802) • Interconnection of Boards • Precharge Circuit / Input Filter • Battery Converter and Output Inverter • Fan Control Circuit • Signals • Precharge Circuit / Input Filter (120kVA only) • Rectifier (120kVA only) • Battery Converter (120kVA only) • Inverter (120kVA only) • Output Filter (120kVA only) • Fan Control Circuit (120kVA only) • Details X and Y • Precharge Circuit / Input Filter (160kVA only) • Rectifier (160kVA only) • Battery Converter (160kVA and 200kVA) • Inverter (160kVA only) • Output Filter (160kVA only) • Fan Control Circuit (160kVA only) • Precharge Circuit / Input Filter (200kVA only) • Rectifier (200kVA only) • Inverter (200kVA only) • Output Filter (200kVA only) • Fan Control Circuit (200kVA only) For schematic diagram variations because of options, please refer to: • Input Choke Option • Parallel Option


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 290/ 307Chapter: 11 Circuit Diagrams printed: 15.05.2007, 13:09

The following board diagrams can also be found: • Interface Board AP3, AP4 (drawing no. 15H70843) (item code 15B10853G1) • SMPS Board AP5 (drawing no. 15H70556) (item code 15B10860G1) • Supply Interface Board AP6 (drawing no. 15H70837) (item code 15B10848G1) • Bypass Control Board AP7 (drawing no. 15H70848) (item code 15B10859G1) • LCDisplay AP8 (item code 710-01970) • Connectivity Board AP9 (drawing no. 15H70838) (item code 15B10849G1) • In/Out Board AP10 (drawing no. 15H70844) (item code 15B10854G1) • IGBT Driver Board AP11-17 (drawing no. 15H70841) (item code 15B10851G1) • IGBT Interface Board AP19-26&AP40-53

(drawing no. 15H70842) (item code 15B10857G1) • Fan Speed Control Board AP27-30, AP54

(drawing no. 15H70845) (item code 15B10855G1) • Filter Board AP31-33 (drawing no. 15H70849) (item code 15B10861G1) • Varistor Board AP36-37 (drawing no. 15H70681) (item code 15B10671G5) • DC Modem LIFE.NET AP38 (drawing no. 15H70835) (item code 15B10840G1)


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 291/ 307Chapter: 12 Appendices 12.1 Checklists printed: 15.05.2007, 13:09

12 Appendices

12.1 Checklists The different mentioned checklists and their explanation within this manual were collected and put into a separate document for easier handling concerning updates and file-size. The document is called “Technical Manual 80-NET Checklists” and the document number is “10H52167TM01_CL”.


10H52167TM01 (IDSS/Andrea Weigert) Rev. 2.0 10.May.2007 Page 292/ 307Chapter: 12 Appendices 12.2 List of Figures printed: 15.05.2007, 13:09

12.2 List of Figures

Figure 1-1: Picture 80-NET/80kVA ...................................................................................................... 15 Figure 1-2: Picture 80-NET/120kVA .................................................................................................... 15 Figure 1-3: 80-NET single block system diagram ................................................................................ 22 Figure 1-4: Operating Mode – Online .................................................................................................. 22 Figure 1-5: Operating Mode - Battery .................................................................................................. 23 Figure 1-6: Operating Mode - Bypass.................................................................................................. 23 Figure 1-7: Operating Mode – Maintenance Bypass............................................................................ 23 Figure 1-8: Mimic panel ....................................................................................................................... 29 Figure 2-1: Drawing 80-NET 60/80kVA – IGBTs & SCRs.................................................................... 33 Figure 2-2: Drawing 80-NET 60/80kVA – Boards 1 ............................................................................. 34 Figure 2-3: Drawing 80-NET 60/80kVA – Boards 2 ............................................................................. 35 Figure 2-4: Drawing 80-NET 60/80kVA – Boards 3 ............................................................................. 36 Figure 2-5: Drawing 80-NET 60/80kVA – Boards 4 ............................................................................. 37 Figure 2-6: Drawing 80-NET 60/80kVA – Boards 5 ............................................................................. 37 Figure 2-7: Drawing 80-NET 60/80kVA – Boards 6 – Connectivity...................................................... 38 Figure 2-8: Connectivity Box – Interfaces AP10-XT5, AP10-X4 and AP10-XT6.................................. 38 Figure 2-9: Drawing 80-NET 100/120kVA – IGBTs & SCRs................................................................ 39 Figure 2-10: Drawing 80-NET 100/120kVA – Boards 1 ......................................................................... 40 Figure 2-11: Drawing 80-NET 100/120kVA – Boards 2 ......................................................................... 41 Figure 2-12: Drawing 80-NET 100/120kVA – Boards 3 ......................................................................... 42 Figure 2-13: Drawing 80-NET 100/120kVA – Boards 4 ......................................................................... 43 Figure 2-14: Drawing 80-NET 100/120kVA – Boards 6 – Connectivity.................................................. 44 Figure 2-15: Connectivity Box – Interfaces AP10-XT5, AP10-X4 and AP10-XT6.................................. 44 Figure 2-16: Drawing 80-NET 160kVA – IGBTs & SCRs....................................................................... 45 Figure 2-17: Drawing 80-NET 160kVA – Boards 1 ................................................................................ 46 Figure 2-18: Drawing 80-NET 160kVA – Boards 2 ................................................................................ 47 Figure 2-19: Drawing 80-NET 160kVA – Boards 3 ................................................................................ 48 Figure 2-20: Drawing 80-NET 160kVA – Boards 4 ................................................................................ 49 Figure 2-21: Drawing 80-NET 160kVA – Boards 6 – Connectivity......................................................... 50 Figure 2-22: Connectivity Box – Interfaces AP10-XT5, AP10-X4 and AP10-XT6.................................. 50 Figure 2-23: Drawing 80-NET 200kVA – IGBTs & SCRs....................................................................... 51 Figure 2-24: Drawing 80-NET 200kVA – Boards 1 ................................................................................ 52 Figure 2-25: Drawing 80-NET 200kVA – Boards 2 ................................................................................ 53 Figure 2-26: Drawing 80-NET 200kVA - Capacitors .............................................................................. 54 Figure 2-27: Drawing 80-NET 200kVA – Boards 3 ................................................................................ 54 Figure 2-28: Drawing 80-NET 200kVA – Boards 4 ................................................................................ 55 Figure 2-29: Drawing 80-NET 200kVA – Boards 5 ................................................................................ 55 Figure 2-30: Drawing 80-NET 200kVA – Boards 6 – Connectivity......................................................... 56 Figure 2-31: Connectivity Box – Interfaces AP10-XT5, AP10-X4 and AP10-XT6.................................. 56 Figure 2-32: Communication Input/Output ............................................................................................. 57 Figure 2-33: Picture of CU-Board with explanation of parts ................................................................... 59 Figure 2-34: AP1 CU1 Rectifier CU-Board............................................................................................. 61 Figure 2-35: AP2 CU2 Inverter CU-Board.............................................................................................. 63 Figure 2-36: AP3, AP4 Interface Board ................................................................................................. 64 Figure 2-37: AP5 SMPS Board .............................................................................................................. 66 Figure 2-38: AP6 Supply Interface Board .............................................................................................. 69 Figure 2-39: AP7 Bypass control Board................................................................................................. 70 Figure 2-40: AP8 LCDisplay ................................................................................................................ 71 Figure 2-41: AP9 Connectivity Board..................................................................................................... 72 Figure 2-42: AP10 In/Out Board ............................................................................................................ 73 Figure 2-43: AP11- AP17 IGBT Driver Board ........................................................................................ 74 Figure 2-44: AP19-22, AP23, AP24-26 IBT Interface Board.................................................................. 75 Figure 2-45: AP27-30 Fan Speed Control Board ................................................................................... 76 Figure 2-46: AP31-AP33 Filter Board .................................................................................................... 77 Figure 2-47: AP36-AP37 Varistor Board................................................................................................ 77 Figure 2-48: Current Thyristor Rectifier ................................................................................................ 78 Figure 2-49: Current IGBT Rectifier ...................................................................................................... 78 Figure 2-50: IGBT diagram .................................................................................................................... 79 Figure 2-51: Rectifier – Overview .......................................................................................................... 81 Figure 2-52: Voltage and Current for a capacitor................................................................................... 83 Figure 2-53: Precharge.......................................................................................................................... 84 Figure 2-54: Rectifier current-walk-in..................................................................................................... 86 Figure 2-55: Charging method: 1-stage charging with pause ................................................................ 88 Figure 2-56: Charging method: 1-stage charging without pause ........................................................... 88



