NXL UPS Module 500/800kVA User Manual

NXL UPS Module 500/800kVA

User Manual

Version V1.1

Revision date 2009-01-16

BOMCode 31011918

Emerson Network Power provides customers with technical support. Users may contact the nearest

Emerson local sales office or service center, and can also contact company headquarter.

Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China

Post Code: 518057

Homepage: www.emersonnetworkpower.com.cn

Customer hotline: 4008876510

E-mail: [email protected]

Important Notes

This manual is about the installation and operation of Emerson HIPULSE-NXL 500/800kVA UPS Module. Please carefully read this manual prior to installation.

The UPS cannot be put into operation until it is commissioned by the manufacturer or authorized engineer.

Otherwise, the damage of UPS will not belong to the warranty scope.

HIPULSE-NXL 500/800kVA UPS is only used for commercial / industrial purpose and cannot be used as life support equipment.

This manual describes the following parts

Equipment

500kVA UPS (12-pulse)

800kVA UPS (12-pulse)

500kVA Trap filter (50Hz)

800kVA Trap filter (50Hz)

Bypass load sharing inductor

Dust filter

D-level SPD box

BCB box

BCB cabinet

SNMP card

Battery temperature sensor

Optional parts

Input dry contact board

Programmable relay board

-

-

-

Model

Liebert HIPULSE-NXL 500kVA

Liebert HIPULSE-NXL 800kVA

Model

-

UF-BCB-NXL 500kVA

UF-BCB-NXL 800kVA

UF-SNMP810

UF-BTS-NXL

UF-ICI-NXL

UF-PRB-NXL

Safety Precautions

CONFORMITY AND STANDARDS

This equipment complies with the following UPS standards: z IEC60950-1, IEC62040-1-1— ‘General and safety requirements for use in operator access area z IEC62040-3‘Performance requirements and test methods’

Continued compliance requires installation in accordance with these instructions and the use of manufacturer approved accessories only.

WARNING

High earth leakage current: Earth connection is critical before connecting the input supply (include both utility supply and battery).

This equipment must be earthed in accordance with local electrical codes.

WARNING

Upstream power distribution protection device of the UPS must be selected according to local electrical codes.

WARNING

If any internal fuse of the UPS is damaged, it must be replaced by professionals with a new one of the same specifications.

Caution

This equipment is fitted with EMC filters.

Earth leakage current is between 3.5mA and 3000mA.

Transient and steady-state earth leakage currents, which may occur when starting the equipment, should be taken into account when selecting instantaneous residual current circuit breaker (RCCB) or residual current detector (RCD) devices.

RCCBs must be selected insensitive to DC unidirectional pulses (Class A) and transient current pulses.

Be sure to select the RCCB that is not sensitive to single-direction DC pulse (A level) and transient current pulse.

Note also that the earth leakage currents of the load will be carried by this RCCB or RCD

WARNING

This system has a control signal available for use with an automatic device, externally located, to protect against backfeeding voltage through the mains Static Bypass circuit. If this protection is not used with the switchgear that is used to isolate the bypass circuit, a label must be added at the switchgear to advise service personnel that the circuit is connected to a UPS system.

The text is the following or equivalent: Isolate the UPS before working on the circuit of this UPS.

WARNING

When this product is used in the commercial and industrial applications in the category 2 environment, the installation limits or relevant methods should be used to suppress the disturbance.

General

As with other types of high power equipment, dangerous voltages are present within the UPS and BCB box. However, the risk of contact with these high voltages is minimized as the live component parts are housed behind a hinged, lockable door.

Further internal safety screens make the equipment protected to IP20 standards.

No risk exists to any personnel when operating the equipment in the normal manner, following the recommended operating procedures in this manual.

All equipment maintenance and servicing procedures involve internal access and should be carried out only by trained personnel.

Batteries

Battery manufacturers supply details of the necessary precautions to be observed when working on, or in the vicinity of, a large bank of battery cells. These precautions should be followed implicitly at all times. Particular attention should be paid to the recommendations concerning local environmental conditions and the provision of protective clothing, first aid and fire-fighting facilities.

The warning triangle indicates all the personal safety instructions.

Contents

Chapter 1 General Description............................................................................................................................................ 1

1.1 Features................................................................................................................................................................ 1

1.2 Design Philosophy ................................................................................................................................................ 1

1.2.1 System Design .......................................................................................................................................... 1

1.2.2 Bypass Supplies ........................................................................................................................................ 2

1.2.3 System Control Principles.......................................................................................................................... 2

1.2.4 UPS Power Switch Configuration .............................................................................................................. 3

1.2.5 Battery Circuit Breaker............................................................................................................................... 3

1.2.6 Battery Temperature Compensation.......................................................................................................... 3

1.3 Operation Mode .................................................................................................................................................... 3

Chapter 2 Mechanical Installation ....................................................................................................................................... 5

2.1 Cautions................................................................................................................................................................ 5

2.2 Environmental Requirements................................................................................................................................ 5

2.2.1 UPS Positioning......................................................................................................................................... 5

2.2.2 Battery Positioning..................................................................................................................................... 6

2.3 Mechanical Requirements .................................................................................................................................... 6

2.3.1 Components of System ............................................................................................................................. 6

2.3.2 Transporting The Cabinets ........................................................................................................................ 6

2.3.3 Clearances Required For Operating.......................................................................................................... 6

2.3.4 Removing Transportation Rubber Bar and Restraints ............................................................................... 6

2.3.5 Cable Entry Method................................................................................................................................... 7

2.3.6 Mechanical Connection Between Cabinets ............................................................................................... 7

2.4 Preliminary Inspection........................................................................................................................................... 9

2.5 Installation Drawings........................................................................................................................................... 10

Chapter 3 Electrical Installation......................................................................................................................................... 12

3.1 Power Cabling..................................................................................................................................................... 12

3.1.1 System Configuration .............................................................................................................................. 12

3.1.2 Cable Specificatios .................................................................................................................................. 12

3.1.3 General Cautions..................................................................................................................................... 13

3.1.4 Cable Connection Terminals ................................................................................................................... 13

3.1.5 Protective Earth ....................................................................................................................................... 13

3.1.6 Protective Devices................................................................................................................................... 13

3.1.7 Cabling Procedure................................................................................................................................... 14

3.2 Distance From Floor To UPS Connection Point.................................................................................................. 16

3.3 Control Cabling ................................................................................................................................................... 16

3.3.1 Descriptions............................................................................................................................................. 16

3.3.2 Input Dry Contact Interface...................................................................................................................... 17

3.3.3 Dry Contact Output Port .......................................................................................................................... 20

3.3.4 EPO Input Port ........................................................................................................................................ 20

3.3.5 Auxiliary DC power output port ................................................................................................................ 21

3.3.6 Communication Ports .............................................................................................................................. 21

3.3.7 Battery Circuit Breaker Interface.............................................................................................................. 22

3.3.8 TB1101 Port ............................................................................................................................................ 22

3.4 Electrical Connection Between Cabinets ............................................................................................................ 23

3.4.1 Power Connections ................................................................................................................................. 23

3.4.2 Signal Connection ................................................................................................................................... 29

Chapter 4 Operator Control And Display Panel................................................................................................................. 31

4.1 Introduction ......................................................................................................................................................... 31

4.2 LCD Screen Types.............................................................................................................................................. 32

4.2.1 Startup Screen......................................................................................................................................... 32

4.2.2 Main Display Screen................................................................................................................................ 32

4.3 Power Flow Diagram........................................................................................................................................... 35

4.4 Detailed Description Of Menu Items ................................................................................................................... 37

4.4.1 Configuration ........................................................................................................................................... 38

4.4.2 Status Report........................................................................................................................................... 43

4.4.3 Power-on ................................................................................................................................................. 43

4.4.4 Power-off ................................................................................................................................................. 43

4.4.5 Transfer ................................................................................................................................................... 45

4.4.6 Battery Management ............................................................................................................................... 45

4.4.7 Measured Values..................................................................................................................................... 48

4.4.8 Help ......................................................................................................................................................... 48

4.4.9 Clear Event Log....................................................................................................................................... 48

4.4.10 Alarm Silence ........................................................................................................................................ 48

4.5 EPO Button......................................................................................................................................................... 48

4.6 UPS Event and Alarm List .................................................................................................................................. 49

Chapter 5 Operating Instructions ...................................................................................................................................... 57

5.1 Introduction ......................................................................................................................................................... 57

5.1.1 Notes ....................................................................................................................................................... 57

5.1.2 Power Switches ....................................................................................................................................... 57

5.2 Start-Up Procedure (Into Normal Mode) ............................................................................................................. 58

5.3 Battery Test Procedures ..................................................................................................................................... 60

5.4 Maintenance Bypass Procedure (UPS Shut Down) ............................................................................................ 60

5.5 Transfer from Maintenance Bypass Mode to Normal Mode................................................................................ 62

5.6 Shutdown Procedure (Complete UPS And Load Shutdown) .............................................................................. 62

5.7 EPO Procedure................................................................................................................................................... 63

5.8 UPS Reset Procedure after EPO Procedure ...................................................................................................... 63

5.9 Auto Restart........................................................................................................................................................ 63

5.10 Language Selection .......................................................................................................................................... 64

5.11 Changing The Current Date And Time.............................................................................................................. 64

5.12 Change Password............................................................................................................................................. 64

Chapter 6 Battery .............................................................................................................................................................. 66

6.1 Introduction ......................................................................................................................................................... 66

6.2 Safety.................................................................................................................................................................. 66

6.3 UPS Batteries ..................................................................................................................................................... 68

6.4 Installation Design Considerations...................................................................................................................... 69

6.5 Battery Installation Environment and Number of Batteries Needed .................................................................... 69

6.5.1 Installation Environment .......................................................................................................................... 69

6.5.2 Number of Batteries Needed ................................................................................................................... 70

6.6 Battery Protection ............................................................................................................................................... 70

6.7 Battery Connection ............................................................................................................................................. 71

6.7.1 Fitting The Batteries ................................................................................................................................ 71

6.7.2 Connecting The Battery........................................................................................................................... 71

6.8 Battery Installation .............................................................................................................................................. 71

6.9 Battery Cabinet (Optional) .................................................................................................................................. 72

6.10 Battery Temperature Detecting Resistor........................................................................................................... 75

6.11 Battery Maintenance ......................................................................................................................................... 75

6.12 Recycle of Batteries .......................................................................................................................................... 75

Chapter 7 1+N Parallel System Installation....................................................................................................................... 76

7.1 Configuration ...................................................................................................................................................... 76

7.1.1 Overview.................................................................................................................................................. 76

7.1.2 External Protective Devices..................................................................................................................... 77

7.1.3 Install Cabinet.......................................................................................................................................... 77

7.1.4 Power Cables .......................................................................................................................................... 77

7.1.5 Parallel Communication Board (IMC) ...................................................................................................... 78

7.1.6 Control Cable........................................................................................................................................... 79

7.1.7 Remote EPO ........................................................................................................................................... 79

7.2 Hot Standby System ........................................................................................................................................... 80

7.2.1 External Protection Devices..................................................................................................................... 80

7.2.2 Install Cabinet.......................................................................................................................................... 80

7.2.3 Power Cables .......................................................................................................................................... 81

7.2.4 Control Cables......................................................................................................................................... 81

7.3 Dual-bus System................................................................................................................................................. 81

7.3.1 External Protection Devices..................................................................................................................... 81

7.3.2 Install Cabinet.......................................................................................................................................... 82

7.3.3 Power Cables .......................................................................................................................................... 82

7.3.4 Control Cables......................................................................................................................................... 82

Chapter 8 Specifications ................................................................................................................................................... 84

8.1 Conformity And Standard.................................................................................................................................... 84

8.2 Environmental Requirements.............................................................................................................................. 84

8.3 Mechanical Characteristics ................................................................................................................................. 84

8.4 UPS Electrical Characteristics (Input Rectifier) ................................................................................................... 85

8.5 UPS Electrical Characteristics (DC Intermediate Circuit).................................................................................... 85

8.6 UPS Electrical Characteristics (Inverter Output) ................................................................................................. 86

8.7 UPS Electrical Characteristics (Bypass Input) .................................................................................................... 87

8.8 UPS Electrical Characteristics (System Performance)........................................................................................ 87

Chapter 9 Service & Maintenance..................................................................................................................................... 88

9.1 Safety.................................................................................................................................................................. 88

9.2 UPS Key Components And Their Lives .............................................................................................................. 88

9.2.1 Magnetic Components: Transformer, Inductor ........................................................................................ 88

9.2.2 Power Semiconductor Devices................................................................................................................ 88

9.2.3 Electrolytic Capacitors ............................................................................................................................. 88

9.2.4 AC Capacitors ......................................................................................................................................... 88

9.2.5 Dust Filter ................................................................................................................................................ 89

9.2.6 Lives And Recommended Replacement Time Of Key Components ....................................................... 89

9.2.7 Replacing Fuses...................................................................................................................................... 89

9.3 Maintenance ....................................................................................................................................................... 89

Appendix 1

Transportation Restraints Removing Procedures ......................................................................................... 90

1. Rectifier Input Transformer Transportation Restraints Removing Procedures...................................................... 90

2. Inverter Output Transformer Transportation Restraints Removing Procedures .................................................... 91

Appendix 2 : Hazardous Substances or Elements Announcement

............................................................................ 92

Chapter 1 General Description 1

1. General Description

This chapter briefly introduces the features, design philosophy and operation mode of the HIPULSE-NXL 500/800kVA

UPS.