Figure 2-57: Charging method: 2-stage charging with pause ................................................................ 88 Figure 2-58: Charging method: 2-stage charging without pause ........................................................... 89 Figure 2-59: Booster/Charger 80-NET (80kVA) ..................................................................................... 90 Figure 2-60: Boost-Mode functional sketch............................................................................................ 91 Figure 2-61: Buck Mode (Charger Mode) functional sketch................................................................... 92 Figure 2-62: Battery status during reduction of the commercial AC source. .......................................... 93 Figure 2-63: Automatic power upgrade.................................................................................................. 97 Figure 2-64: Overview Inverter .............................................................................................................. 98 Figure 2-65: Pulse Width Modulation................................................................................................... 102 Figure 2-66: Static Bypass Overview................................................................................................... 105 Figure 2-67: Overview interfaces connectivity ..................................................................................... 108 Figure 2-68: Slot XS3 .......................................................................................................................... 108 Figure 2-69: Slot XS6 .......................................................................................................................... 108 Figure 2-70: Interface X3 ..................................................................................................................... 109 Figure 2-71: Interface X3 and slot XS3 interaction .............................................................................. 110 Figure 2-72: Interface X6 ..................................................................................................................... 111 Figure 2-73: Interface X7 – PRESET Siemens .................................................................................... 113 Figure 2-74: Interface X7 – PRESET IBM AS400................................................................................ 114 Figure 2-75: Interface XT1................................................................................................................... 116 Figure 2-76: Interface XT2................................................................................................................... 117 Figure 2-77: Interface XT3................................................................................................................... 117 Figure 2-78: Interface XT4................................................................................................................... 118 Figure 2-79: Interface AP10-XT6 ......................................................................................................... 118 Figure 2-80: Interface AP10-XT5 ......................................................................................................... 119 Figure 2-81: Interface AP10-X4 ........................................................................................................... 120 Figure 2-82: Battery Calculation – Constant Power Discharge Table of Battery Manufacturer Data

Sheet ............................................................................................................................... 133 Figure 2-83: Battery re-calibration of discharging characteristics ........................................................ 136 Figure 2-84: Battery discharging characteristics .................................................................................. 138 Figure 2-85: Charging method: 1-stage charging with pause .............................................................. 139 Figure 2-86: Charging method: 1-stage charging without pause ......................................................... 139 Figure 2-87: Charging method: 2-stage charging with pause .............................................................. 140 Figure 2-88: Charging method: 2-stage charging without pause ......................................................... 140 Figure 2-89: Initial Charging................................................................................................................. 143 Figure 2-90: Temperature-dependent charging voltage correction ...................................................... 144 Figure 2-91: Imminent Shutdown Curve ↔ End of Discharge Curve.................................................. 147 Figure 2-92: LCD page structure ......................................................................................................... 152 Figure 2-93: Flash Mode Setting – Jumper.......................................................................................... 156 Figure 2-94: C16X Flasher................................................................................................................... 157 Figure 2-95: C16X Flasher Settings..................................................................................................... 157 Figure 2-96: 44F Block Terminal for interface X120 an CU-Board....................................................... 160 Figure 2-97: Direct connecting cable from PC to X120 in CU-Board ................................................... 160 Figure 2-98: Pin connection for the direct connecting cable from PC to X120 in CU-Board ................ 161 Figure 2-99: Hitachi Flash Development Toolkit Installation ................................................................ 162 Figure 2-100: Hitachi Flash Development Toolkit .................................................................................. 163 Figure 2-101: Hitachi Flash Development Toolkit – New Workspace .................................................... 163 Figure 2-102: Hitachi Flash Development Toolkit – Project Name......................................................... 163 Figure 2-103: Hitachi Flash Development Toolkit – Choose Device ...................................................... 164 Figure 2-104: Hitachi Flash Development Toolkit – Communication Port .............................................. 164 Figure 2-105: Hitachi Flash Development Toolkit – Device Settings ..................................................... 165 Figure 2-106: Hitachi Flash Development Toolkit – Connection Type ................................................... 165 Figure 2-107: Hitachi Flash Development Toolkit – Programming Options ........................................... 166 Figure 2-108: Hitachi Flash Development Screen ................................................................................. 166 Figure 2-109: Hitachi Flash Development Screen – Add Files to Project .............................................. 167 Figure 2-110: Hitachi Flash Development Screen – Add Files to Project 2 ........................................... 167 Figure 2-111: Hitachi Flash Development Screen – Open .mot file ....................................................... 167 Figure 2-112: Hitachi Flash Development Screen – Connect to Device ................................................ 168 Figure 2-113: Hitachi Flash Development Screen – Download.............................................................. 168 Figure 4-1: Guided Procedure – Starting Screen for Procedure “Manual Bypass” ............................ 172 Figure 4-2: Guided Procedure – Start and Stop Symbol.................................................................... 172 Figure 6-1: Overload capacity............................................................................................................ 197 Figure 6-2: Imminent Shutdown Curve – End of Discharge Curve .................................................... 198 Figure 6-3: Power Circuit Test (CU2) – Parameters for Test ............................................................. 203 Figure 6-4: Power Circuit Test (CU2) – Status Display...................................................................... 204 Figure 6-5: Power Circuit Test (CU2) – Reset after Test ................................................................... 204 Figure 6-6: IGBT dual-pack internal circuit......................................................................................... 206 Figure 6-7: IGBT dual-pack layout schematic .................................................................................... 206 Figure 6-8: Overview Temperature Ranges for Ambient, Battery, Rectifier, Booster/Charger, Inverter

and Neutral Booster......................................................................................................... 212



Figure 6-9: Output filter board AP33 with damage on line 2...................................................................... 216 Figure 6-10: Bypass Control Board with a damaged overvoltage protection on line 2......................... 216 Figure 6-11: Damaged cable due to overheating................................................................................. 216 Figure 6-12: Output chokes with removed side cover and visible damage on the second choke ........ 217 Figure 6-13: Closer look to the melted isolation................................................................................... 217 Figure 6-14: Fan replacement –1–....................................................................................................... 221 Figure 6-15: Fan replacement –2–....................................................................................................... 222 Figure 6-16: Fan replacement –3–....................................................................................................... 222 Figure 7-1: Distributed parallel systems (modular) ............................................................................ 227 Figure 7-2: SBS for Modular Parallel Configuration ........................................................................... 229 Figure 9-1: LIFE connection between parallel UPSs ......................................................................... 240 Figure 9-2: PPVIS – LIFE.net – UPS Main Menu – LIFE status screen............................................. 242 Figure 9-3: PPVIS – LIFE.net – UPS Main Menu – LIFE configuration ............................................. 243 Figure 9-4: MUN configuration via DCU – 1....................................................................................... 250 Figure 9-5: MUN configuration via DCU – 2....................................................................................... 250 Figure 9-6: MUN configuration via DCU – 3....................................................................................... 251 Figure 9-7: MUN configuration via DCU – “ManageUPS NET page”................................................. 251 Figure 9-8: Environmental Sensor ..................................................................................................... 252 Figure 9-9: Principal Software Application ......................................................................................... 253 Figure 9-10: Definition “system” (Software) ......................................................................................... 253 Figure 9-11: MopUPS Professional Edition – Screen Host Level View............................................... 257 Figure 9-12: MopUPS Professional Edition – Screen “Event Options” ................................................ 257 Figure 9-13: MopUPS P/R Edition – Screen “System”......................................................................... 259 Figure 9-14: ManageUPS CIO – Service Information .......................................................................... 261 Figure 9-15: ManageUPS CIO – Pin Map............................................................................................ 261 Figure 9-16: ManageUPS CIO – Alarm View....................................................................................... 262 Figure 9-17: ManageUPS DCU ........................................................................................................... 264 Figure 9-18: Remote Alarm Unit (R.A.U.) ............................................................................................ 266 Figure 9-19: Remote Alarm Unit - Panel .............................................................................................. 267 Figure 9-20: Remote Alarm Unit – inside ............................................................................................. 268 Figure 9-21: Battery Circuit Breaker – Electrical Drawing.................................................................... 269 Figure 9-22: MBSM – PCB layout........................................................................................................ 272 Figure 9-23: MBSM – Connection of AP1 board.................................................................................. 273 Figure 9-24: JBUS – Details ................................................................................................................ 275 Figure 9-25: JBUS ............................................................................................................................... 276 Figure 9-26: Special – Input Choke for 80kVA..................................................................................... 283 Figure 9-27: Special – Input Choke for 120kVA................................................................................... 284


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12.3 List of Parameters List of important parameters, described in detail on corresponding page.

Parameter 0053 – Enabling Parameterisation............................................................................................................246 0058 – Fast Off .........................................................................................................................................121 0067 – External Synchronisation Settings ................................................................................................274 0071 – Line Voltage....................................................................................................................................99 0072 – Mains Frequency ..........................................................................................................................100 0073 – Bypass Installed.................................................................................................................... 100, 230 0074 – Separate lines ...............................................................................................................................100 0080 – Output contacts.............................................................................................................................121 0081 – Function of Output Contacts .........................................................................................................122 0082 – Negated Output Contacts .............................................................................................................125 0087 – On Delay of Output Contacts ........................................................................................................125 0088 – Off Delay of Output Contacts ........................................................................................................126 0090 – On Delay of Input Contacts...........................................................................................................128 0091 – Off Delay of Input Contacts...........................................................................................................128 0093 – Function of Input Contacts ............................................................................................................126 0094 – Negated Input Contacts ................................................................................................................128 0095 – Optional Modules Slot 2................................................................................................................228 0110 – Mains Failure Warning Delay........................................................................................................129 0113 – Battery Pre-warning Voltage Level................................................................................................129 0115 – Asynchronous Transfer.................................................................................................................104 0116 – Bypass Delay ................................................................................................................................104 0117 – Battery Stored-Energy Time..........................................................................................................129 0118 – V Correction ..................................................................................................................................100 0125 – UPS Operation in Manual Bypass.................................................................................................205 0129 – Parallel Operation .........................................................................................................................236 0132 – Inverter Forced ON/OFF ...............................................................................................................235 0511 – Time Discharge Characteristic .............................................................................................. 135, 148 0513 – Shutdown Voltage Table....................................................................................................... 136, 148 0567 – Control of Overload Reaction..........................................................................................................26 0578 – System Bypass Switch installed....................................................................................................230 0579 – External Synchronisation Enable ..................................................................................................274 0590 – Message Configuration .................................................................................................................148 0591 – Delta Shutdown Imminent .............................................................................................................148 0605 – Battery Cell Number......................................................................................................................225 0683 – Bus Address..................................................................................................................................245 0684 – Baud Rate.....................................................................................................................................245 0688 – Serial Protocol X2 .........................................................................................................................245 0690 – Parity Settings X2 .........................................................................................................................246 0783 – Test Operation ..............................................................................................................................205 0786 – Test Voltage..................................................................................................................................205 0921 – CB Process Data Selection (Profibus) ..........................................................................................280 1049 – No. of Mains Failure Total .............................................................................................................177 1077 – Enabling Parameterisation............................................................................................................246 1158 – Rectifier hold-off delay ....................................................................................................................86 1159 – Half VDC link minimal Voltage ........................................................................................................85 1161 – Battery Temperature Channel active ............................................................................................144 1166 – Current-walk-in time........................................................................................................................86 1174 – Converter Temperature Threshold..................................................................................................82 1426 – Minimal Battery Voltage .......................................................................................................... 94, 146 1433 – Battery Calculation Active .............................................................................................................135 1436 – Manual/Automatic Charging..........................................................................................................130 1438 – Automatic Battery Test..................................................................................................................145 1440 – Battery Current Display Calibration...............................................................................................224 1534 – Power Discharge Characteristic............................................................................................ 135, 137 1535 – Time Discharge Characteristic .............................................................................................. 135, 137 1536 – Battery Calibration Values ............................................................................................................136 1540 – Temperature Factor ......................................................................................................................144 1547 – Charging Pause Duration..............................................................................................................141 1554 – Max. Charge Current ............................................................................................................ 141, 224 1555 – End-of-Charging Voltage 1 ...........................................................................................................141 1557 – Battery Temperature Limits...........................................................................................................129


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1578 – Battery Recharge Time .................................................................................................................141 1584 – Mains Failure Statistics .................................................................................................................178 1585 – Total Duration of Mains Failures ...................................................................................................178 1617 – Charging Method .................................................................................................................... 89, 139 1618 – Initial Charge On...........................................................................................................................143 1619 – Initial Charge Duration ..................................................................................................................143 1620 – Initial End-of-Charge Voltage........................................................................................................143 1622 – End-of-Charging Voltage 2 ...........................................................................................................141 1624 – Battery Current Limit On-Time ......................................................................................................141 1625 – Current V2 V1...........................................................................................................................142 1626 – Max. Stage 2 Time........................................................................................................................142 1629 – Battery Cell Number......................................................................................................................142 1629 – Cell Number ............................................................................................................................ 95, 135


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12.4 List of Abbreviations µP Microprocessor ABC Advanced Battery Care AC Alternating Current AC CT Alternating Current Current Transformer AIF Adjustment in Field BVM Battery Voltage Measuring (Module) BTR UPS mode [Inverter] (german: USV-Betrieb [WR])

BYP UPS off [Inverter off, Bypass mode possible] (german: USV aus [WR aus, Bypass-Betrieb möglich])

COC Common Output Cubicle CU Control Unit DC Direct Current DCM Double Conversion Mode DCU Discovery and Configuration Utility DHCP Dynamic Host Configuration Protocol DIM Digital Interactive Mode DPR Dual Port RAM DSP Digital Signal Processor DVM Digital Volt Meter EEPROM Electrically Erasable and Programmable Read Only Memory EPO Emergency Power Off EPROM Erasable and Programmable Read Only Memory IBS Commissioning (german: Inbetriebsetzung) ICT IGBT Isolated Gate Bipolar Transistor LCD Liquid Crystal Display LED Light Emitting Diode LIFE Long distance Insurance For Energy MOSFET Metal-Oxide-Semiconductor Field-Effect Transistor MUN ManageUPS NET NiCd Nickel-cadmium (battery) PFC Power Factor Correction PLL Phase-Locked Loop PRU Testing (german: Prüfen) SBS System Bypass Switch SIB Service Information Bulletin SLA Sealed Lead-Acid (battery) SNMP Simple Network Management Protocol THD Total Harmonic Distortion TTL Transistor-Transistor-Logic UPS Uninterruptible Power Supply URL Bootstrap (german: Urladen)

USS protocol Universal Serial interface protocol (Siemens AG trade mark) German: Universelles Serielles Schnittstellenprotokoll

VLA Vented Lead Acid VRLA Value-Regulated Lead-Acid


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12.5 Glossary

Display The control panel comprises a liquid crystal, alphanumeric display, which provides diagnostic and operational information about the UPS.

Electronic Bypass QS2 A thyristor switch which connects the load directly to mains in event of inverter overload; also referred to as a static switch or static bypass.

Qualified Personal Personnel who are familiar with the installation, assembly, commissioning and operation of the product and are qualified to carry out the respective activities.

Service Bypass QS3 The switch that allows continuous supply to the load via the bypass input mains during maintenance work; also referred to as the maintenance bypass.

PLL

In electronics, a phase-locked-loop (PLL) is a closed-loop feedback control system that maintains a generated signal in a fixed phase relationship to a reference signal. Since an integrated circuit can hold a complete phase-locked loop building block, the technique is widely used in modern electronic devices, with signal frequencies from a fraction of a cycle per second up to many gigahertz.

Dynamic line support Due to high current on the inverter output, the bypass line will be put in parallel to the mains line to share the current

DHCP

Within a network, there might be an so called DHCP server which gives currently free IP Addresses to devices which requires one. This DHCP supplies the device with all the necessary information such as IP Address, Subnet Mask, Gateway, DNS Server etc. So if you have such a DHCP server it will assign a free IP Address to your adapter which is excellent for first configuration but it should be changed during setup to fixed/static IP Address by the user or the person who configures it. It should be changed because those DHCP leases are only for a certain amount of time, which might change after a while, and if you have programs connected to the adapter, they will point to the wrong IP address which will lead to an error.