Features

The HIPULSE-NXL 500/800kVA UPS is connected between a critical load, such as a computer, and its 3-phase mains power supply to provide high quality 3-phase output power supply. The system offers the user the following advantages:

increased power quality

The UPS has its own internal voltage and frequency regulators which ensure that its output is immune to voltage and frequency variations on the mains power lines.

increased noise rejection

By rectifying the input AC power to DC power, and then converting it back to AC power, any electrical noise present on the input mains supply line is effectively isolated from the UPS output, therefore the critical load sees only clean power.

power blackout protection

If the mains power fails, the UPS continues to power the critical load from its battery, leaving the load immune from power disturbances.

Design Philosophy

System Design

This section describes the operating principle of HIPULSE-NXL 500/800kVA UPS single module. The HIPULSE-NXL

UPS basically operates as an AC-DC-AC converter (see Figure 1-1). The first conversion stage (from AC to DC) uses a 3-phase, fully controlled silicon-controlled resistor (SCR) bridge rectifier to convert the incoming mains supply into a regulated DC bus.

Fig.1- 1 Single module block diagram

The rectifier provides battery charging power – using advanced temperature compensated battery technology, to prolong battery life. The inverter uses the latest large capacity integrated gate bipolar transistor (IGBT) and space vector pulse width modulation (SVPWM) control circuit to reconvert the DC bus voltage back into an AC voltage waveform.

During normal operation, both the rectifier and inverter sections are active and provide regulated load power whilst simultaneously charging the battery. In the event of a mains power failure, the rectifier becomes inoperative and the inverter is powered solely from the battery. Critical load power is maintained under these conditions until the battery is discharged below EOD voltage, whereupon the UPS shuts down (if bypass is normal, the system transfers to bypass mode). The end of battery discharge has been preset. The period for which the load can be maintained following a

HIPULSE-NXL UPS Module 500/800kVA User Manual

2 Chapter 1 General Description mains power failure is known as the system’s “Autonomy Time”, and this time is dependent upon both the battery

A/Hr capacity and the applied percentage load.

Bypass Supplies

Through the intelligent control of “Static switch” in Figure 1-2 that contains an electronically controlled switching circuit, the topology enables the critical load to be connected either to the inverter output or to a bypass supply. During normal operation, the load is connected to the inverter, and the inverter-side of the static switch is turned on. But in the event of a UPS overload (overload time is out) or inverter failure, the “Static switch” module automatically transfers the load to the bypass.

Fig.1- 2 UPS power switches configuration

To provide an uninterrupted load transfer between the inverter and bypass, the inverter output and bypass supply must be fully synchronized during normal operation.

To achieve this, the inverter control circuit makes the inverter output frequency track to the bypass，provided that the bypass remains within an acceptable frequency window.

A manually maintenance bypass switch is also incorporated into the HIPULSE-NXL 500/800kVA UPS design. Its purpose is to enable the critical load to be powered from the maintenance bypass while the UPS is shut down for routine maintenance.

Note: The power supply quality of load equipment is not ensured when load on bypass side or maintenance bypass.

System Control Principles

Normal operation

During normal operation, that is, when the UPS input supply is present and within nominal window, both the rectifier and inverter sections are active and the inverter powers the critical load. The battery circuit breaker (BCB) is also closed and the battery is therefore permanently float charged at the DC bus voltage level.

Mains input failure

If the mains power is interrupted or is out of nominal window, the rectifier will turn off automatically, while the inverter will continue to operate from the battery for a period of time which depends on the load and the capacity of the battery.

If the mains supply has not returned within this time untill the battery voltage drops to the end of discharge voltage, the inverter will turn off automatically and an alarm message will appear on the operator and display panel of the

UPS.

Return of mains power

When the mains returns within the required time limit, the rectifier will start up again automatically and its output power increases gradually, supplying power to the inverter and recharging the battery at the same time. There will be no interruption of the critical load.


Chapter 1 General Description 3

Battery disconnection

If the battery system needs to be taken out of service for maintenance, it can be disconnected by means of (an) external disconnect breaker (s). The UPS shall continue to function and meet all of the specified steady-state performance criteria, except for storage mode.

UPS single module fault

In the event of an inverter fault, the load will be automatically transferred to the bypass without interruption. In such an event, please seek technical assistance from Emerson local customer service center.

Overload

In the event of an overload at the inverter output which lasts longer than the specified nominal time/current (refer to table 8-6), the load will be automatically transferred to the bypass without interruption. If the actual load falls within the specified nominal time/current, the load will be returned to the inverters. In the event of a short circuit in the output, the load will normally be transferred to the bypass, and the inverter will shut down. This transfer is determined by the features of the protective devices used in the system.

In both above cases, an alarm message will appear on the operator and display panel of the UPS.

Maintenance bypass

A second bypass circuit contained in the UPS cabinet, identified as the maintenance bypass, is included to provide an unprocessed mains supply to the load while facilitating a safe working environment for carrying out scheduled UPS system maintenance or trouble shooting. This circuit is manually selected by the maintenance bypass switch, and it is disconnected when it is in the OFF position.

WARNING

Do not use the internal maintenance bypass when the UPS system is comprised of more than two UPS modules in parallel.

CAUTION: If an automatic circuit breaking device is not present in the input distribution panel, there remains a dangerously high voltage at the output busbars and also on the input busbars of the UPS module that is switched off.

UPS Power Switch Configuration

Figure 1-2 illustrates the block diagram of HIPULSE-NXL UPS module in what is known as the distributed bypass configuration (that is, the bypass uses independent mains power input). In the distribued bypass configuration, the static bypass and maintenance bypass shares one independent bypass power source. When the UPS is in normal operation, all the other switches except maintenance bypass switch Q3 should be closed.

Battery Circuit Breaker

The battery should be connected to the DC bus bar through a battery circuit breaker. The battery circuit breaker is a standard optional part that should be located adjacent to the batteries. This circuit breaker is closed manually, but it contains an undervoltage release coil which enables it to be tripped when receiving a trip signal from the UPS control electronics following certain detected DC bus under voltage faults.

Battery Temperature Compensation

HIPULSE-NXL 500/800kVA UPS system offers a battery temperature compensation function. As the battery ambient temperature rises, the DC bus voltage reduces in order to sustain the battery at its optimum charge voltage (charges the battery). This must be used in conjunction with the battery temperature sensing device. The battery temperature measurement sensor is a standard battery temperature detecting component.

Operation Mode

The UPS has the following operating modes:


4 Chapter 1 General Description

Normal mode

The mains power is firstly rectified through the UPS rectifier, and is then inverted by an inverter that continuously supplies the load. In the meantime, the rectifier/charger perform float or equalize charging to backup battery.

Battery mode

In battery mode, the critical AC load is supplied by the inverter, which obtains power from the battery. There is no interruption in power to the load upon failure of the AC mains input power because the UPS will transfer to battery mode automatically. When the AC mains input power is restored, the system will return to the Normal mode operation automatically, and the power to the load will not be interrupted.

Auto-restart mode

The UPS provides the auto-restart function. That is: The battery becomes exhausted following a prolonged AC mains failure. The inverter shuts down when the battery reduced to the end-of-discharge voltage. When the mains power returns, the UPS can be programmed to Auto restart after a set variable delay time. This mode and any delay time of auto-restart can be configured by the commissioning engineer authorized by Emerson.

Bypass mode

The load power is supplied by the mains power of static bypass. This mode can be considered as an intermediate operating condition which is for the load transfer between inverter and maintenance bypass or a power supply mode under abnormal operating conditions.

Maintenance mode

The UPS is shut down but the load is connected to the mains power of through the maintenance bypass switch.

Load Sharing mode

Due to the Load sharing mode, the UPS has the capability of fully supporting its load while limiting the amount of power taken from the incoming AC mains supply. Any balance of power required is supplied by the UPS battery. This feature is useful in applications where peak-hour tariffs apply or where a generator that has smaller capacity than needed powers the UPS during mains-power outages. The Load sharing mode is user-activated and the ratio of the mains AC input power is programmable from 50% to 125% of the rated UPS output power.


Chapter 2 Mechanical Installation 5

2. Mechanical Installation

This chapter briefly introduces the mechanical installation of the HIPULSE-NXL 500/800kVA UPS, including the cautions, environmental and mechanical requirements for installation, inspections before installation and installation drawings.

Cautions

WARNING

Do not apply electrical power to the UPS equipment before the commissioning engineer arrives at installation site.

WARNING

The UPS should be installed by a qualified engineer in accordance with the information contained in this chapter. All equipment this manual not referred is shipped with details of its own mechanical and electrical installation information.

WARNING: battery hazards

Special care should be taken when installing the batteries. When connecting the battery, the battery terminal voltage will exceed

540Vdc and is potentially lethal.

1. Eye protection should be worn to prevent injury from accidental electrical arcs.

2. Remove rings , watches and all metal objects.

3. Only use tools with insulated handles.

4. Wear rubber gloves.

5. If a battery leaks electrolyte, or is otherwise physically damaged, it must be replaced, stored in a container resistant to sulfuric acid and disposed of in accordance with local regulations.

6. If electrolyte comes into contact with the skin, the affected area should be washed immediately with water.

WARNING

The UPS system can be connected to a power system whose neutral point is not earthed (that is an IT system).

This chapter describes the environmental and mechanical requirements that must be taken into account when positioning and cabling the UPS equipment.

Because every site has its peculiarities, this chapter does not provide step-by-step installation instructions, but to provide generic installation procedures and practices that should be observed by the installing engineer according to actual site conditions.

Environmental Requirements

UPS Positioning

The UPS module should be located in a cool, dry, clean-air environment with adequate ventilation to keep the environmental parameters within the specified operating range (see Table 8-2 environmental conditions).

The HIPULSE-NXL 500/800kVA UPS uses forced convection cooling by internal fans. Cooling air enters the module through ventilation grills located at various parts of the cabinet and exhausted through grills located in the cabinet roof.

When the UPS cabinet is installed on a raised floor, and bottom cable entry is used, additional cooling air also enters the UPS through the floor void. If necessary, a system of extractor fans should be installed to aid cooling-air flow, and air filters are used where the UPS is to operate in a dirty environment.


6 Chapter 2 Mechanical Installation

Note 1: When battery cabinet is mounted adjacent to the UPS, it is the battery which dictates the designed maximum ambient temperature, not the UPS.

Note 2: The UPS should be installed on a cement surface or other surface that is not combustible.

Note 3: Since the UPS has a greater power loss when it operates in inverter mode, the cooling capacity of air conditioner should be selected according to the power loss in inverter mode. Refer to table 7-8 Electrical performance

(system performance)

Battery Positioning

Ambient temperature is a major factor in determining the battery capacity and life. The nominal operating temperature of battery is 20°C. Operating above this temperature will reduce the battery life, and operation below this temperature will reduce the battery capacity. In a normal installation the battery temperature is maintained between

15°C and 25°C. Batteries should be mounted in an environment where the temperature is constant stable. Keep batteries away from main heat sources or main air outlets.

The batteries can be mounted in specific battery cabinet, which is positioned adjacent to the UPS module. Brackets are needed for the batteries when they are located on raised floors, in the same way as for the UPS cabinets. If the batteries are rack-mounted, or otherwise located remote to the UPS cabinet, the battery circuit breakers must be mounted as close as possible to the batteries, and the connecting cables should be as short as possible. The battery interface board (BIB) and the battery circuit breaker (BCB) should be placed inside the BCB box.

Mechanical Requirements

Components of System

A UPS system can comprise a number of cabinets such as UPS cabinet and battery cabinet, depending on the specific system design requirements. The 500kVA UPS cabinet comprises 2 cabinets which are a rectifier cabinet and an inverter cabinet. The 800kVA UPS cabinet comprises 3 cabinets which are a rectifier cabinet, an inverter cabinet and a switch cabinet. In general, all the cabinets used in the same installation site are of the same height and should be positioned side-by-side to achieve an aesthetically appealing effect.

Transporting The Cabinets

WARNING

1. Ensure that any lifting equipment that used in moving the UPS cabinet has sufficient lifting capacity.

2. Do not lift the cabinet in installation.

Ensure that the UPS weight is within the weight loading capacity range of any hoisting equipment. See Table 8-3 for

UPS weight.

The UPS cabinet can be moved by a forklift. Before moving the UPS cabinet, it is necessary to remove both the front, rear (or side) grille panels located at the base of the cabinet.

Clearances Required For Operating

As HIPULSE-NXL 500/800kVA UPS has no ventilation grills at either the sides or the rear, no clearances are required for the side and rear sides. However, where space permits, a clearance of approximately 600mm at the back will ease access to magnetic component parts. Clearance around the front of the equipment should be sufficient to enable free passage of personnel with the doors fully opened.

Removing Transportation Rubber Bar and Restraints

In order to avoid the friction between the internal doors of the cabinet during transportation, some rubber bars are mounted between the internal doors before the delivery of the UPS. After the UPS has arrived at the customer site, these rubber bars need to be removed.



Before the UPS is put in place, remove the transportation restraints that hold the input and output transformers in place. For procedures, refer to Appendix 1 Transportation Restraints Removing Procedures.

Cable Entry Method

The HIPULSE-NXL500/800kVA UPS can use either the top cabling or bottom cabling mode.

Top cabling can be made by removing cover boards of the rectifier cabinet and switch cabinet to expose the installation holes of copper busbars.

Bottom cabling can be made by removing left cover boards at the bottom of the rectifier cabinet to expose the installation holes of copper buss, and the installation holes of copper buses are visible if you remove the right cover board at the bottom of the inverter cabinet (switch cabinet of 800kVA). For bottom cabling, the cables should enter from the rear side of the rectifier cabinet and inverter cabinet.

Note: When selecting the power cables for bottom entry to a UPS, consideration must be given to the minimum permissible radius of the proposed cables and proper routing of the cables so as to ensure that they can be orderly connected the UPS connection copper bars.