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12.6 Index

1 1-Stage Charging With Charging Pause ...................... 88, 139 1-Stage Charging Without Charging Pause ................. 88, 139

2 2-Stage Charging With Charging Pause ...................... 88, 139 2-Stage Charging Without Charging Pause ................. 89, 139

A AC CT..................................................... 82, 99, 184, 196, 199 AC Reading Circuits Current ................................................ 64 AC Reading Circuits Voltage................................................ 64 Accumulators

NiCd......................................................................... 93, 140 Sealed, Low-maintenance Lead Acid...................... 93, 140 Sealed, Maintenance-free Lead Acid ...................... 93, 139

Adaptor RS232/RS485....................................................... 275 Advanced Battery Care ................................................ 94, 297 AIF 219

108 – 15B10853G1 Interface Board........................ 65, 219 Air Inlet Protection Level..................................................... 282 Ambient Temperature Channel ............................................ 62 AP1 – CU1 Rectifier ..36, 42, 48, 54, 60, 62, 79, 84, 120, 159,

285 AP10 – In/Out Board .38, 44, 50, 56, 60, 62, 69, 73, 107, 118,

119, 120, 122, 125, 126, 128, 159, 285 AP11-AP17 – IGBT Driver Board .. 35, 41, 47, 53, 74, 79, 189,

194, 285 AP19-AP26 – IGBT Interface Board..... 34, 40, 46, 75, 79, 285 AP19-AP26, AP40-AP53 – IGBT Interface Board................ 52 AP2 – CU2 Inverter ................ 36, 42, 48, 54, 60, 62, 155, 285 AP27-AP28 (AP29) – Fan Speed Control Board..... 36, 42, 48,

54, 76, 191, 285 AP3 – Interface Board Rectifier . 36, 42, 48, 54, 60, 64, 65, 69,

75, 79, 82, 173, 182, 183, 185, 187, 193, 285 AP31-AP33 – Filter Board .......................... 37, 43, 49, 77, 285 AP31-AP33 – RFI Filter Board ............................................. 55 AP35 – Filter Board .............................................................. 77 AP36-AP37 – Varistor Board................ 37, 43, 49, 55, 77, 285 AP38 – DC Modem LIFE.NET.................... 38, 44, 50, 56, 285 AP4 – Interface Board Inverter .. 36, 42, 48, 54, 62, 64, 65, 75,

173, 182, 186, 187, 188, 190, 191, 192, 195, 285 AP40-AP46 – IGBT Interface Board............................... 40, 46 AP5 – SMPS................................... 34, 40, 46, 52, 64, 66, 285 AP6 – Supply Interface Board ........ 34, 40, 46, 52, 69, 84, 285 AP7 – Bypass Control Board....... 34, 40, 46, 52, 70, 106, 174,

189, 191, 285 AP8 – LCDisplay .................................................... 62, 71, 285 AP9 – Connectivity Board .............. 38, 44, 50, 56, 69, 72, 285 AS400................................................. 107, 112, 114, 121, 265 Asynchronous Transfer (PNU 0115) .................................. 104 Automatic Battery Test (PNU 1438) ............................. 94, 145 Automatic Battery Test (PNU 1438.2) ................................ 145

B Backfeed............................................... 65, 104, 106, 124, 189

Current Detector .............................................................. 65 Load Capacitor .............................................................. 106 Protection ...................................... 104, 107, 118, 190, 210

Backup Time less than specified........................................ 200 Battery .15, 21, 22, 24, 32, 113, 130, 151, 153, 169, 171, 185,

206, 223 Automatic Test................................................. 94, 145, 148 Autonomy ........................................................................ 21 Autonomy Test ...................................................... 146, 187 Back-up Time ................................................ 113, 123, 136 Cabinet Temperature..................................................... 116 Calculation............................................. 130, 131, 151, 200 Calculation active (PNU 1433) ...................................... 135 Calibration Values (PNU 1536) ..................................... 136 Capacity........................................................................... 21 Cell Number (PNU 1629)............................................... 142 Cells......................................................... 95, 135, 136, 225 Charger.................................................... 93, 124, 127, 183 Charger Mode.................................................................. 87 Charger Output................................................................ 93 Charger Voltage ...................................................... 93, 144 Charger/Booster ......................................... see Booster/Charger Charger/Booster DIM.......................... see Booster/Charger DIM Charging .................................................................... 92, 93 Charging Check............................................................. 223 Charging Inhibited ........................................................... 86 Charging Methods ............................................. 88, 89, 139 Charging Voltage........................................................... 174 Conditioning................................................................... 127 Connection Check ......................................................... 223 Current Limit On-time (PNU 1624) ................................ 141 Current Limit Setting...................................................... 224 Current Measuring........................................................... 91 Data Sheet..................................................................... 130 Dis-/Recharging Inhibited .............................................. 186 Discharging Characteristic..................... 135, 136, 137, 148 Earthing ......................................................................... 173 Emergency DCM ............................................................. 24 End Current for 240 Cells ................................................ 17 End of Discharge........................................... 147, 185, 198 End of Discharge Curve ................................................ 137 End Voltage for 240 Cells................................................ 17 Energy ........................................................................... 147 External Circuit Breaker................................................. 269 External Switch.............................................................. 117 Faults............................................................................. 193 Fuses FU7-FU8............................see FU7-FU8 – Battery Fuses Handling Instructions ..................................................... 170 Imminent Shutdown....................................... 147, 184, 197 Initial Charging............................................................... 143 Life Cycle....................................................................... 223 Life Time........................................................................ 223 Loop............................................................................... 185 Low........................................................ 113, 114, 122, 131 Maintenance.................................................................. 179 Manual/Automatic Charging (PNU 1436) ...................... 130 Min. Recharge Current .................................................... 17 Min. Voltage without Discharge....................................... 16 Mode.............................. 23, 29, 82, 86, 122, 130, 183, 200 Mode Check .................................................................. 223 Operation......................................................................... 23 Output Load Supplied.................................................... 184 Overvoltage Protection.................................................... 93 Pre-warning Voltage Level (PNU 0113) ........................ 129 Real Life Time ............................................................... 223 Recharge DCM................................................................ 24 Recharge DIM ................................................................. 26 Recharge Time (PNU 1578) .......................................... 141 Remaining Time ............................................ 114, 129, 136



Removing of one Block.................................................. 225 Settings.......................................................................... 174 Stored Energy Time (PNU 0117)........... 129, 147, 184, 197 Switch QS9......................................... see QS9 – Battery Switch Temperature ............................................................ 65, 200 Temperature Alarm........................................................ 186 Temperature Channel.............................................. 60, 200 Temperature Channel active (PNU 1161) ..................... 144 Temperature Dependent Power Upgrade ....................... 97 Temperature High.......................................................... 186 Temperature Limits (PNU 1557).................................... 129 Temperature Range ...................................................... 212 Temperature Sensor.............................................. 173, 186 Test Duration ................................................................. 145 Test Fault....................................................................... 195 Test Inhibit Time ............................................................ 145 Test Interval Time.......................................................... 145 Undervoltage ................................................. 146, 185, 198 Undervoltage limit............................................................ 94 Voltage ...................................... 12, 94, 115, 146, 184, 185 Voltage Range................................................................. 17 While Maintenance.......................................................... 27

Battery Cell Number (PNU 605) ......................................... 225 Battery Current Display Calibration (PNU 1440) ................ 224 Battery Measuring Modules................................................ 282 Baud Rate (Flashing Tool).................................................. 157 Baud Rate (PNU 0684)....................................... 240, 245, 276 Blue Bus ............................................................................. 252 Boost Mode .............................................................. 87, 91, 93 Booster/Charger ..24, 25, 26, 32, 74, 75, 78, 87, 91, 145, 151,

183, 185 Fault............................................................................... 193 IGBT .............................................................. 33, 39, 45, 51 Mode................................................................................ 91 Temperature ............................................................ 65, 187 Temperature Channel...................................................... 60 Thermal Protection Threshold ......................................... 91 Warning ......................................................................... 198

Bus address (PNU 0683).................................................... 245 Buzzer Pattern.................................................................... 181 Bypass................................................................................ 153

Active..................................................................... 113, 114 Automatic Transfer .......................................... 24, 103, 211 Backfeed Protection .............................................. 104, 190 Control Signal .................................................................. 65 Delay (PNU 0116) ......................................................... 104 DIM .................................................................................. 25 Dynamic Line Support ................................................... 191 Emergency DIM............................................................... 26 Failure Rate DIM ............................................................. 25 Fault............................................................................... 190 Fuses............................................................................... 13 Input Contact ................................................................. 126 Integrated Static Bypass.................................................. 21 Mode................................................................ 23, 113, 114 Out of Tolerance............................................................ 182 Output Contact .............................................................. 122 Overload .............................................................. see Overload Right-hand Field ............................................................ 173 SCR............................................... 33, 39, 45, 51, 174, 189 Separate Lines .............................................................. 100 Static Switch .................................................... 32, 103, 115 Supply Detector ............................................................... 70 Supply Switch – QS2..................see QS2 – Bypass Supply Switch Switching Delay ............................................................. 103 Technical Data................................................................. 19 Transfer Inhibited........................................................... 103 Transfer Time ................................................................ 103 Two Separate Mains.............................................. 169, 171