Mechanical Connection Between Cabinets

The HIPULSE-NXL 500/800kVA UPS is composed of multi cabinets and the mechanical connections between the cabinets are needed to fix the cabinets and avoid the movement of the cabinets due to mechanical vibration.

Moreover, the mechanical connection can ensure the reliable grounding of the cabinets.

As shown in Figure 2-1, the HIPULSE-NXL 500kVA UPS comprises of the rectifier cabinet and the inverter cabinet.

The cabinets should be connected by bolts mounted at location A (upper) and location B (lower) in the front part of the cabinet. The corresponding upper and lower locations on the rear part of the cabinet should also be connected via bolts. The bolts used in these four locations in the front and rear part should be identical and each location should use 2 bolts, that is, the connection between the cabinets should use 15 PCS M10×30 bolts, M10 plain washer and

M10 spring washers each. The recommended tightening torque for M10 bolt and nut is 35Nm.



Fig.2- 1 Mechanical connections between 500kVA UPS cabinets

As shown in Figure 2-2, the HIPULSE-NXL 800kVA UPS is composed of three cabinets that are the rectifier cabinet, the inverter cabinet and the switch cabinet. The cabinets should be connected by bolts mounted at the locations A, B,

C and D in the front part of the cabinet. The bolts mounted at locations A, C and D should be identical and each location should be mounted with 2 bolts. The location B should be mounted with 1 bolt. The corresponding locations

A, B, C and D in the rear part of the cabinet should be also mounted with the identical bolts to connect the cabinets.

Each location should be mounted with 2 bolts. Therefore, the mechanical connection between the cabinets need 15

PCS M10×30 bolts, M10 plain washer and M10 spring washer each. The recommended tightening torque for M10 bolt and nut is 35Nm.


B


C

A D

Bolt M10×30 (2PCS)

Flat washer M10 (2PCS)

Spring Washer M10 (2PCS)

A detail

Fig.2- 2 Mechanical connections between 800kVA UPS cabinets

Preliminary Inspection

Carry out the following preliminary inspections before you install the UPS:

1. Verify that the UPS room satisfies the environmental conditions stipulated in the equipment specification, paying particular attention to the ambient temperature, ventilation conditions, and dust density.

2. Remove the packages of the UPS and batteries, visually examine if there is any damage inside and outside the

UPS and battery equipment due to the transportation. Report any such damage to the shipper immediately.



Installation Drawings

The following drawings of Figure 2-3 and Figure 2-4 illustrate the key mechanical characteristics of the

HIPULSE-NXL 500/ 800kVA UPS cabinets.

Left view

右视图

Fig.2- 3 Top, front, side and bottom views of 500kVA UPS (unit in mm)



Fig.2- 4 Top, front, side and bottom views of 800kVA UPS (unit in mm)


12 Chapter 3 Electrical Installation

3. Electrical Installation

This chapter introduces the electrical installation of the HIPULSE-NXL 500/800kVA UPS, including the procedures or methods for power cabling and control cabling, and the distance from floor to connection point, dry contact wiring and the electrical connection between cabinets.

The UPS requires both power cabling and control cabling once it has been mechanically installed. All control cables, whether shielded or not, should be run separately from the power cables in metal conduits or metal ducts which are electrically bonded to the metalwork of the cabinets to which they are connected.

Power Cabling

WARNING

Prior to cabling the UPS, confirm the status and positions of the switches of the UPS rectifier input power supply / bypass power supply and mains power distribution board.

Ensure that these switches are opened and attached with WARNING label so as to prevent unauthorized operation to these switches.

For cable entry, refer to 2.3.5 Cable Entry.

System Configuration

The power cables of the system must be size with respect to the following description:

UPS input cables

The input cables must be sized for the maximum input current, including the maximum battery recharge current, given in the Table 3-1, with respect to the UPS capacity rating and the input AC voltage.

UPS bypass and output cables

The bypass and output cables must be sized for the nominal output current or bypass current, given in the Table 3-1, with respect to the UPS capacity rating and the output AC voltage.

Battery cables

Each UPS module is connected to its battery through cables, positive cables and negative cables. The battery cables must be sized for the battery discharge current when the battery voltage is close to the end-of-discharge voltage, as given in Table 3-1 with respect to the UPS capacity rating.

Cable Specificatios

The cable specifications of HIPULSE-NXL 500/800VA UPS are given in Table 3-1.

Table 3- 1 UPS power cable specifications

UPS rating

(kVA)

Input current 1

Nominal current: Amps

Rated output / bypass current

380V 400V 415V 380V 400V 415V

Battery discharging current at minimum battery voltage 2

Busbar bolt size

Input/battery cables

Recomm ended

ΦHol torque

Bolt e

(Nm)

Output/bypas s input cables

Nut

Recomm ended torque

(Nm)

500 1068 1041 1030 760 722 696

800 1703 1689 1685 1216 1155 1113

1174

1978

M12

M12

13

13

50

50

M12

M12

50

50

Notes:

1. EN50091-3: rated load, input rated voltage of 380V/400V/415V, battery is charged with the 15% of rated current, without Trap


Chapter 3 Electrical Installation 13 filter.

2. Lowest battery voltage is 400V (the lowest votlage can be set through host computer)

The power cables selection should comply with the current and voltage ratings in the above table 3-1, the requirements in table 3B in IEC60950-1 and the local electrical codes for cabling and actual application environment.

General Cautions

The following are generic guidelines only and superseded by local regulations and codes of practice where applicable:

1. The neutral conductor should be sized for 1.1 times the output / bypass phase current.

2. The protective earth conductor should be sized two times of output / bypass cables (dependent on the fault type, cable length and protection type).

3. Consideration should be given to the use of paralleled smaller cables for heavy currents, as this can ease installation considerably.

4. When sizing battery cables, a maximum volt drop of 3Vdc is permissible at the current ratings given in Table 3-1.

Cable Connection Terminals

The rectifier input, bypass input, output and battery power cables are connected to copper busbars besides the power switches, as shown in Figure 3-2. The external interface board (EIB) including the dry contacts connect to the corresponding interface of the battery interface board (BIB). See 3.3.2 Dry contacts, 3.3.4 Emergent Stop Input

Interface and 3.3.7 Battery Control.

Protective Earth

The protective earth busbar is located near the input and output power supply connections as shown in Figure 3-2.

The protective earth cable must be connected to the earth busbar and bonded to each cabinet in the system. All three cabinets must be reliably connected through parallel connection bolts. All the cabinets and cable chutes should be earthed in accordance with local regulations. The earth cable should be bounded with binding strips onto the metallic column for cabling, so as to prevent the fixing screw of the earth cable from loosening, in the case the earth cable is pulled.

WARNING

Failure to follow the grounding procedures will result in electric hazard or fire accident.

Protective Devices

For safety concerns, it is necessary to install external circuit breakers for the input AC supply and the battery of the

UPS system. Since every installation has its own characteristics, this section provides generic practical information for installation engineers, including the knowledge of operating practices, of regulatory standards, and of the equipment to be installed.

Rectifier and bypass input supply of the UPS

1. Protection against over currents and short circuits in the mains supply input

Install suitable protective devices in the distribution unit of the incoming mains supply, considering the power cable current-carrying capacity and overload capacity of the system (see Table 8-6 and Table 8-7).

2. distributed bypass

The 500/800kVA UPS uses a distributed bypass, so separate protective devices should be installed in the incoming mains distribution unit and bypass distribution unit respectively. During installation, the current carrying capacity of the power cables and the system overload capability should be taken into consideration (see table 8-6 and table 8-7).

3. Protection against earth faults

If a residual current detector (RCD) device is installed upstream of the input supply, be sure to take into account the transient and steady state earth leakage currents that are produced during start-up of the UPS.



Residual current circuit breakers (RCCB) should meet the following requirements:

Be sensitive to DC unidirectional pulse (Class A) in the entire power network

Be insensitive to transient current pulses

There is an average sensitivity that is adjustable between 0.3A and 1A.

The symbols of RCCB are shown in Figure 3-1:

Fig.3- 1 The symbols of RCCB

There is an EMC filter inside the UPS, so residual current presents in the protective earth line and the current is between 3.5mA and 3000mA. It is recommended to confirm the sensitivity of each RCD of upstream input distribution and downstream distribution (to load).

UPS battery

The UPS Battery is protected by means of a control circuit that operates the tripping mechanism of an automatic circuit breaking device (having an adjustable tripping threshold range). The tripping mechanism uses an undervoltage release coil that activates at the minimum battery voltage level.

The circuit breaker is essential for maintenance of the battery and is normally installed near the battery.

Output of the system

If the load has an external distribution panel, protective device must differ from input of the UPS, ensure tha the protection is selectable.

Cabling Procedure

After the equipment has been finally positioned and secured, refer to Figure 3-2 to connect the power cables as described in the following procedures:

1. Verify that all the input distribution switches of the UPS are completely opened and all the UPS internal power switches are opened. Attach necessary warning signs to these switches to prevent unauthorized operation.

2. Open the front doors of the UPS rectifier cabinet and inverter cabinet (for 800kVA UPS, it is the switch cabinet), open the internal doors and then connection copper bars are visible.

3. Connect the protective earth and any necessary grounding cables to the copper grounding busbar located in the

UPS rectifier cabinet or inverter cabinet (for 800kVA UPS, it is the switch cabinet).

Note: The grounding cable and neutral cable must be connected in accordance with local and national codes practice.

Distributed Bypass Connections

4. The 500/800kVA UPS uses a distributed bypass, so you need to connect the AC input supply cables to the rectifier input copper busbars (U1-V1-W1 terminals), and connect the bypass AC supply cables to the bypass input copper busbars (N2-U2-V2-W2 terminals). Be sure to tighten the fixing screws / bolts of the connections with the torque specified in Table 3-2. ENSURE CORRECT PHASE ROTATION.

Table 3- 2 Torques used to fix the screws / bolts of the connection cables

UPS connection cables

Rectifier input cable

Bypass input cable

Output cable

Battery cable

Grounding cable

Nuts / bolts

M12 bolt

M12 nut

M12 nut

M12 bolt

M12 bolt

Recommended torque(Nm)

50

50

50

50

50

Output System Connections


Chapter 3 Electrical Installation 15

5. Connect the system output cables between the output copper busbars (N3-U3-V3-W3 terminals) and the load and tighten the fixing screws / bolts of the connections with the torque specified in Table 3-2. ENSURE CORRECT

PHASE ROTATION.

WARNING

If the load equipment will not be ready to accept power on the arrival of the commissioning engineer then ensure that the system output cables are safely insulated at their ends.

Battery Connections

6. Connect the battery cables between the UPS terminals (+/-) and its associated battery circuit breaker, and tighten the fixing screws / bolts of the connections with the torque specified in Table 3-2. Connect shielded CAN communication cables between BIB board (battery interface board) and EIB board (external interface board). Note:

OBSERVE THE BATTERY CABLE POLARITY .

WARNING

Do not close the battery circuit breaker until the equipment installation is completed.

7. After confirming that all the cables are connected. First close the inner door and then the cabinet door.

C

A

PE bar

B

Fig.3- 2 Power cable connections for 500kVA UPS



Fig.3- 3 Power cable connections for 800kVA UPS

Distance From Floor To UPS Connection Point

The distance between the UPS connection point to floor is given in Table 3-3.

Table 3- 3 The distances from floor to connection points

UPS connection points

Rectifier AC input bus

Bypass AC input bus

UPS AC output bus

Battery input bus

Grounding bus of rectifier cabinet

Grounding bus of switch cabinet

Battery CAN communication cables

Control Cabling

Minimum distance to floor(mm)

500kVA 800kVA

1079 690

543

895

330

1323

1703

600

759

1279

1252

510

910

1200

Descriptions

Based on your site’s specific needs, the UPS may require auxiliary connections to manage the battery system, communicate with a personal computer or provide alarm signal to external devices or for remote Emergency Power

Off (EPO). All these functions are realized through an external interface board (EIB) and the TB1101 interface on the

CB interface board that is located on the back side of the front door of rectifier cabinet. As shown in Figure 3-4, the

EIB provides the following ports:

dry contact input ports (X3)

dry contact output port (X1)

Emergency Power Off (EPO) input port (X2)

auxiliary DC power output port (X4)



Communication ports: Intellislot ports for intelligent card and CAN dry contact interface card

DUAC

+24V_EIB

ALBER P/S

OPT P/S

2-pin

MNL

3-term reg

BATT MTR OP

LBS V

CAN

Isolation

Service

Terminal

+24V to +48V, +24V, +12V, and

+5V Isolated Power Supply

REPO

Intellislot

Comms

DB9

SVT

DUAC

HMI

RS485

MC9S12DT128 circuit

X3

GFI 1

SPARE

AUX 1

MOB

MIB

RIB

MBB

BIB

KEY

STATUS

DUAC

TEMP1

DUAC

TEMP2

Active Filter

In

Active Filter

Out

REPO

ON

GEN

LOAD ON

BYP

BYP

CNTRL

RECT

CNTRL

INV

CNTRL

X2

LEPO

X3

X1

X3

X1

X3

INT BATT CAN EXT BATT CAN

EXT CAN

REPO

STATUS

X1

X4

34

Intellislot connections

Fig.3- 4 Ports of external interface board (EIB)

Input Dry Contact Interface

X3 is the dry contact input port. The dry contact input port(X3) includes:

1. Input dry contact of auxiliary switch:

Status detection port TB0810 of RIB (rectifier input circuit breaker) or Q11 (external input isolation circuit breaker in maintenance bypass cabinet)

Status detection port TB0811 MIB (maintenance isolation circuit breaker) or QOP (external output isolation circuit breaker)

Status detection port TB0812 BIB (bypass input circuit breaker) or Q22 (bypass isolation circuit breaker)

Status detection port TB0813 MBB (maintenance bypass circuit breaker) or QBP (external maintenance bypass circuit breaker)

TB0815 Status detection port TB0815 MOB(rectifier output circuit breaker) or QFS (external input isolation circuit breaker in transformer cabinet).