Warning ......................................................................... 182 Wrong Phase Rotation .................................................. 184

Bypass Control Board AP7..............see AP7 – Bypass Control Board Bypass Installed (PNU 0073) ..................................... 100, 230 Bypass Supply.................................................................... 270

C C.O.C.................................................................................. 226 C16X Flasher...................................................................... 157 C1-C3 – Input Filter Capacitors .................................... 82, 194 Cell Number (PNU 1629) ............................................. 95, 135 Charge Mode (Buck Mode) ............................................ 87, 92 Charge Principle................................................................. 139 Charger/Booster .............................................. see Booster/Charger Charging Method (PNU 1617)...................................... 89, 139 Charging Pause Duration (PNU 1547) ............................... 141 Circuit Diagrams................................................................. 289 Client .................................................................................. 253 Commands Disabled ............................................................ 30 Commissioning................................................................... 171 Communicate with CU........................................................ 110 Connectivity Board AP9 .....................see AP9 – Connectivity Board Control of Overload Reaction (PNU 567) ............................. 26 Converter Temperature Threshold (PNU 1174) ................... 82 Crystal Oscillator ................................................................ 270 CU Board.............................................. 36, 42, 48, 54, 58, 285 CU1 Rectifier – AP1 ..................................see AP1 – CU1 Rectifier CU2 Inverter – AP2 ................................... see AP2 – CU2 Inverter Current V2 V1 (PNU 1625) ............................................ 142 Current-Walk-In .................................................................... 86 Current-Walk-In Time (PNU 1166) ....................................... 86

D DC CT..................................................................... 82, 99, 183 DC Modem LIFE.NET AP38....... see AP38 – DC Modem LIFE.NET DC-Link

Calibration ..................................................................... 213 Voltage .......................................................................... 213

DC-Offset............................................................................ 214 DCU Software.............................................. see ManageUPS DCU Delta Shutdown Imminent (PNU 0591) .............................. 148 DHCP Network Configuration............................................. 247 Diesel Generator .................................................................. 80 Digital Interactive Mode (DIM)................................ 21, 25, 103

Battery ............................................................................. 26 Emergency ...................................................................... 26 Inverter Stop .................................................................... 25 Overload .......................................................................... 25

Digital Signal Processor ........................................... 28, 58, 96 Diode .................................................................................... 78 DIP Switch

SW1................................................................................. 71 SW1.1.................................................................... 162, 168 SW1.2.................................................................... 162, 168 SW1.3.................................................................... 162, 168

Disabled Battery Calculation .............................................. 131 Discovery and Configuration Utility .................................... 264 Display................................................................................ 298

Not Present.................................................................... 200 Double Conversion Mode (DCM) ................................... 21, 24

Emergency ...................................................................... 24 Overload .......................................................................... 24 Recharge ......................................................................... 24

Dynamic Line Support ........................................................ 298



E Earthing System ................................................................. 200 Electric shock ....................................................................... 13 Electronic Box..................................................................... 279 Electronic Bypass........................................................see Bypass Email Alert Messaging................................................ 254, 256 Emergency ........................................................................... 12 Enabling Parameterisation (PNU 0053) ............................. 246 Enabling Parameterisation (PNU 1077) ............................. 246 End of Discharge................................................................ 147 End of Discharge Curve ..................................................... 137 End-of-Charging Voltage 1 (PNU 1555) ............................. 141 End-of-Charging Voltage 2 (PNU 1622) ............................. 141 Environmental Sensor ........................................................ 252 EPO................................12, 65, 107, 115, 117, 189, 210, 229 EPO Feedback ................................................................... 115 Event and Data Logging..................................................... 248 Event Log File..................................................................... 259 Event Response (MopUPS) ............................................... 259 Event Storage..................................................................... 238 External Alarm Systems ..................................................... 107 External Battery Switch .............................................. 107, 117 External Battery Temperature .................................... 107, 116 External Reference Frequency........................................... 270 External Synchronisation enable (PNU 0579).................... 274 External Synchronisation Settings (PNU 0067).................. 274

F Fan Control........................................................................... 65 Fan Replacement ............................................................... 221 Fan Speed Control Board AP27-AP28 (AP29)..... see AP27-AP28

(AP29) – Fan Speed Control Board Fans (High Speed) ............................................................. 130 Fast off (PNU 0058)............................................................ 121 Fault.......................................................... 22, 29, 31, 150, 181

033................................................................................. 188 034................................................................................. 188 035................................................................................. 188 036................................................................................. 188 037................................................................................. 188 039................................................................................. 189 040................................................................................. 189 041................................................................................. 189 042................................................................................. 189 043................................................................................. 189 044................................................................................. 189 045................................................................................. 189 046................................................................................. 190 047......................................................................... 190, 196 048................................................................................. 190 049................................................................................. 190 050................................................................................. 190 051................................................................................. 191 052........................................................................... 25, 191 053................................................................................. 191 054................................................................................. 191 055................................................................................. 191 056................................................................................. 191 057................................................................................. 191 058................................................................................. 191 059................................................................................. 191 060................................................................................. 192 061................................................................. 192, 235, 236 062................................................................................. 192 072................................................................................. 192

073................................................................................. 192 083................................................................................. 193 101................................................................................. 193 133................................................................................. 193 139................................................................................. 193 140................................................................................. 193 141................................................................................. 194 142........................................................................... 84, 194 143................................................................................. 194 155................................................................................. 194 156......................................................................... 194, 195 157................................................................................. 195 159................................................................................. 195 162................................................................................. 195 173................................................................................. 195 182................................................................................. 195 183......................................................................... 146, 195

Filter Board AP31-AP33 ....................see AP31-AP33 – Filter Board Filter Board AP35 ...................................... see AP35 – Filter Board Filter Chokes L1-L3 ................................. see L1-L3 – Filter Chokes Firmware..................................................................... 151, 155 Flashing.............................................................................. 150

Board Replacement....................................................... 220 CU1-Board............................................................... 73, 159 CU2-Board............................................................... 71, 155 CU-Board....................................................................... 155 Direct Connection Cable ............................................... 160 LCDisplay ...................................................................... 162 Parameter Reset ........................................................... 189

Freeze LCD Function ............................................. 30, 71, 153 Frequency Converter.......................................................... 237 Front Panel Key.................................................................... 30 FU1-FU3 – Input Fuses................ 34, 40, 46, 52, 82, 194, 200 FU4-FU6 – Output Fuses ............. 34, 40, 46, 52, 99, 183, 190 FU7-FU8 – Battery Fuses .... 37, 43, 49, 55, 91, 171, 173, 174

G GSM Link............................................................................ 238 GUI ............................................................................. 254, 258 Guided Procedure .............................................................. 172

H Half UDC Link Minimal Voltage (PNU 1159) ........................ 85 Heat-Conductive Paste ...................................................... 208 Hitachi Flash Development Toolkit ..................................... 163 Hold-off Delay Rectifier Start ................................................ 86 HYPERTERMINAL (JBUS) ................................................ 277

I IGBT ............................................................... 78, 79, 206, 208

Changing ....................................................................... 208 Converter......................................................................... 21 ESD Handling Instructions ............................................ 208 Examination................................................................... 206

IGBT Driver Board AP11-AP17 see AP11-AP17 – IGBT Driver Board IGBT Interface Board

AP19-AP26...................... see AP19-AP26 – IGBT Interface Board AP19-AP26, AP40-AP53.....see AP19-AP26, AP40-AP46 – IGBT

Interface Board AP40-AP46 see AP40-AP46 – IGBT Interface Board, see AP40-AP46

– IGBT Interface Board Imminent Shutdown.................................................... 147, 197 In/Out Board AP10 .................................. see AP10 – In/Out Board Initial Charging.................................................................... 143 Input Contacts .................................................................... 118



Function (PNU 0093)..................................................... 126 Negated (PNU 0094) ..................................................... 128 OFF Delay (PNU 0091) ................................................. 128 ON Delay (PNU 0090) ................................................... 128