2. Input dry contact of control status:

Detection port TB0830 of Active Filter

Detection port TB0816 of ON_GEN(Generator powers the UPS)

Detection port TB0817 of Rectifier

Detection port TB0818 of Inverter

Detection port TB0820 of Key Status(status of MBB switch lock)

Detection port TB0821 of Rly (maintenance bypass enable)

Detection port P0801 of GNDFLT(battery grounding fault)

The dry contact input ports are shown in Figure 3-4 and the descriptions are given in Table 3-5.



The UPS accepts external signal from zero-voltage (dry) contacts connected through Phoenix terminals. Through software programming, these signals become active when these contacts connect to +24V or to ground. The cables connected to Phoenix terminal must be separated from power cables to avoid EMI. Moreover, these cables should be double insulated with a typical 0.5 to 1.5mm

2 cross-section area for maximum connection length between 25 and 50 meters.

TB0810 TB0811 TB0812 TB0813 TB0830

TB0815 TB0816 TB0817 TB0818 TB0820

TB0821 P0801

Fig.3- 5 Input dry contact port

Note

In the drawing, the black block (■) indicates pin 1, and same for the following drawings.



Table 3- 4 Description of dry contact input port

Position Name

TB0810.1 EIB_RIB_IS_CLOSED

TB0810.2 +24V_RIB

TB0810.3 EIB_RIB_IS_OPEN

TB0811.1 EIB_MIB_IS_CLOSED

TB0811.2

TB0811.3

+24V_MIB

EIB_MIB_IS_OPEN

TB0812.1 EIB_BIB_IS_CLOSED

TB0812.2 +24V_BIB

TB0812.3 EIB_BIB_IS_OPEN

TB0813.1 EIB_MBB_IS_CLOSED

TB0813.2 +24V_MBB

TB0813.3 EIB_MBB_IS_OPEN

TB0815.1 EIB_MOB_IS_CLOSED

TB0815.2

TB0815.3

TB0830.1

TB0830.2

TB0830.3

TB0816.1

+24V_MOB

EIB_MOB_IS_OPEN

EIB_ACTFLT_OPERABLE

+24V_SPARE2

EIB_ACTFLT_NOT_OPERABLE

EIB_ON_GEN

TB0816.2

TB0816.3

+24V_ONGEN

EIB_NOT_ON_GEN

TB0817.1 EIB_RECTIFIER_ON

TB0817.2 +24V_RECTCTRL

TB0817.3

TB0818.1

TB0818.2

EIB_RECTIFIER_OFF

EIB_INVERTER_ON

+24V_INVCTRL

TB0818.3

TB0820.1

EIB_INVERTER_OFF

EIB_KEY_IS_REMOVED

TB0820.2 +24V_KEY

TB0820.3 EIB_KEY_IS_INSERTED

TB0821.1

TB0821.2

EIB_RLY_NOT_ACTIVE

+24V_RLY_COM

TB0821.3

P0801.1

EIB_RLY_ ACTIVE

+24_ISO_PTC

P0801.2 EIB_GNDFLT_SIG1_L

P0801.3 CGND

P0801.4 EIB_GNDFLT_SIG2_L

Meaning detection of RIB or Q11(normally closed)

+24V power supply detection of RIB (normally opened) detection of MIB or QOP (normally closed)

+24V power supply

Status detection of MIB (normally opened) detection of BIB or Q22 (normally closed)

+24V power supply

Status detection of BIB (normally opened)

Status detection of MBB or QBP (normally closed)

+24V power supply

Status detection of MBB (normally opened)

Status detection of MOB or QFS (normally closed)

+24V power supply

Status detection of MOB (normally opened)

Active filter can work (normally closed)

+24V power supply

Active filter cannot work (normally opened)

Generator powers the UPS (normally opened)

+24V power supply

Generator does not power the UPS (normally closed)

Rectifier works(normally opened)

+24V power supply

Rectifier shuts down(normally closed)

Inverter works (normally opened)

+24V power supply

Inverter does not work (normally closed)

MBB switch lock is disabled(normally opened)

+24V power supply

MBB switch lock is enabled(normally closed)

Maintenance bypass is disabled(normally closed)

Power supply earth

Maintenance bypass is enabled (normally opened)

+24V power supply

Battery grounding fault signal 1

Battery grounding fault signal 2

Note

All auxiliary cables must be double insulated twisted cables with cross sectional area of 0.5~1.5mm

2 .



Dry Contact Output Port

X1 is the dry contact output port.

X1 port provides 3 dry contact output signals. The pins of dry contact port are shown in Figure 3-5 and the descriptions of the port are given in Table 3-5:

TB0819 TB0835 TB0823

Fig.3- 6 Output dry contact port

Table 3- 5 Description of dry contact output port

Position

TB0819.1 EIB_BYPASS_ON

Name

TB0819.2 +24V_BYPVTRL

TB0819.3 EIB_BYPASS_OFF

TB0835.1

TB0835.2

EIB_ACTFILT_OFF

EIB_ACTFILT_COM

TB0835.3 EIB_ACTFILT_ON

TB0823.1 EIB_EPO_IS_NOT_ACTIVE

TB0823.2

TB0823.3

EIB_EPO_STATUS_COM

EIB_EPO_IS_ ACTIVE

Meaning

Bypass is on(normally closed)

+ 24V power supply

Bypass is off(normally opened)

Active filter is off(normally opened)

Power supply earth

Active filter is on (normally closed)

Power supply earth

EPO is enabled (normally opened)

Note

All auxiliary cables must be double insulated twisted cables with cross sectional area of 0.5~1.5mm

2 .

EPO Input Port

X2 is EPO input port.

The UPS has an Emergency Power Off (EPO) function. This function can be activated by pressing a button on the front door of UPS rectifier cabinet or through a remote contact provided by the user. The UPS provides 3 kinds of

EPO functions, which are REPO(remote EPO), REPO_FORM_C(remote EPO) and LEPO(local EPO). REPO and

REPO_FORM_C have different interfaces. However their effects are same. LEPO is the EPO button on the front door of UPS rectifier cabinet.

Figure 3-7 shows the two kinds of EPO input ports. The NC and NO of REPO input port are compatible, but the NC of

REPO_FORM_C input port is just inverse to NO. Figure 3-7 shows the local EPO input port. The descriptions of these three ports are given in table 3-6.



TB0825 TB 0824

NC NO

REPO

REPO input port

NC NO

REPO_ FORM_C

Fig.3- 7 LEPO input port

Table 3- 6 Description of EPO input relay

Position

TB0825.1

TB0825.2

TB0825.3

TB0825.4

TB0824.1

TB0824.3

P0806.1

Name

REPO_NO

REPO_NO

REPO_NC

REPO_NC

REPO_FORM_C_NO

REPO_FORM_C_NC

LEPO.NC

Meaning

EPO is activated when it is short circuited with TB0825.2


EPO is activated when it is disconnected from TB0825.4



EPO is activated when it is short circuited with TB0824.1 and disconnected from TB0824.3


EPO is activated when it is disconnected from P0806.1

P0806.2 LEPO.NC EPO is activated when it is disconnected from P0806.2

The external emergency power off device uses shielded cables to connect to the normally open or normally closed

REPO switch between the two terminals of REPO or REPO_FORM_C. If REPO function is not needed, take the following steps:

1. Disconnect pin 1 and pin 2 of TB0825, and short circuit pin 3 and pin 4 of TB0825.

2. Short circuit pin 2 and pin 3 of TB0824, and disconnect pin 1 of TB0824.

If LEPO function is not needed, short circuit pin 1 and pin 2 of P0806.

Note

The emergency stop action within the UPS shuts down the rectifier, inverter and static bypass. However, it does not internally disconnect the mains input power supply. To disconnect ALL power to the UPS, open the upstream input circuit breaker(s) when the EPO is activated.

Auxiliary DC power output port

The auxiliary DC power output port X4 provides auxiliary DC power for optional SNMP card. X4 connects the pin 6 of

Intellislot intelligent communication port. The voltage is 11V. The maximum current is 650mA.

Communication Ports

The communication ports are the Intellislot intelligent communication ports and CAN dry contact interface card.

HIPULSE-NXL 500/800kVA UPS offers 1 Intellislot intelligent communication port and 1 port for CAN dry contact interface card, which are used for installing the communication optional part of SNMP card and dry contact card.



Intellislot only supports RS485 serial port communication and the supported monitoring devices include SNMP card.

The CAN port supports CAN communication and the supported monitoring devices include the dry contact card.

Battery Circuit Breaker Interface

EXT BATT CAN (TB1154A) is the interface of battery circuit breaker.

The BCB (battery circuit breaker) is controlled by the BIB (Battery interface board). Both are located in the battery box(cabinet). This BIB controls the under-voltage release coil of battery circuit breaker. When DC under voltage happens, UPS control circuit sends signal to this coil to trip the battery circuit breaker, and it also provides a path for the circuit breaker auxiliary contacts to report the circuit breaker status to the UPS control logic.

The BIB connects to the UPS through the EXT BATT CAN(TB1154A) port on the EIB board on UPS rectifier cabinet.

The pin distribution of TB1154A port is shown in Figure 3-8. The pin descriptions are given in Table 3-7.

Fig.3- 8 Pins of TB1154A port

Table 3- 7 Definition of TB1154A port

Pins

1

2

3

4

BATT +24V

GND

BATT CANH

BATT CANL

Label

Power supply +

Power supply earth

Meaning

CAN signal

CAN signal

Notes

1. The CAN cable of battery must be shielded and the shielding layer should be earthed.

2. Use multiple-conductor shielded cables with a cross sectional area of 0.5 to 1.5 mm 2 .

Connect the BCB control cables between the UPS EIB (external interface board) and BIB as shown in Figure 6-5. All these cables should be shielded. The temperature detecting sensor should be connected to P1153 of BIB.

Note

If battery temperature compensation is needed, this function must be activated through the host computer by the commissioning engineer.

TB1101 Port

The TB1101 port on the CB interface board provides the drive signal of 48VDC coil. In addition, it sends the switching signal of BFB (bypass back-feeding circuit breaker) to UPSC board. The pins of TB1101 port are shown in Figure 3-9 and the descriptions of pins are given in Table 3-8.



TB1101

Fig.3- 9 Pins of TB1101 port

Table 3- 8 Definition of pins of TB1101port

Pins Name

TB1101.1 COM

TB1101.2

TB1101.3

OPEN

ClOSED

TB1101.4

TB1101.5

48V_COIL_DRIVE

48V_COIL

Meaning

48V power supply-

CB is opened

CB is closed

48VDC coil drive signal

48V power supply +

Note:

1. After BFB is enabled, the pin 4 and pin 5 TB1101port of CB interface board output 0V.

2. When bypass back-feeding happens, the pin 4 and pin 5 TB1101 port of CB interface board output 48V/40ms pulse signal to trip BFB.

3. The TB1101 output load of CB interface board needs to connect the inductive components (with coils) .

Electrical Connection Between Cabinets

HIPULSE-NXL 500/800kVA UPS cabinets include multi cabinets. The electrical connection among these cabinets are needed after the mechanical connections, which include power connection and signal connection.

Power Connections

The power connections among the cabinets of HIPULSE-NXL 500/800kVA UPS are made through power cables and copper busbars. The installation engineers must connect the copper busbars strictly according to the illustration drawings. The recommended torque of M12 bolt / nut is 50Nm.

There is only copper busbar connection between rectifier cabinet and inverter cabinet of 500kVA UPS and there is no power cable connection between them. The connections of copper busbars are shown in Figure 3-10.



Connection copper-bus 1

Half-round head square neck bolt M10X35(8 PCS)

Connection copper-bus 1

A detail

Flat washer M10(8 PCS)

Spring washer M10(8 PCS)

Nut M10(10 PCS)

Fig.3- 10 Copper bus connections between 500kVA UPS rectifier cabinet and inverter cabinet

The connections of power cables of 800kVAUPS are shown in Figure 3-11 and the connections of copper busbars are shown in Figure 3-11 to Figure 3-16. There is only copper busbar connection between rectifier cabinet and inverter cabinet and there is no power cable connection between them. But there are both copper busbar connection and power cable connection between inverter cabinet and switch cabinet. The connection methods of power cables are shown in Table 3-9.

Table 3- 9 Power cable connection method between 800kVA UPS inverter cabinet and switch cabinet

Label of power cable

W28

Start point(inverter cabinet)

TOUT-X0, neutral line of transformer

End point(switch cabinet)

Neutral copper bus of Q4

Quantity


4

Meaning

Output neutral line


The installation engineers must connect the copper busbars strictly according to the illustration drawings. The recommended torque of M12 bolt/nut is 50Nm.


第三章电气安装 26

Fig.3- 11 Power cable connections among rectifier cabinet, inverter cabinet and switch cabinet


A


B

C

D

Fig.3- 12 Copper bus connections among rectifier cabinet, inverter cabinet and switch cabinet

Fig.3- 13 Enlarged view of copper busbar connections between UPS rectifier cabinet and inverter cabinet

A相

B相

C相

Fig.3- 14 Phase A/B/C of UPS inverter cabinet



Fig.3- 15 Detailed view of copper busbar connection between phase A of UPS inverter cabinet and switch cabinet

Fig.3- 16 Enlarged view of copper busbar connection between phase B of UPS inverter cabinet and switch cabinet

Fig.3- 17 Enlarged view of copper busbar connection between phase C of UPS inverter cabinet and switch cabinet



Signal Connection

There are signal cables connected between the HIPULSE-NXL 500/800kVA UPS cabinets. When connecting the signal cables, be sure to connect them to the corresponding ports on associated boards.

The connection of the signal cables between the rectifier cabinet and inverter cabinet of 500kVA UPS is described in table 3-10.

Table 3- 10 Signal cable connections between 500kVA UPS rectifier cabinet and inverter cabinet

Label of signal cable

Start point(rectifier cabinet)

W121 02-806701 board, P0300SS port

W126 02-806701 board, P0400A port

W133 02-806701 board, P0400B port

W141 02-806701 board, P0400C port

W180 02-806708 board, P55 port

W221 02-806710#1 board, P1011 port

W290 02-806708 board, P0814 port

W300 02-806701 board, P0500 port

W301 02-806701 board, P0501 port

W302 02-806701 board, P0700 port

W303 02-806701 board, P0701 port

Start or end point(inverter cabinet)

02-806803O board, P0300 port

02-806704 board, phase A P0400 port

02-806704 board, phase B P0400 port

02-806704 board, phase C P0400 port

UL544CSA8 board, P55A port







Quantity

1

1

1

1

1

1

1

1

1

1

1

Meaning

INV output SCR drive

IGBT phase A drive

IGBT phase B drive

IGBT phase C drive

EIB board power supply

Fan board 1 power supply

DC fuse detecting

BPSS board signal transmission

BPSS board signal transmission

VI Load board signal transmission

VI Load board signal transmission

W306

W307

02-806701 board, P99 port

02-806802 board, P66 port

02-806710#1 board, P66 port

02-806708 board, P99B port

UL544CSA8 board, PAA port

UL544CSA8 board, PBA port

1

1

CAN line A loop

CAN line B loop

W308 02-806701 board, P1300 port

W309 02-806701 board, P1302 port



1

1

Signal transmission of auxiliary power supply

Signal transmission of auxiliary power supply

W311

Q1_A2 copper busbar of rectifier circuit breaker


Q1_B2 copper busbar of rectifier circuit breaker

1

Power source for auxiliary power supply

The signal connection between rectifier cabinet, inverter cabinet and switch cabinet of 800 KVA UPS is shown in

Figure 3-11.

Table 3- 11 Signal connection between rectifier cabinet, inverter cabinet and switch cabinet


Start point(rectifier cabinet) Start or end point(inverter cabinet)

W121

W126

W136

02-806701 board, P0300SS port

02-806701 board, P0400A port

02-806701 board, P0400B port

02-806803 board, P0300 port

02-806704 board, phase A P0400 port

02-806704 board, phase B P0400 port

End point(switch cabinet) Quantity

1

Meaning

INV SCR drive




Start point(rectifier cabinet) Start or end point(inverter cabinet)

W146

W156

W157

W158

02-806701 board, P0400C port

ULW346SX1 board, P44 port

02-806701 board, P0500 port

02-806701 board, P0501 port

02-806704 board, phase C P0400 port

(BPSS) board, P44 port

BPSS board, P0500 port


End point(switch cabinet) Quantity

1

1

1

W159

W163

W164

W177

W178

W179

W180

W185

W186

W187

W188

W199

W201

W220

W221

W262

W264

W271

02-806701 board, P0700 port

02-806701 board, P0701 port




BPSS board, P1100B port

BPSS board, P1100C port

02-806707 board, P0700 port

02-806707 board, P0701 port

02-806707 board, P0702 port

02-806707 board, P0703 port

02-806707 board, P0713 port

02-806707 board, P0714 port

02-806707 board, P0715 port

02-806707 board, P1100 port

02-806710#1 board, P1011 port

02-806710#1 board, P66 port

02-806708 board, P66B port

02-806708 board, P0814 port

02-806716 board, P1011A port

02-806710#2 board, P99 port

02-806710#4 board, P66 port

DC FAP or DC F FCN

02-806716 board, P1601 port circuit breaker Q2 auxiliary contacts of circuit breaker Q3

auxiliary contacts of circuit breaker Q2

circuit breaker Q4

circuit breaker

Q4-2 output current transformer CT7

output current transformer CT8

output current transformer CT9

Q4 auxiliary contacts

Fuse base FB4

Fuse base FB3

circuit breaker

Q4-2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Meaning

Power supply

Bypass detecting signal

Bypass drive signal bypass input detection

Switching status detecting


Load voltage and current detecting

Load voltage and current detecting

Output voltage detecting

Rectifier voltage detecting

Output phase A current detecting

Output phase B current detecting

Output phase C current detecting


Bypass source for auxiliary power

Bypass source for auxiliary power power supply

CAN cable

CAN cable

DC fuse status detecting

Powerr source for fan


Chapter 4 Operator Control And Display Panel 31

4. Operator Control And Display Panel

This chapter introduces the functions and use of the components on the operator control and display panel of the

HIPULSE-NXL 500/800kVA UPS, and provides LCD display information, including the LCD power flow diagram, detailed menu messages, prompt windows, EPO button and UPS alarm event list.

Introduction

The operator control and display panel is located on the front right door of the UPS rectifier cabinet as shown in

Figure 4-1 and Figure 4-2. This operator control and display panel also provides LCD and EPO button. The HMI

(human machine interface) of the HIPULSE-NXL 500/800kVA UPS uses touch-screen LCD design. Through this LCD panel, the operator can operate and control the UPS, and check all measured parameters, UPS and battery status and event and alarm logs. EPO button provides the emergent power off function for the user.

操作控制显示面板

LCD显示屏

EPO按钮

Fig.4- 1 Location of 500kVA LCD panel

Fig.4- 2 Location of 800kVA LCD panel

The user can perform the operations through the LCD panel:

Clearly and fast display the UPS operating status


32 Chapter 4 Operator Control And Display Panel

Monitor the UPS power flow and display input and output values

Execute some control operations through the panel such as switch on/off, load transfer and close Trap

Query UPS alarm and event log

Set UPS parameters

LCD Screen Types

Startup Screen

When the UPS starts up, the system is powered on and the LCD displays the startup screen that shows the characters of “HMI 2 Liebert

®

NXL”, and this display will last for 30 seconds, as shown in Figure 4-3.

Fig.4- 3 Startup screen

Main Display Screen

After the UPS startup is completed, the Main Display Screen is as shown in Figure 4-4:



Fig.4- 4 Main Display Screen

If there is no operation to the screen for 15 minutes, the LCD backlight will turn off automatically, and then the LCD becomes dark, and enters sleeping status. The LCD will be activated and enter main display if any part of the LCD is touched.

The LCD screen can be divided into 10 zones according to its functions as shown in Table 4-1.

Table 4- 1 Layout of main display screen

Code of Zones Descriptions

2

3

Event clearing and alarm silence button

Event information zone

4 button

5 Current date and time

7 status

8

9

10

Display zone of output parameters

Display zone of input parameters

Display zone of air inlet temperature

If the system is a parallel system, the Main Display Screen is as shown in Figure 4-5, that is, an additional “System

View” menu is displayed on the upper right part of the power flow diagram, and if this menu is clicked, the parallel system information is as shown in Figure 4-6.



Fig.4- 5 Main Display Screen of parallel system

Fig.4- 6 Information of parallel system



Power Flow Diagram

Overview

The power flow diagram is consisted of input, output, block frame, switch and power path as shown in Figure 4-7. The power flow diagram is introduced as below:

Bypass input: Display bypass input line-to-line voltage and frequency, and the status of bypass switch Q2 (open or closed);

Rectifier input: Display rectifier input line-to-line voltage, input current and frequency, and the status of rectifier input switch Q1 (open or closed);

Output: Display the output line-to-line voltage, line-to-neutral voltage, output current, apparent and active power load ratio of each phase, power factor PF, apparent power KVA, active power KW and frequency. When overload happens, the remaining time before the transfer is displayed at the bottom of the frame. The re-transfer time after the transfer is also displayed here;

Bus: Display bus voltage, battery charging status (float charging or equalize charging), and battery charging or discharging current;

Battery: Display the voltage of each battery string, battery temperature and capacity, and status of BCB (Battery

Circuit Breaker).

Fig.4- 7 Power flow diagram

The current operating status of UPS is indicated by the colours (green, orange, gray and black) of power paths and the status (constant green, flashing and white) of block frame. The meanings of the colours of each power path and block frame and the status block frame are given in Table 4-2.

Table 4- 2 Meanings of the color of the power path and frames

Color of power path

Green

Meanings

Colour and status of frame

Constant green

Orange

Gray

Black

Normal operation

Input power supply voltage or frequency is out of normal range

Input power supply voltage or frequency abnormal or power failure

Not sure

Flash

White

The power flow diagram of each operating mode of UPS is introduced below:

Meanings

Stable operation

In startup or power off status

Not working

Normal mode

Figure 4-8 shows the power flow diagram of normal mode.

In normal mode, if the inverter fails or the inverter overload time is out, the system will transfer to bypass. After the fault or overload is cleared, the system transfers back to normal mode.



Fig.4- 8 Power flow diagram of normal mode

Bypass mode

Figure 4-9 shows the power flow diagram of bypass mode. The load is powered by bypass and at this time the quality of the power to the load is not guaranteed. The UPS works in bypass mode during startup or inverter failure.

Fig.4- 9 Power flow diagram of bypass mode

Battery mode

Figure 4-10 shows the power flow diagram of battery mode. When the mains power fails or exceeds normal operation range, the battery will power the load and the operating time is determined by the battery capacity and load. When the battery voltage is close to the EOD voltage, the control panel will report alarm information of “battery voltage low”.

The battery frame on the control panel displays battery voltage, battery discharging current and discharging time, and charging ratio.

Fig.4- 10 Power flow diagram of battery mode

Maintenance bypass mode

Figure 4-11 shows the maintenance bypass mode. In this mode, the load is powered by maintenance bypass and at this time the quality of the power to the load is not guaranteed. The UPS operates in maintenance bypass mode when the system needs maintenance.



Fig.4- 11 Power flow diagram of maintenance bypass mode

Detailed Description Of Menu Items

The LCD of the HIPULSE-NXL500/ 800kVA UPS offers 10 groups of menus. The structure is shown in Figure 4-12.

The functions of main menus are configuring, status reporting, switching on/off, transferring, battery management, measured values, help, alarm silence and event clearing. User can expand the menus level by level according to his actual needs and perform relevant parameter setting, status browse and system on/off operations.

Fig.4- 12 Structure of HIPULSE-NXL 500/800kVA UPS menu tree

The menu structure shown in Figure 4-12 is described below



1.1.1 Configuration

Rated values

This menu will display the system parameters in details and will display the following parameters if it is clicked (as shown in Figure 4-13):

Fig.4- 13 Rated parameter drawing

System setting

Click this menu, the LCD will display the interface as shown in Figure 4-14. The panel display settings can be modified through this menu.

Fig.4- 14 System setting dialog

Backlight brightness ―― High or low(default setting is low)

Time(24-hour system)――Hour, minute and second can be adjusted

Date(Format: Month/ Day/ Year)――Month, day and year can be adjusted

Password ―― reset password (upper case and lower case are different for the password)

Language―― English, Chinese, French, Spanish, German, Italian, Portuguese (the display only supports

Chinese, English)

Volume ―― level 1 to level 10(default setting is level 5)



Phase marking ――Auto, ABC, RST, XYZ, RYB, RWB, UVW, 123 and L1L2L3 (default setting is Auto)

Machine position number

Position ID―― Both letter and number are acceptable

System number―― Both letter and number are acceptable

Module number―― Numbers(1 to 99)

Module label―― Both letter and number are acceptable

Settings that can be modified by user

The alarm settings can be modified through this menu and the following dialog will be popped (as shown in Figure

4-15):

Fig.4- 15 Dialog for settings that can be modified by user

Maximum load alarm

Load percentage of output phase A―― settable from 10% to 105% (default setting is 95%)

Load percentage of output phase B―― settable from 10% to 105% (default setting is 95%)

Load percentage of output phase C ――settable from 10% to 105% (default setting is 95%)

Delay (second)―― settable from 0 to 60 (default setting is 5s)

Voltage limits for manually transfer to bypass

High voltage limit for manually transfer to bypass ――1% to 15%( default setting is 5%)

Low voltage limit for manually transfer to bypass ――1% to 20%( default setting is 5%)

Temperature alarm of air inlet port

Temperature alarm of air inlet port ——30ºC to 40 ºC (default setting is 35 ºC)

Note: the temperature has two units of ºC and ºF.

Battery management

The settings related to battery can be modified through this menu. The battery management dialog will be displayed as shown in Figure 4-16.



Fig.4- 16 battery management dialog

Battery equalize charge setting

Equalize charge voltage, voltage of each cell——2.3V to 2.45V (default setting is 2.3V)

Equalize charge time (hour)——0 to 200 hours(default setting is 1)

Warning

The equalize charge must be set to “enabled” through host computer. Otherwise this function cannot be used and this menu item will not be displayed.

If the system is in equalize charge status, then the equalize charge time will be effective when the next equalize charge starts.

Battery test

Auto test——Enabled / disabled (default setting is “disabled”)

Test cycle (week)——1 to 26 weeks (default setting is 13)

Test time——Set hour and minute, and is used to set the battery auto test start time

Start date (month/day/year)——Set month/day/year, is used to set the start date of battery auto test

Continuous test time (minute)——0.5 minute to 30% total operating time (default setting is 0.5 minutes)

Minimum battery voltage (only for lead-acid battery)——1.75VPC (Voltage per Cell) to 1.95VPC (default setting is

1.75VPC); the test will stop when minimum voltage is reached.