Input Filters Capacitors C1-C3 ....see C1-C3 – Input Filter Capacitors Input Fuses FU1-FU3.......................... see FU1-FU3 – Input Fuses Input Mains Supply Switch – QS1 .....see QS1 – Mains Input Switch Input Transient Suppressor ................................................ 199 Installation .......................................................................... 169 Integrated Modem (LIFE) ................................................... 238 Intelligent Double Conversion Technology........................... 21 Interface.............................................................................. 108

X107 .........................................................................see X107 X109 .........................................................................see X109 X110 .........................................................................see X110 X120 .........................................................................see X120 X130 .........................................................................see X130 X3 see X3 – Service Interface X4–AP10 ............................................................ see X4–AP10 X6 see X6 – Serial Interface X7 see X7 – AS400 X8 see X8 – EPO XS3............................................................................ see XS3 XS6................................................................. see XS6 – LIFE XT1 ..........................see XT1 – External Battery Temperature Sensor XT2 ......................................... see XT2 – External Battery Switch XT3 ...................................................... see XT3 – EPO activated XT4 ............................................... see XT4 – Backfeed Protection XT5–AP10 ........................................................ see XT5–AP10 XT6–AP10 ........................................................ see XT6–AP10

Interface Board AP3/AP4 see AP3 – Interface Board Rectifier OR AP4 – Interface Board Inverter

Intermediate Circuit .............................................................. 12 Interruption of Power .......................................................... 200 Inverter ........................................................................... 32, 96

Automatic Output Power Upgrade (Amb. Temp.)............ 97 Forced ON/OFF............................................................. 235 OFF Button ...................................................................... 30 ON Button........................................................................ 30 Overload .......................................................................... 96 Short Circuit Capacity...................................................... 97 Temperature Channel...................................................... 62

Inverter Forced ON/OFF (PNU 0132) ................................ 235 Inverter Output Frequency.................................................... 96 Inverter PWM Signal............................................................. 65 IP address (MopUPS)......................................................... 254

J JBUS .................................................................................. 275 Jumper

CN11 ....................................................................... 71, 156 X160 ...................................................................... 156, 159

K KM1 – Mains Contactor34, 40, 46, 52, 65, 79, 82, 83, 84, 119,

194, 199 KM2 .............................................................................. 65, 119 KM2A – Aux. Contact AP3 ............................................. 82, 83 KM3 – Precharge Contactor .... 34, 40, 48, 79, 82, 83, 84, 183,

186, 194

L L1-L3 – Filter Chokes ..................... 35, 41, 47, 53, 79, 82, 193 L4 36, 42, 195

L6-L8 .................................... 35, 41, 47, 53, 99, 188, 189, 190 LCDisplay ......................................... 21, 29, 60, 150, 156, 285 LCDisplay Board AP8....................................see AP8 – LCDisplay LED

Green............................................................................... 30 Indicators ......................................................................... 30 Red .................................................................................. 31 Yellow.............................................................................. 30

License Key (MopUPS) ...................................................... 254 LIFE

Security.......................................................................... 239 LIFE.net .............................................................................. 238

Adapter .......................................................................... 239 Alarm Call ...................................................................... 238 Buffer Full Call ............................................................... 238 Configuration ................................................................. 241 Delayed Call .................................................................. 242 Manual Call.................................................................... 238 Modem........................................................... 107, 110, 111 Next Scheduled Call ...................................................... 242 Protocol ......................................................................... 265 Routine Call ................................................................... 238

Line Voltage (PNU 0071) ..................................................... 99 Line-Fail...................................................................... 113, 114

M Mains Contactor KM1...........................see KM1 – Mains Contactor Mains Failure Statistics (PNU 1584) .................................. 178 Mains Failure Warning Delay (PNU 0110) ......................... 129 Mains Frequency (PNU 0072)............................................ 100 Maintenance......................................................... 27, 176, 177

Bypass Mode................................................................... 23 Bypass Switch QS3............ see QS3 - Maintenance Bypass Switch

ManageUPS ............................................................... 107, 110 CIO ................................................................ 253, 255, 260 DCU............................................................... 248, 253, 264 NET Adapter II............... 247, 252, 255, 257, 258, 262, 264

ManageUPS NET Adapter II .............................................. 265 Max. Charge Current (PNU 1554)..................................... 141 Max. Charge Current (PNU 1554)...................................... 224 Max. Stage 2 Time (PNU 1626) ......................................... 142 MBSM................................................................................. 270

AP1 (SSC Board) .......................................................... 271 Offset Compensation..................................................... 274 RJ45 .............................................................................. 271 XT1 ................................................................................ 271 XT2 ................................................................................ 271

Message Configuration (PNU 0590) .................................. 148 Microcontroller ...................................................................... 58 Minimal Battery Voltage (PNU 1426) .......................... 94, 146 MopNSA ...........................................................See MopUPS NSA MopUPS ............................................................................. 107

Event Response ............................................................ 259 GUI ................................................................................ 254 NSA ....................................................... 247, 253, 255, 262 P/R......................................... 247, 253, 254, 255, 258, 262 Professional................................... 247, 253, 254, 255, 256 UPS Diagnostic ............................................................. 256

Multi Bus Synchronisation Module ..................................... 270 Multi-Module Systems ........................................................ 226 Multiple Network Access Methods ..................................... 247 MUN ............................................. See ManageUPS NET Adapter II MUX............................................................................ 240, 265



N Network Shutdown ............................................. 247, 256, 258 Network Shutdown Agent ................................................... 262 Neutral Switch QS14 ..............................see QS14 – Neutral Switch No Communication (UPS/PC) ............................................ 200 No. of Mains Failure Total (PNU 1049) .............................. 177 NTC .................................................................................... 116

O Online Mode ......................................................................... 22 Optional I/O connection...................................................... 107 Optional Modules Slot 2 (PNU 0095) ................................. 228 Output Contacts.......................................................... 119, 129

(PNU 0080).................................................................... 121 Function (PNU 0081)..................................................... 122 Negated (PNU 0082) ..................................................... 125 OFF Delay (PNU 0088) ................................................. 126 ON Delay (PNU 0087) ................................................... 125

Output Switch – QS4................................see QS4 – Output Switch Over Current Protection........................................................ 13 Overheating ........................................................................ 200 Overload ............................................................................. 196

Ambient Temperature.................................................... 196 Amount .......................................................................... 197 Bypass................................................................... 103, 191 Bypass (DCM) ................................................................. 24 Period ............................................................................ 197

P Pager .................................................................. 254, 256, 258 Parallel Operation (PNU 0129)........................................... 236 Parallel Operation Board ............................................... see POB Parallel System

Inverter OFF .................................................................. 227 Inverter ON.................................................................... 227

Parameters ....................................................................see PNU Parity settings X2 (PNU 0690)............................................ 246 Personal safety..................................................................... 12 PFC ...................................................................................... 16 PLL ..................................................................................... 298 PNU

0006 – U Bypass Mains 1.............................................. 153 0007 – U Bypass Mains 2.............................................. 153 0008 – U Bypass Mains 3.............................................. 153 0009 – U Output 1 ......................................................... 153 0010 – U Output 2 ......................................................... 153 0011 – U Output 3 ......................................................... 153 0013 – Operating Hours ................................................ 153 0014 – I Output L1......................................................... 153 0015 – I Output L2......................................................... 153 0016 – I Output L3......................................................... 153 0017 – Output Frequency.............................................. 153 0018 – Bypass Mains Frequency .................................. 153 0019 – Output Real Power ............................................ 153 0020 – Output Apparent Power ..................................... 153 0022 – Battery Hold-up Time......................... 147, 184, 197 0023 – Battery Current .................................................. 153 0024 – U Batt./Cell ........................................ 153, 184, 185 0026.2 – Temperature, external .................................... 153 0031.12 – Operating Hours ........................................... 153 0031.8 – Rectifier PZD RxD .......................................... 153 0051 – Access Level ............................. 202, 213, 214, 220 0052 – Function Selection.... 158, 174, 175, 185, 214, 220,