Battery low voltage alarm time

Battery low voltage alarm time (minute)——2 to 120 minutes, dependent on the battery used (default setting is 5 minutes)

Battery temperature

Battery temperature alarm——30ºC to 50ºC (default setting is 40ºC)

Battery temperature limit——35ºC to 60ºC (default setting is 50ºC)

Disconnection——Enabled / disabled (default setting is “disabled”)

Note

If the battery disconnection is set to “enabled” and the battery temperature limit condition is met, the battery circuit breaker will open automatically.



Adjustment of battery cells

Adjustment of battery cells ——-12 cells to 6 cells (default setting is 0 cell)

Battery float charging voltage

Battery float charging voltage (V/cell)——2.15 to 2.3(default setting is 2.25)

Internal Optional Part Settings

The internal optional part settings can be modified through this menu.

Note

This function must be set to “enabled” through host computer. Otherwise this function cannot be used and this menu item will not be displayed.

The internal optional part setting includes the settings of input dry contact board and programmable relay board, and the setting dialog is as shown in Figure 4-17 and Figure 4-18 respectively.

Fig.4- 17 Dialog for setting input dry contact board



Fig.4- 18 Dialog for setting programmable relay board

input dry contact board

Setting―― Self-defined and pre-allocated (default setting is “disabled”)

Delay (second)――0 to 99.9 seconds (default setting is 0)

Message—— Self-defined: 0 to 19 characters

Programmable relay board

Setting——0 to 4 events (default setting is 0)

Delay (second)――0 to 99.9 seconds (default setting is 0)

Event management

The alarm, fault and status information processing method of the UPS can be modified by this menu as shown in

Figure 4-19.

Fig.4- 19 Dialog for event management



Lock (Yes/No)——After the event is activated, the event is locked until user clears the event log even if the fault clearing event is still displayed in the screen.

Silence (Yes/No)——Whether the sound can be heard when an event happens.

Event log (Yes/No)——Whether the event will be displayed in event log when an event happens.

Status Report

This menu can be used to query all current and history event log.

Event log―― Be able to store 0 to 1024 events. When the number of events exceeds 1024, the oldest event will be deleted and replaced by the newest one.

The UPS event list is given in Table 4-3.

System Status

Total operating hours——The total number of operating hours of UPS

Battery operating hours——Total discharging time of battery, and the data will be saved until it is finally deleted from the event log.

Power-on

This menu can be used to start UPS, input Trap filter, MBD and BCB.

Manually power-on——It is used to turn on UPS, see 5.2 UPS Power-on Procedures (inverter mode) for detailed procedures

Equipment control

Turn on Trap——If input Trap filter is installed, turn on Trap filter

Turn on MBD/BCB——If MBD is controlled electrically, turn on to enable it, it will be turned on through electrical control. If MBD is not controlled electrically, it has to be manually turned on. If MBD is not installed, it will not be displayed on the panel and only BCB is displayed.

Power-off

This menu can be used to turn off UPS, input Trap filter, MBD and BCB as shown in Figure 4-20.



Fig.4- 20 Power off menu

Open Trap——Turn off input Trap filter

Open MBD/BCB——Turn off MBD or BCB

UPS——Turn off rectifier, inverter and battery circuit breaker. If the condition for transferring to bypass is met, the system will transfer to bypass.

Note

When powering off UPS, a dialog for confirmation will be popped up as shown in Figure 4-21. The UPS can only be shut down if you click the “OK” button.

Fig.4- 21 Dialog for turning off UPS

System——Turning off rectifier, inverter and battery circuit breaker will completely shut down the system.

Note

This command will cause load power off. In order to avoid risk, a dialog will be popped up for confirmation, as shown in Figure

4-22. The system can only be shut down if you click the “OK” button.



Fig.4- 212 Dialog for turning off system

Transfer

This menu enables the system to transfer between inverter mode and bypass mode. The window will display if the bypass is in the synchronization range of the UPS. If it is, press “Bypass”, the system will transfer to bypass mode and press “UPS”, the system will transfer back to inverter mode as shown in Figure 4-23.

Fig.4- 223 Dialog for transfer/transfer back

Battery Management

This menu is used to modify the battery setting.

Battery remaining time curve——The remaining time curve is displayed in the window. The “battery voltage VS time” curve in some discharging process will be plotted (as shown in Figure 4-24).



Fig.4- 234 Battery remaining time curve

Manual battery test——Start / Stop

Manual battery equalize charging—— Start / Stop equalize charging

Note

You cannot execute the manual equalize charging to the battery until the equalize charging function is enabled via host computer.



Battery cycle monitoring——Display the number of discharging processed in following time spans: 0 to 30 seconds, 31 to 90 seconds, 91 to 240 seconds, 4 to 15 minutes, 15 to 30 minutes, 30 to 60 minutes, 60 to 240 minutes, 4 to 8 hours, longer than 8 hours. The information of each discharging log includes:

# Minimum active power

Date Maximum active power

Time AH (Ampere-hour) number

Continuous time Start temperature ℃

Start active power End temperature ℃

Fig.4- 245 Battery remaining time curve



Summary

As shown in Figure 4-26, using this menu can check the following information: Battery commission date / time, latest battery discharging date / time, activebattery discharging time, active battery AH (Ampere-hour) number, active battery capacity kW and total number of discharging times.

Fig.4- 256 Battery cycle monitoring summary

Clear log——This command will reset the first battery discharging date. A dialog will be popped up to warn the user that these data will be lost permanently and should be downloaded before the next operation step.

Measured Values

Click this menu, the screen will display relevant readings of the system parameters.

Help

Click this menu, the screen will display relevant the help information of the system.

Clear Event Log

Click this menu, the system will clear some locked events that have been ceased.

Alarm Silence

Click this menu, the alarm sound will be silenced.

EPO Button

There is an emergency power off (EPO) button on the front door of the UPS rectifier cabinet. This button is located at the right bottom part of the LCD control panel as shown in Figure 4-1 or Figure 4-2. This button is the LEPO button described in section 3.3.4 Emergency Power Off Input Button. The button is housed underneath a safety cover to


Chapter 4 Operator Control And Display Panel 49 prevent inadvertent operation. After the EPO button has been pressed, it disables the static switch block entirely

(removing load power). It also disables the rectifier and inverter, and trips the battery circuit breaker. Under normal circumstances it does not remove UPS input power since this is applied through a manually controlled external circuit breaker, and you have to manually turn off the upstream input circuit breaker. If the UPS input supply is connected through a circuit breaker having an electrical trip facility, the EPO switch can be used to drive the external circuit breaker’s trip circuit so as to remove the UPS input power.

If remote EPO is used, connect the wires according to descriptions of wiring in section 3.3.4 Emergency Power Off

Input Button

.

UPS Event and Alarm List

The event messages of UPS are the system prompt, fault and alarm information. When the event happens, the current event window of HMI will display this event. After this event is ceased, this event will be recorded in “Event

Log”. The LCD panel function includes recording and browsing all kinds of event information. Table 4-3 provides the complete list of UPS events. The UPS uses colors to differentiate the severity of the events: The color for prompt event is green, that for alarm is orange and that for fault is red.

Prompt information

Input Fault

Input Phase Failure

Input Reverse

Phase Rotation

Input Under Voltage

Input Over Voltage

Input OF/UF

Input Current Limit

Input Current

Imbalance

Rectifier Fault

D/Y Input Current

Imbalance

Rectifier

Synchronization

Loss

Table 4- 3 UPS Event Log

Meanings

Input mains power has fault, including input under voltage /over voltage, input over frequency / under frequency, input phase failure and input power failure.

One or more than one input phase of the rectifier has no phase voltage. Check if any input wiring is missed or if the input wiring is damaged.

The rectifier input phase rotation is not A-B-C. Under normal condition, the rectifier input phase rotation is clockwise, that is, A-B-C. Phase B lags phase A by 120 degree and phase C lags phase B by 120 degrees. Power off the UPS and check if the rectifier input phase rotation is correct.

The voltage of one or more than one input phase is less than a specified percentage value of rated voltage. Check the rectifier input voltage.

The voltage of one or more than one input phase is higher than a specified rectifier input voltage, which results in the shutdown of rectifier. Check the rectifier input voltage.

Input frequency exceeds the rectifier input frequency range, which results in the shutdown of rectifier.

Check the rectifier input frequency.

This alarm is triggered when input current RMS value reaches the input current limit or has exceeded the input current limit for some time. In generator mode, if the input current RMS value reaches the input current limit set in generator mode, the alarm of input current limit will also be triggered.

The difference between some phase current and the average current of three phases exceeds 25% due to the wrong operation of rectifier or input filter.

The rectifier shuts down due to rectifier fault, including D/Y load sharing failure, bus voltage detection fault and rectifier synchronization failure.

When the rectified DC currents of two rectifiers has a difference of 8%, and input power reaches 60% of rated power, this alarm will be triggered.

After the rectifier starts up, the input cross-current point of the rectifier is abnormal.

Bypass Fault

Bypass Line Fail

Bypass

Synchronization

Error

Bypass input power failure including bypass synchronization error, bypass over voltage, under voltage, bypass phase rotation fault and bypass no voltage input.

The RMS value of bypass input line-to-line voltage is less than 30V.

The Phase angle of inverter differs from that of bypass by a certain degree. Transfer to bypass is prohibited.

Bypass Overvoltage

Bypass

Undervoltage

Manual Transfer

Inhibit

Man Re-transfer

Inhibit

Bypass Overload

The line-to-line voltage RMS value of one or more than one input phase of bypass is higher than the rated line-to-line voltage by a certain percentage, which results in bypass shuts down.

The line-to-line voltage RMS value of one or more than one input phase of bypass is lower than the rated line-to-line voltage by a certain percentage, which results in bypass shuts down.

This event means the condition for manual transfer to bypass is not met (the inverter must synchronize with the bypass).

This event means the condition for manual re-transfer to inverter is not met (the inverter must synchronize with the bypass).

When UPS works on bypass, phase A has overload, that us, bypass phase A current RMS value is



Prompt information

Phase A

Bypass Overload

Phase B

Bypass Overload

Phase C

Bypass OF/UF

Bypass Reverse

Phase Rotation

Meanings greater than 110% rated current.If the overload cannot be cleared within a specified time, the control unit will shut down the system. The length of this time is reverse proportional to the amplitude of overload. For example, the higher amplitude of the overload, the shorter the time.

When UPS works on bypass, phase A has overload, that us, bypass phase B current RMS value is greater than 110% rated current. If the overload cannot be cleared within a specified time, the control unit will shut down the system. The length of this time is reverse proportional to the amplitude of overload. For example, the higher amplitude of the overload, the shorter the time.

When UPS works on bypass, phase C has overload, that us, bypass phase C current RMS value is greater than 110% rated current. If the overload cannot be cleared within a specified time, the control unit will shut down the system. The length of this time is reverse proportional to the amplitude of overload. For example, the higher amplitude of the overload, the shorter the time.

Bypass frequency exceeds the synchronization frequency range of inverter.

Under normal condition, the bypass input phase rotation is clockwise, that is, A-B-C. Phase B lags phase A by 120 degree and phase C lags phase B by 120 degrees. Power off the UPS and check if the bypass input phase rotation is correct. Correct the wrong phase rotation.

Auto Re-transfer

Primed

Inverter Current

Limit

Under current condition, auto re-transfer has the priority.

Auto Re-transfer

Failure

Excess Auto

Re-transfer

The condition that causes failure of auto transfer to bypass has not been cleared in specified time.

The number of auto re-transfer times in recent hours exceed the permitted maximum value.

Transfer to Inverter

DC Bus Qualified

Inverter Fault

External signal prohibits the load to transfer from bypass to inverter.

Inhibit

Low Battery

Warning

The calculated battery remaining time reaches the low battery alarm value and the UPS will shut down..

Low Battery

Shutdown

DC Bus Over

Voltage Transient

The battery voltage is lower than EOD, which leads to shutdown. The battery capacity is inadequate to power the inverter..If the bypass is available, when the battery voltage reaches EOD, the UPS will try to transfer to bypass.

Low Battery

Capacity

This alarm means the system contains several battery strings. At least one battery circuit breaker is closed and at least one battery circuit breaker is opened.

Battery Discharging

UPS is working in battery mode and the battery is discharging.

Battery Over-temp

Warning

The battery temperature sensor reports battery temperature exceeds alarm limit. Check battery temperature and ventilation.

Temperature of battery X reaches the alarm limit of battery temperature. If the BCB tripping is

Battery X Over-temp

Limit enabled, the BCB will trip after over temperature. Check battery temperature and ventilation.Note: “X” means the number of the battery cabinet / battery string and it ranges from 1 to 8.

This alarm is triggered when the bus voltage is higher than the rated voltage by a certain percentage, or bypass SCR has short circuit fault. In the mean time the battery circuit breaker opens.

All the parameters of bus are within the allowed range of rectifier and inverter.

The inverter shuts down due to fault. The fault includes bus transient over voltage, inverter over voltage, inverter under voltage, inverter IGBT-A fault, inverter IGBT-B fault, inverter IGBT-C fault, DC bus over current IDC peak value fault and inverter sensor fault.

Inverter current reaches the limit.

Inverter Over

voltage

Inverter Under

Voltage

Inverter Overload

Phase A


Phase B

This alarm is triggered when inverter output transient voltage exceeds 125% of rated voltage for 1 second, or bypass SCR has short circuit fault. This fault will result in inverter shutdown, and if the inverter is shut down, the UPS transfers to bypass.