235 0053 – Enabling parameterisation......................... 240, 246

0058 – Fast off............................................................... 121 0067 – External Synchronisation Settings..................... 274 0071 – Line Voltage......................................... 99, 182, 203 0072 – Mains Frequency....................................... 100, 182 0073 – Bypass Installed ........................................ 100, 230 0074 – Separate Lines .................................................. 100 0075 – Power Rating Class..................................... 86, 152 0076.19 – VDC Link neg. .............................................. 213 0076.20 – VDC Link pos................................................ 213 0076.21 – VDC Out L1 .................................................. 214 0076.22 – VDC Out L2 .................................................. 214 0076.23 – VDC Out L3 .................................................. 214 0080 – Output Contacts................................................. 121 0081 – Function of Output Contacts.............. 112, 122, 129 0082 – Negated Output Contacts ................................ 125 0087 – On delay of Output Contacts ............................. 125 0088 – Off delay of Output Contacts ............................. 126 0090 – On delay Input Contacts .................................... 128 0091 – Off delay Input Contacts .................................... 128 0093 – Function of Input Contacts 126, 184, 186, 189, 191,

192, 193, 229 0094 – Negated Input Contacts.................................... 128 0095 – Optional Module Slot 2 ...................................... 228 0101 – UDC min .............................................. 99, 183, 188 0104 – Frequency Tolerance Bypass Input................... 182 0105 – Delta Frequency .................................................. 96 0106 – Voltage Tolerance Bypass Input ....................... 182 0109 – Replacing the Fan ............................................. 185 0110 – Mains Failure Warning Delay .... 113, 114, 129, 182 0113 – Battery Pre-warning Voltage Level .................... 129 0115 – Asynchronous Transfer ..................................... 104 0116 – Bypass Delay..................................................... 104 0117 – Battery Stored Energy Time ..... 113, 114, 129, 147,

184, 197 0118 – V Correction....................................................... 100 0125 – UPS Operation in Manual Bypass..... 185, 203, 205 0129 – Parallel Operation.............................................. 236 0132 – Inverter Forced ON/OFF.................................... 235 0133 – Ambient Temperature........................................ 186 0135 – UDC Link Minimal Voltage ................................ 186 0142 – Enable Backfeed Protection .............................. 190 0152 – Inverter Temperature Threshold................ 182, 188 0153 – Neutral Booster Temperature Threshold... 182, 192 051 – Access Level ....................................................... 224 0511 – Time Discharge Characteristic ... 94, 135, 136, 138,

145, 147, 148, 184, 185, 198 0511 – Time Discharge Table ....................................... 131 0513 – Shutdown Voltage Table .... 94, 131, 136, 145, 147,

148, 184, 185, 198 052 – Function Selection............................................... 224 0565 – Inverter/System max. Output............................. 153 0566 – Maximum Output ............................................... 153 0567 – Control of Overload Reaction ...... 26, 184, 187, 190 0578 – System Bypass Switch installed........................ 230 0579 – External Synchronisation enable....................... 274 0588 – Restart Delay of Inverter ................................... 185 0590 – Message Configuration ..... 147, 148, 184, 197, 198 0591 – Delta Shutdown Imminent ......... 147, 148, 184, 198 0605 – Battery Cell Number .......................................... 225 0626.2 – Battery Current Limit....................................... 134 0651 – Output contactor Present .................................. 188 0683 – Bus address............................................... 240, 245 0684 – Baud Rate.................................................. 240, 245 0688 – Serial protocol X2 ...................................... 240, 245 0690 – Parity setting X2 (serial 2) ......................... 240, 246 0720 – SW Version................................................ 151, 152 0721 – Software Issue Date .................................. 151, 152 0724 – CU1 Firmware Code.................................. 151, 152 0725 – DSP Firmware Code ......................................... 152 0783 – Test Operation........................... 175, 185, 203, 205



0786 – Test Voltage ...................................... 203, 204, 205 0791 – Test Rectifier ON/OFF Manual .......................... 175 0799 – Superservice.............................. 202, 213, 214, 220 0921 – CB Process Data Selection (Profibus)............... 280 0952 – UPS Manufacturer ............................................. 152 1030 – U Mains 1 .......................................................... 153 1031 – U Mains 2 .......................................................... 153 1032 – U Mains 3 .......................................................... 153 1036 – U DC-Link .......................................................... 153 1042 – Mains Frequency............................................... 153 1045 – Battery Capacity ................................................ 153 1046 – Battery Hold-up Time......................................... 153 1048 – U Batt./Cell ........................................................ 185 1049 – Mains Failure Total ............................................ 177 1050 – Temperature .............................................. 186, 187 1062.1 – U DC pos. and neg. ........................................ 153 1062.2 – U DC pos. and neg. ........................................ 153 1075 – Access Level ..................................... 213, 214, 225 1076 – Function Selection............................. 175, 185, 225 1077 – Enabling parameterisation......................... 240, 246 1078 – Operation Source Control.................................. 185 1100.19 – VDC Link neg. .............................................. 213 1100.20 – VDC Link pos................................................ 213 1100.24 – VEC_I_INV_OFFSET_L1............................. 214 1100.25 – VEC_I_INV_OFFSET_L2............................. 214 1100.26 – VEC_I_INV_OFFSET_L3............................. 214 1128 – Frequency Tolerance Input................................ 183 1130 – Voltage Tolerance Input .................................... 183 1134 – Mains Failure Warning Delay ............................ 183 1158 – Rectifier hold-off delay......................................... 86 1159 – Half UDC Link Minimal Voltage83, 84, 85, 183, 194 1161 – Battery Temperature Channel active. 130, 144, 200 1166 – Current-Walk-In Time .......................................... 86 1174 – Converter Temperature Threshold ...... 82, 187, 193 1175 – Booster/Charger Temperature Threshold . 187, 195 1424 – Manual Battery Charge Voltage ........................ 130 1426 – Minimal Battery Voltage............................. 145, 146 1426 – Minimal Battery Voltages.... 94, 136, 146, 185, 195,

198 1433 – Battery Calculation Active.......... 130, 131, 135, 200 1436 – Manual/Automatic Charging .............................. 130 1438 – Automatic Battery Test ................................ 94, 145 1440 – Battery Current Display Calibration ................... 224 1534 – Power Discharge Characteristic ................ 136, 137 1534 – Power Discharge Table ..................................... 131 1534– Power Discharge Characteristic ......................... 135 1535 – Time Discharge Characteristic . 135, 136, 137, 138,

148 1535 – Time Discharge Table ....................................... 131 1536 – Battery calibration values .................................. 136 1536 – Battery Calibration Values................................. 131 1540 – Temp. Factor ............................................. 130, 144 1547 – Charging Pause................................................. 140 1547 – Charging Pause Duration .......................... 130, 141 1547– Charging Pause Duration ................................... 139 1554 – Max. Charge Current ......... 130, 139, 140, 141, 224 1555 – End-of-Charging Voltage 1........ 130, 139, 140, 141 1557 – Battery Temperature Limits ....................... 129, 186 1578 – Battery Recharge Time.............. 130, 139, 140, 141 1584 – Mains Failure Statistics...................................... 178 1584.1 – Mains Failure Statistics................................... 153 1585 – Total Duration of Mains Failure ......................... 153 1585 – Total Duration of Mains Failures ....................... 178 1617 – Charging Method........................... 88, 89, 130, 139 1618 – Initial Charge On........................................ 130, 143 1619 – Initial Charge Duration............................... 130, 143 1620 – Initial End-of-Charge Voltage .................... 130, 143 1622 – End-of-Charging Voltage 2................ 130, 140, 141 1624 – Battery Current Limit On-time.................... 130, 141 1624 – Battery Current Limit On-Time .......................... 140

1625 – Current V2 V1 ....................................... 140, 142 1626 – Max. Stage 2 Time .................................... 140, 142 1626– Max. Stage 2 Time ............................................. 140 1629 – Battery Cell Number .... 95, 130, 135, 136, 142, 225 1744 – SW Version................................................ 151, 152 1745 – Software Issue Date .................................. 151, 152 1748 – Firmware Code.......................................... 151, 152 1749 – DSP Firmware Code ......................................... 152 1807 – Test Operation................................................... 175 1823 – Superservice...................................... 213, 214, 225 560 – Mains Failure Total .............................................. 177 799 – Superservice........................................................ 224

POB............................................................ 182, 192, 226, 228 Power Circuit Test .............................................................. 202 Power Discharge Characteristic (PNU 1534) ............. 135, 137 Power Factor Correction ...................................................... 16 Power Management ........................................................... 258 PPVIS................................................................. 107, 121, 149 Precharge............................................................................. 83

Contactor Feedback ........................................................ 84 Contactor KM3.............................see KM3 – Precharge Contactor Not Finished .................................................................... 84 Short Circuit..................................................................... 84