This alarm is triggered at non inverter current limiting status, non soft start when inverter output voltage transient value is lower than the rated voltage by 75% for 1 second, or bypass SCR has short circuit fault. This fault will result in inverter shutdown, and if the inverter is shut down, the UPS transfers to bypass.

Phase A is overload when inverter is operating, that is, the phase A RMS current value is higher than

105% of rated current RMS value or phase A output power is higher than 105% rated output power.

When this alarm happens, a countdown timer will be displayed on the power flow diagram to display the remaining time for transfering to bypass. The length of the remaining time is proportional to the severity of the overload.

Phase B is overload when inverter is operating, that is, the phase B RMS current value is higher than

105% of rated current RMS value or phase B output power is higher than 105% rated output power.

When this alarm happens, a countdown timer will be displayed on the power flow diagram to display the remaining time for transfering to bypass. The length of the remaining time is proportional to the



Prompt information


Phase C


Time Exceeded

Inverter Phase A

IGBT Fault

Inverter Phase B

IGBT Fault

Inverter Phase C

IGBT Fault

Output Fault

Output OF/UF

Output Over

Voltage

Output Under

Voltage

Fan X Fault

Manual transfer to

Bypass

Manual transfer to

Inverter

Trap Fuse Fail

Output Fuse Fail

HF Filter Fuse Fail

Load on UPS

Load on Bypass

Load on

Maintenance Bypass

Low Power Factor

BFB open

CB3 Open Fail

CB3 Close Fail

CB2 Close Fail

CB2 Trip Fail

Pulse Paralleling

Transfer to Bypass

Failed

On Generator

Active

Rectifier Off Input

Low

Input Line Fail

Event Log Clear

Bypass/Output

Phase Error

Meanings severity of the overload.

Phase C is overload when inverter is operating, that is, the phase C RMS current value is higher than

105% of rated current RMS value or phase C output power is higher than 105% rated output power.

When this alarm happens, a countdown timer will be displayed on the power flow diagram to display the remaining time for transfering to bypass. The length of the remaining time is proportional to the severity of the overload.

This information means at least one phase has overload. When the overload happens, a countdown timer will be displayed on the HMI to display the remaining time for transfering to bypass. The length of the remaining time is proportional to the severity of the overload. If the timer reaches 0, the UPS will transfer to bypass if the bypass is available, and this alarm will enter the active event window.

The system detects IGBT A fault, and IGBT phase A short circuit is one of the reasons for the alarm.

This will result in the shutdown of rectifier and inverter, and if the shutdown is allowed, the UPS transfers to bypass.

The system detects IGBT B fault, and IGBT phase B short circuit is one of the reasons for the alarm.


The system detects IGBT C fault, and IGBT phase C short circuit is one of the reasons for the alarm.


UPS output has fault including output over frequency / under frequency, and output over voltage / under voltage.

Output frequency exceeds the allowed rated frequency range.

This alarm is triggered when the output voltage exceeds the high limit for some time (the time is determined by the over voltage value), or inverter SCR is opened or bypass SCR has short circuit fault.

This fault will result in inverter shutdown, and if the shutdown is allowed, the UPS transfers to bypass.

This alarm is triggered when the output voltage is lower than the low limit for some time (the time is determined by the under voltage value), or inverter SCR is opened or bypass SCR has short circuit fault. This fault will result in inverter shutdown, and if the shutdown is allowed, the UPS transfers to bypass.

The fan X has faults. Note: “X” means the fan number of 1~32.

The system is manually transferred to bypass.

The system is manually transferred to inverter.

If the module is installed with input filter, the fuse of one or more than one filter has fault.

One or more than one output fuse has fault.

The fuse of Grass Filter fails.

The load power comes from the inverter and the UPS operates in normal mode.

The load power comes from the bypass and the UPS operates in bypass mode.

The load power comes from the maintenance bypass and the UPS operates in maintenance bypass mode.

The load power factor is lower than the rated low value at maximum load. For a certain kind of load, the UPS output current will be increased with the decrease of power factor, which requires the UPS output power to be derated.

BFB is opened.

Bypass circuit breaker cannot be opened.

Bypass circuit breaker cannot be closed.

Inverter output circuit breaker cannot be closed.

Inverter output circuit breaker does not respond to the open signal.

The bypass SCR is on for a short time to help the inverter to power the load.

One event (such as inverter fault) results in the automatic system’s transfer to bypass but the transfer fails.

The generator powers the system.

Rectifier is shut down because one phase or multi-phase input voltage is low. Check the input voltage.

Power supply input has fault that results in the rectifier shutdown. Check the input voltage.

Event log is cleared.

The phase difference between bypass and output is wrong and is bigger than 16 degrees.



Prompt information

Battery Equalizing

Meanings

Battery status (battery is in equalize charging status)

Battery

The rectifier output voltage setting (bus voltage) is increased to the commissioning voltage level.

Commissioning

Battery Self Test

PRB1

UPS performs battery self test.

Timed communication failure of PRB1 board

Communication Fail

PRB2

Timed communication failure of PRB2 board


EPO Shutdown

REPO Shutdown

EPO command is detected, the UPS is shut down in emergency. If EPO button is pressed manually, this alarm is triggered. This fault cannot be recovered.

Remote EPO command is detected. This alarm happens if the REPO button is pressed. This fault cannot be recovered.

Battery Detection X

Fail

Battery temperature sensor X detects that the temperature data is outside of normal range, for example, high or low temperature is detected or the temperature change within 1 second is too big.Note: “X” means the battery temperature sensor number 1 to 8.

Battery Sensor Fail

Among group 1 to group 8 battery temperature sensors, at least one group detects abnormal data.

Battery Temp

Battery temperature sensor detects the battery string temperature different is bigger than 5ºC.

Imbalance

Battery Test Fail

Auto or manual battery test fails. The battery “continuous test time” is adjustable. Before the battery continuous test time is over, the criteria for judging the battery test failure is triggered.

Battery Test Passed Battery test is passed.

Inverter Backfeed

This alarm is triggered when the inverter is turned on, the inverter power flow is detected reversed and the reverse power flow is higher than a certain value for some time. The bypass SCR short circuit can also trigger this alarm.

Redundant Fan Fail This alarm means some fan has failed.

FIB 1


FIB 2


FIB1 (fan interface board 1) communication fails.


FIB 3


FIB 4


Configuration

Modified

User Shutdown



User makes modifications to one or more than one configuration items in configuration menu and save the modifications.

User shuts down the inverter or system.

User Startup

Initialization

DC Fuse Fail

Input P/S Fail

Bypass P/S Fail

DC P/S Fail

Option P/S Fail

Output P/S Fail

EPO P/S Fail

Power Supply Fail

BFB Trip Signaled

BFB Open Fail

CB1 Open Fail

CB1 Close Fail

Battery CBX Open

Fail

Batt CBX Close Fail

Batt CBX Open

Inlet Over-temp

Outlet Over-temp

User issues the manual or auto power on command from the interface of “Start / Shut down”.

Inverter DC input fuse is opened.

Input auxiliary power supply fails but UPS still operates normally.

Bypass auxiliary power supply fails but UPS still operates normally.

Bus auxiliary power supply fails but UPS still operates normally.

Optional auxiliary power supply fails but UPS still operates normally.

Output auxiliary power supply fails but UPS still operates normally.

EPO auxiliary power supply fails but UPS still operates normally.

Auxiliary power supply fails

BFB receives tripping signal.

BFB does not open after receiving the tripping signal.

Rectifier input circuit breaker does not open after receiving the tripping signal.

Rectifier input circuit breaker does not close after receiving the closing signal.

Battery circuit breaker X (MBD/BIS/BCB) does not open after receiving the tripping signal.Note: “X” means the battery circuit breaker (MBD/BIS/BCB) 1 to 5. BIS: When there is no MBD, BCB is BIS

Battery circuit breaker X (MBD/BIS/BCB) does not respond to close signal. Note: “X” means the battery circuit breaker (MBD/BIS/BCB) 1 to 5.

Status of battery circuit breaker X (open) Note: “X” means the battery circuit breaker (BIS) 1 to 8.

UPS module air inlet temperature exceeds the preset highest value. UPS only alarms but does not act upon this.

Difference between temperature of air outlet port and that of air inlet port exceeds the specified maximum temperature difference. This fault will result in inverter shutdown, and if the shutdown is



Prompt information

Equip Over-temp

Meanings allowed, the UPS transfers to bypass.

This event means the UPS is close to the over temperature limit including the rectifier over temperature, BPSS over temperature, inverter over temperature, and ISS over temperature. UPS only alarms but does not perform protective actions.



Prompt information

Equip Over-temp

Limit

Rectifier Over-temp

Rectifier Over-temp

Limit

Aux Over-temp

Meanings

This event means the temperature of one or more parts in the UPS exceeds the maximum temperature limit setting including rectifier over temperature limit, BPSS over temperature limit, inverter over temperature limit, and ISS over temperature limit.

The temperature of rectifier’s semiconductor heatsink exceeds the stable temperature. UPS only alarms but does not perform protective actions.

The temperature of rectifier’s semiconductor heatsink exceeds the maximum temperature limit. The rectifier will shut down. If allowed, the UPS will transfer to battery or bypass.

The temperature of auxiliary temperature sensor exceeds the stable temperature.

Inv Over-temp

Inv Over-temp Limit

Temp Sense Fail

The temperature of inverter’s semiconductor heatsink exceeds the stable temperature. UPS only alarms but does not perform protective actions.

The temperature of inverter’s semiconductor heatsink exceeds the maximum temperature limit. This fault will result in inverter shutdown, and if the shutdown is allowed, the UPS transfers to bypass.

The temperature detected by temperature sensor exceeds the measurement range of the sensor. For example, the detected temperature is too high or too low, or the temperature difference within 1s is too big.

Excess Paralleling

Battery Protect

The fault status means there are too many paralleling pulse numbers, now the UPS is locked in bypass mode (auto transfer to inverter is prohibited).

Main Control Fault

DSP Comm Failure

Main controller has faults.

The communication between the controller DSP and system DSP fails.

Control DSP Failure The controller DSP has fault.

When the event of low battery voltage happens, the system prevents the battery (lead acid) from deep discharge.

BPSS Board Comm

Bypass static switch has fault.

Fail

Battery Log Cleared The event log of battery discharge is cleared.

Battery Cycle Log

Full

The battery cycle log is full.

Battery Over-temp

The temperature detected by the battery temperature sensor exceeds the setting.

Limit

Password Changed User password is changed.

CB3 Open

SW1 Open

Status of bypass circuit breaker CB3 (open)

Status of bypass circuit breaker SW1 (open)

CB1 Open

CB2 Open

MBB Open

MIB Open

Status of rectifier input circuit breaker CB1 (open)

Status of output circuit breaker CB2 is opened.

Status of maintenance bypass circuit breaker MBB (open)

Status of maintenance isolation circuit breaker MIB (open)

MBDX/BISX


BISX


EIB Comm Fail

Q2 Open

Q3 Open

Q4 Open

MBDX/BISX timed communication failureNote: “X” means the number of MBD or BIS 1 to 5.

BIS communication failure Note: “X” means the number of BIS 6 to 8.

Q11 Open

Q22 Open

QBP Open

Q1 Open

QOP Open

Batt Test Stopped

Batt Test Inhibit

RIB Open

BIB Open

MBD/BCB Comm

Fail

EIB timed communication failure

Status of bypass circuit breaker Q2 (open)

Status of maintenance bypass circuit breaker Q3 (open)

Status of output circuit breaker Q4 (open)

Status of external rectifier input isolation breaker Q11 (open)

Status of bypass isolation breaker Q22 (open)

Status of external maintenance bypass isolation breaker QBP (open)

Status of rectifier input circuit breaker Q1 (open)

Status of external output isolation breaker QOP (open).

Battery test is stopped.

Battery test is inhibited.

Status of rectifier input circuit breaker RIB (open)

Status of bypass isolation circuit breaker BIB (open)

MBD/BCB timed communication failure

Input Dry Contact X

Remote Off Rect

Input contact isolation board is triggered by external contact signal. Reserved for user. Alarm information can be defined by user. Refer to 1.1.1 Internal Optional Parts SettingNote: “X” means the number of dry contacts 11~18 and 21~28.

The rectifier is shut down by external contact signal.This status means that the external contact signal



Prompt information Meanings that shuts down the rectifier is enabled. This kind of signal is connected to the input dry contact board and one of the channels is defined to remotely shut down the rectifier.

Remote Off Inv

The inverter is shut down by external contact signal. This status means that the external contact signal that shuts down the inverter is enabled. This kind of signal is connected to the input dry contact board and one of the channels is defined to remotely shut down the inverter.

MBD/BCB Open Fail MBD/BCB cannot be opened.

MBD/BCB Close

Fail

MBD/BCB cannot be closed.

MBD/BCB Open

Batt Not Charging

HMI Comm Fail

ICI#1 Comm Fail

ICI#2 Comm Fail

Internal Comm Fail

Fuse Fail

Controller Error

Breaker Open Fail

Breaker Close Fail

Input Filter Cycle

Stop Chrg Batt OT

Multiple Fan Fail

Out Filter Fuse Fail

Batt Ground Fault

Auto Restart Fail

Restart Inhibited

Restart In Process

EMO Shutdown

Q33 Open

User Event Reset

IDC Peak Fault

Status of MBD/BCB circuit breaker (open)

Battery status is uncharged.

Timed communication failure of HMI

ICI#1 communication failure

ICI#2 communication failure

Communication failure of internal bus in control board

The fuse has fault, which means at least one fuse among the fuse of input filter, the fuse of output filter, the rectifier fuse, the inverter fuse, the fuse of high frequency filter and the output fuse of the system has fault.