Profibus .............................................................................. 265 CB Process Data Selection (PNU 0921) ....................... 280 Interface Card CBP2 ..................................................... 279 PZD ............................................................................... 279

Pulse Frequency IGBT ......................................................... 78 Pulse Width Modulation (PWM) ......................................... 101

Q QS1 – Mains Input Switch .79, 82, 83, 84, 173, 183, 203, 210,

211, 231, 235, 236 QS14 – Neutral Switch ............. 34, 40, 46, 186, 211, 235, 236 QS2 – Bypass Supply Switch.... 106, 157, 174, 182, 203, 210,

211, 232, 235, 236 QS3 – Maintenance Bypass Switch .. 27, 32, 62, 99, 176, 184,

211, 235, 286, 298 QS4 – Output Switch..... 12, 99, 174, 187, 203, 211, 232, 235,

236, 286 QS5 – SBS Bypass Switch................................. 231, 234, 236 QS6 – SBS Output Switch.................................. 186, 234, 236 QS9 – Battery Switch .... 27, 91, 174, 175, 177, 179, 185, 187,

200, 203, 223, 234, 235, 236 Qualified Personal .............................................................. 298 Quartz Crystal Oscillator .................................................... 270 Quick Stop.......................................................................... 121

R R.A.U. (Remote Alarm Unit) ............................................... 266

Acoustic Alarm............................................................... 266 Connecting .................................................................... 268 Panel ............................................................................. 267

RCCMD ...................................................... 247, 253, 255, 263 Rectifier .......................................................................... 32, 78

Hold-off Delay (PNU 1158).............................................. 86 Main Components ........................................................... 79 Principal of Operation...................................................... 78 Start Hold-off Delay (PNU 1158) ..................................... 86 Temperature Channel...................................................... 60

Remote Control Command................................................. 263 Remote Management......................................................... 256 Remote Messaging..................................................... 256, 258 Remote Monitoring (LIFE) .................................................. 238 Removing one Battery Block .............................................. 225 Resistor R1/R2 ............................................... 48, 83, 183, 194



RJ11 Plug Terminal ............................................................ 239 RS232......................................... 107, 109, 111, 149, 161, 277

JBUS ............................................................................. 275 RS485................................................................................. 149

JBUS ............................................................................. 275

S S.B.S. ......................................................... 226, 229, 231, 232 Safety procedures ................................................................ 12 Scalability ........................................................................... 258 SCR (Bypass)..................................................... 33, 39, 45, 51 Second Access Panels......................................................... 13 Security............................................................................... 247 Separate lines (PNU 0074) ................................................ 100 Serial Cable ........................................................................ 155 Serial Interface 1 ................................................................ 265 Serial Interface 2 ................................................................ 265 Serial protocol X2 (PNU 688) ............................................. 245 Server ................................................................................. 253 Service................................................................................ 254 Service Bypass........................see QS3 – Maintenance Bypass Switch Service Interface...................................... see X3 – Service Interface Service Software PPVIS..................................................... 149 Serviceability ...................................................................... 248 Shutdown

Local .............................................................................. 256 Network ......................................................................... 256

Shutdown Voltage Table (PNU 0513) ............................... 148 Shutdown Voltage Table (PNU 513) ................................. 136 Single-Line Diagram............................................................. 29 SMPS Board AP5............................................... see AP5 – SMPS SMS Notification (LIFE) ...................................................... 239 SNMP ................................................................................. 257 Summary Alarm.................................................................. 113 Supply Interface Board AP6 ..........see AP6 – Supply Interface Board Synchronisation .................................................................. 270

Automatic......................................................................... 27 Synchronisation Fault ......................................................... 270 System................................................................................ 253

Security.......................................................................... 258 Shutdown....................................................................... 256

System Bypass Switch installed (PNU 578) ....................... 230

T TA12-TA14 ...37, 43, 49, 55, 99, 183, 184, 190, 191, 196, 199 TA15-TA17 ......................................... 37, 43, 49, 55, 106, 190 TA1-TA3 ......................................... 37, 43, 49, 55, 82, 84, 199 TA4-TA6 ....................................... 34, 40, 46, 52, 82, 199, 214 TA7 ....................................................................................... 91 TA9-TA11 .....................34, 40, 46, 52, 99, 183, 184, 190, 199 Technical Data Table............................................................ 16

Battery ............................................................................. 17 Environmental.................................................................. 19 Inverter output ................................................................. 18 Primary input ................................................................... 16 Static bypass ................................................................... 19 System data..................................................................... 17

Temperature Detection Circuit ............................................. 65 Temperature Factor (Battery charging) (PNU 1540) .......... 144 Temperature Measurement ............................................ 60, 62 Temperature Sensors................................................. 116, 212 Temperature Thresholds .................................................... 212 Test – auto. transfer Inv. to Bypass.................................... 211 Test Operation (PNU 0783)................................................ 205

Test Voltage (PNU 0786) ................................................... 205 Thyristor................................................................................ 78 Time Compensated End of Discharge Voltage .................... 94 Time Dependent Battery Warning ...................................... 197 Time Discharge Characteristic (PNU 1535) ....................... 137 Time Discharge Characteristic (PNU 511) ......................... 148 Time Discharge Characteristic (PNU 511/1535) ................ 135 Total Duration of Mains Failures (PNU 1585) .................... 178

U UPS ON.............................................................................. 114 UPS Operation in Manual Bypass (PNU 0125).................. 205 UPS Status Information...................................................... 247 USS Protocol .............................................................. 149, 265

V V Correction (PNU 1158) ................................................... 100 Varistor Board AP36-AP37............ see AP36-AP37 – Varistor Board Vector Control....................................................................... 28 Vector Control Technology................................................... 21 Voltage Dependent Battery Warning.......................... 197, 198 Voltage-free contacts ......................................................... 112

W Warning ............................................ 23, 29, 30, 147, 181, 197

001......................................................................... 182, 188 002................................................. 169, 171, 173, 174, 182 003........................................................... 84, 169, 171, 183 004................................................................................. 183 005........................................................................... 84, 183 006................................................................. 184, 189, 196 007........................................................................... 84, 184 008......................................................................... 184, 232 009................................................................................. 184 010......................................................... 147, 184, 197, 198 011......................................................... 146, 147, 185, 198 012................................................................................. 185 013................................. 173, 174, 185, 223, 232, 234, 236 014................................................................................. 185 015................................................................................. 185 016................................................................................. 185 017................................................................................. 186 018........................................................................... 23, 186 019................................................................................. 186 020................................................................................. 186 021......................................................................... 186, 187 022......................................... 173, 174, 186, 232, 235, 236 024......................................................................... 187, 193 025................................................................................. 187 026................................................................................. 187 027................................................................................. 187 028................................................................................. 187 029......................................................................... 187, 270 030................................................................................. 187 031................................................................................. 187 032......................................... 173, 174, 187, 232, 235, 236

X X107

CU1 ................................................................................. 60 CU2 ................................................................................. 62

X109 CU1 ........................................................................... 60, 62 CU2 ................................................................................. 62

X110 ................................................................................... 228



CU1 ................................................................................. 60 CU2 ................................................................................. 62

X120 ........................................................................... 156, 228 CU1 ................................................................................. 60 CU2 ................................................................................. 62

X130 ................................................................................... 228 CU1 ................................................................................. 60 CU2 ................................................................................. 62

X140 ................................................................................... 228 X3 – Service Interface107, 109, 110, 149, 156, 202, 240, 265,

277 X4–AP10 ............................................................ 107, 120, 159 X5–AP10 ...................................................................... 73, 107

X6 – Serial Interface........................................... 107, 111, 265 X6–AP10 .............................................................................. 73 X7 – AS400 ........................................ 107, 112, 125, 126, 266 X8 – EPO....107, 115, 117, 121, 126, 128, 184, 189, 229, 232 XS3..................................................... 108, 109, 110, 156, 265 XS6 – LIFE ................................................. 108, 111, 239, 265 XT1 – External Battery Temperature Sensor ............. 107, 116 XT2 – External Battery Switch.................... 107, 117, 185, 223 XT3 – EPO activated.......... 107, 115, 117, 122, 125, 126, 210 XT4 – Backfeed Protection.107, 118, 122, 125, 126, 190, 210 XT5–AP10 .......................................................................... 119 XT6–AP10 .................................................................. 107, 118

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80-NET TM TechnicalManual Rev2!0!2007Mai10-2

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