The controller has fault.

This fault is a general event, which means the system orders that one circuit breaker should be opened or should be opened manually, but the circuit breaker fails to report the open status.

This fault is a general event, which means the system orders that one circuit breaker should be closed or should be closed manually, but the circuit breaker fails to report the closed status.

Input filter is opened and closed automatically for 9 times within one hour and after that, it cannot be automatically opened and closed any more.

The detected battery temperature exceeds the setting, so the battery charging is stopped.

This event means more than one fan in the system fail.

One or more than one fuse in output filter fails.

The detected battery current exceeds the tripping value.

Auto restart is enabled but fails. Reasons: Manual shutdown in auto restart, or bypass source or rectifier source is abnormal in auto restart process, or the bus voltage does not meet the requirement for starting inverter, or the system cannot transfer to rectifier circuit to power the load. All these reasons will trigger this alarm.

When the signal from the input dry contact board is enabled, the auto restart function will be disabled.

Auto start is in process. The manual startup is prohibited at this time.

The system detects module emergent power-off command (EMO).

Status of external bypass circuit breaker Q33 (open)

User has executed the event clearing operation.

The system detects IDC peak value fault IGBT short circuit fault or bypass SCR fault, and all these kinds of faults will trigger this alarm.

SERVICE CODE

ACTIVE

This event is used for the purpose of information and is to tell the user that the service code is valid.

LBS Inhibited

Regen Active

Regen Terminated

Regen Failure

Leading Power

Factor

The LBS operation conditions cannot be met when LBS operation is enabled.

This status tells user that the UPS is in regenerative mode.

This status tells user that the UPS is not in regenerative mode. The regenerative time is out or is stopped manually..

The regenerative mode starts or stops under abnormal conditions.

The leading power factor may result in energy waste. If power factor is less than 0.95, UPS output power will be derated to compensate the output power loss.

BPSS Overload

The bypass static switch is closed due to continuous overload.

Exceeded

BPSS Unable

BPSS Open

The bypass static switch cannot be operated in normal mode.

When the system turns on the bypass, the SCR in one or more than one phase of the bypass is opened.

BPSS SCR Shorted

One or more than one SCR has short circuit fault. This fault may be missed for being reported.

The temperature of bypass static switch heatsink exceeds the stable temperature. UPS only alarms

BPSS Over-temp but does not perform protective actions

BPSS Over-temp

Limit

Remote Off BPSS

The temperature of bypass static switch heatsink exceeds the maximum temperature limit. The bypass can be enabled /disabled through the software programming in host computer.

The bypass static switch is closed by external contact signal. This status means that the external



Prompt information

Vdc Sense Fail

Controls Reset Req

ISS SCR Shorted

Meanings contact signal that shuts down the BPSS is enabled. This kind of signal is connected to the input dry contact board and one of the channels is defined to remotely shut down the BPSS.

The system detects the error in the detection of DC bus voltage. If the difference of the DC bus voltage detected in different time is too big, this alarm will be triggered.

This alarm means one or more than one setting is modified in the UPS operating process. The system can reset through power off or pressing the reset button on the UPSC board.

The inverter is not turned on and the output circuit breaker is not closed. When the fuse is normal, the system detects that the inverter side voltage of inverter static switch is higher than the rated voltage by a certain percentage, so this alarm is triggered.

ISS Over-temp

ISS Over-temp Limit

The temperature of output static switch heatsink exceeds the stable temperature. UPS only alarms but does not perform protective actions.

The temperature of output static switch heatsink exceeds the maximum temperature limit. This fault will result in inverter shutdown, and if the shutdown is allowed, the UPS transfers to bypass.

Input Filter Open

Input filter is opened.

If the sum of the transient values of three phase currents exceeds one threshold, the inverter sensor

Inverter Sense Fail fails because the sum of the transient values of three phase currents should be zero in principle.

Controls Comm Fail The communication between the control system DSP and external device fails.

Rectifier Fuse Fail

Max Load Exceeded

Ph A


Ph B


Ph C

LBS Active

One or more than one fuse in the rectifier fails.

The load exceeds the maximum load alarm value of phase A. This alarm value can be set by user through HMI and the alarm detecting delay time can also be set.

The load exceeds the maximum load alarm value of phase B. This alarm value can be set by user through HMI and the alarm detecting delay time can also be set.

The load exceeds the maximum load alarm value of phase C. This alarm value can be set by user through HMI and the alarm detecting delay time can also be set.

LBS is enabled and is active.


Chapter 5 Operating Instructions 57

5. Operating Instructions

This chapter provides detailed operating notes and routine operating instructions of the HIPULSE-NXL 500/800kVA

UPS.

Introduction

Notes

Important

Only after an authorized engineer has conducted the first-time power-on and completed the UPS commissioning is the user allowed to operate the UPS.

Components behind inner doors, which require a tool to remove, is not accessable for users. Only qualified service personnel are authorised to open inner doors.

Hazardous voltages are always present at the UPS input and output terminals. If the UPS is fitted with an internal EMC filter, the filter carries hazardous voltages too.

1. All the operator control and display panel, the buttons and power switches mentioned in these procedures are described in Chapter 4 Operator Control And Display Panel.

2. The UPS system incorporates an optional automatic boost charge facility, which can be used in systems containing conventional lead-acid batteries. If this type of battery is used in your installation you may notice that the battery charger voltage may be greater than its normal charging voltage (that is 540V) when the mains supply returns from a prolonged outage. This is the normal response, and the charger voltage should return to normal after a few hours.

Power Switches

The power switches, mounted inside the UPS cabinet are accessible after opening the front door with a key. The location of the UPS power switches is shown in Figure 5-1 and Figure 5-2, which includes:

Q1 — input switch: Connects the UPS with the mains supply.

Q2 — bypass switch: Connects the UPS with the bypass supply.

Q3 — maintenance bypass switch (locked): The load directly powered by the maintenance bypass line during the maintenance process of the UPS module.

The internal maintenance bypass must not be used when the UPS system has more than two UPS modules in parallel.

Q4 — output switch: Connects the output of the UPS to the load.

Note: The battery circuit breaker is not expected inside of the UPS and should be installed in the proximity of the respective battery. Figure 5-1 and Figure 5-2 show the view of the 500/800kVA UPS after front door is removed.


58 Chapter 5 Operating Instructions

输入开关

输出开关

维修旁路开关

旁路开关

Fig.5- 1 Power switch locations of 500kVA UPS

输入开关

输出开关

维修旁路开关

旁路开关

Fig.5- 2 Power switch locations of 800kVA UPS

Start-Up Procedure (Into Normal Mode)

This procedure must be followed when turning on the UPS from a fully powered down condition, that is, where the load is not being initially supplied at all or where supplied by the maintenance bypass switch. It is assumed that the installation is complete, the system has been commissioned by authorized personnel and the external power isolators are closed.

Warning – Mains voltage will be applied to UPS output terminals

This procedure results in mains voltage being applied to the UPS output terminals.

Isolate and attach warning labels to any downstream load connections, as applicable.

Be sure to strictly follow the start-up procedures, otherwise user will be responsible for the severe consequences resulted from wrong operation.

1. Open the front doors of 500kVA UPS rectifier cabinet and inverter cabinet (rectifier cabinet and switch cabinet for

800 kVA UPS) to gain access to the power switches. Confirm whether the internal maintenance bypass switch Q3 is opened. Confirm whether the fuse FB1, FB2, FB3, FB4 are closed.

(Note: FB1~FB4 are located in the middle part of the inverter cabinet of 500 kVA UPS. And FB1, FB2 are in the upper part of the rectifier cabinet, while FB3, FB4 are in the upper part of the switch cabinet of 800 kVA UPS)



Note

All the operations that are related to the open/close of the maintenance bypass switch should be completed within 3 seconds to avoid fault, and this also applies to the operations of maintenance bypass switch in sections 5.4, 5.5, and 5.6.

2. Close the external circuit breakers of rectifier and bypass input.

At this time, the system is powered on and the LCD displays the startup screen. See 0Startup Screen

3. Close the bypass switch Q2, the output switch Q4 and all the output external circuit breakers (if there is any).

At this time, you need to check if the LCD displays that the bypass input power path is in green color. Otherwise check if the switch Q2 and switch Q4 are closed. Click “STARTUP”-> “Manual Start” menu The LCD displays the dialog of “Click OK button to turn on the bypass or skip the bypass to turn on the rectifier”. Click OK button and another dialog shows up, that is, “click OK button to send ‘Turn on BPSS command’”. Click “OK” button again, the bypass starts up and the UPS operates in bypass mode. At this time the power flow displayed by LCD is as shown in

Figure 5-3. If you click “Skip”, then directly enter step 4 of starting rectifier.

Fig.5- 3 Bypass mode displayed by LCD

4. Check out if there is any alarm shown in the left bottom window in the LCD. If there is any alarm, stop the next step operation, power off the UPS and check according to the Table 4-3 or contact the local customer service center.

5. Close the input switch Q1.

At this time, you need to check if the LCD displays that the rectifier input power frame is in green color. Otherwise check if the switch Q1 is closed.The LCD displays a dialog of “Click ‘OK’ button to send the command of turning on the rectifier”. Click “OK”, the rectifier performs soft-start and the rectifier frame is in flashing green color. After several seconds, the rectifier starts stable operation, and then the rectifier frame become normally lighting and is in green color and bus voltage reaches the rated voltage.

6. Then, the LCD displays a dialog of “Click ‘OK’ button to send the command of turning on the inverter”. Click “OK” to start the inverter and the inverter frame become normally lighting and the inverter starts normal operation. After the system detects the battery, the battery frame becomes green.

7. The LCD displays a dialog of “Click ‘OK’ button to send the command of enabling the MBD”. Verify if the bus voltage and the battery polarities are correct. Click OK if the battery charging is needed, and close the external battery circuit breaker. If no battery is connected, click “Skip” to enter the next step. The battery circuit breaker is located in the battery cabinet.

8. Then, the LCD displays a dialog of “Click ‘OK’ button to send the command of transferring”. If the bypass is in the synchronization range of inverter, click OK and the UPS transfers from bypass mode to inverter mode.

At this time the bypass static switch frame becomes dark and the output static switch frame becomes normally lighting and is in green colour. The UPS has entered the normal mode.

9. Close the cabinet door. Check if there is any alarm shown in the active event window in the LCD. Check if the power flow displayed in LCD is as shown in Figure 5-4.

If there is any alarm, handle the fault according to Table 4-3.



Fig.5- 4 LCD display in normal mode

UPS operates in normal mode

Battery Test Procedures

The Battery test procedures transfer the UPS into shared source mode wherein approximately 20% of the load power is supplied by the battery and the balance by the main input power.

Battery test type and preconditions

1. There are two kinds of battery tests to select from:

Battery maintenance test: Verifies the battery integrity and partially discharges the battery (20%).

Battery capacity test: Verifies precisely the battery capacity and fully discharges the battery (until low battery voltage alarm)

2. The tests can be carried out when the two following conditions are satisfied:

The load must be larger than 25% of rated UPS capacity.

The battery must have been undergone float charging for 5 hours or more.

The battery test procedures are driven through operator control and display LCD menus. The test is immediately terminated in the event of a battery or a mains power failure and the total load power is supported from the utility source or batteries without interruptions.

Test procedure

1. Manual Test

Perform battery test

Select “battery management” from the UPS operator control and display LCD, and then select “Manual battery test” menu and click “start” button to start the battery test.

After this test is completed, the system automatically updates the battery information, including the battery autonomy time. The battery autonomy time is the battery discharging time when the UPS is in battery mode.

Stop the test

During the battery test procedures, you can select the “Stop” in the menu of “Manual battery test” to stop the battery test.

2. Auto test

Select “Configuration->Battery management” in the UPS operator control and display LCD, and then select “Auto test”. A dialog is popped up and select “Enable” for auto test, set relevant auto test parameters and save them. When the preset start time is reached, the battery enters auto test. See 4.4.1Battery Management for relevant procedures.

Maintenance Bypass Procedure (UPS Shut Down)

The following procedure transfers the load supply from being protected by the UPS into being connected directly to the bypass supply through a maintenance bypass switch.



Caution – risk of load power interruption

Except in emergency situations, so as not to risk a short interruption in powering the load, before initiating this operating procedure, confirm that no warning is displayed in the left bottom corner of the LCD screen. If a warning status is displayed, the operator will be prompted to confirm or cancel any action that can lead to load interruption.

1. Select “SHUTDOWN” menu in the UPS LCD and the interface as shown in Figure 4-20 is displayed.

2. Select and click the “UPS” button to pop up the dialog as shown in Figure 4-21, and click OK button.

This operation will close the UPS rectifier, inverter and battery, and the UPS powers the load via bypass. At this time, the frames of rectifier, inverter and battery become gray, while the bypass frame and power path become green.

3. Open the external door of cabinet and close the internal maintenance bypass switch Q3.

At this time, the maintenance bypass is in parallel with the UPS bypass. The LCD will display relevant operations, that is, the open/close of maintenance bypass switch.

4. Open output switch Q4 and bypass switch Q2.

At this time, the transfer from the UPS to maintenance bypass is completed and the load is powered by the maintenance bypass.

Note

The load equipment is not protected from AC supply aberration.

5. Open the outer door of rectifier cabinet. Open the rectifier input circuit breaker Q1.

6. Open the external battery circuit breaker that is located in battery cabinet.

At this time, all the frames displayed in the LCD become gray. The power path of maintenance bypass becomes constant green with power flow. The power flow displayed in LCD is as shown in Figure 5-5.

7. Confirm if the LCD displays that Q1, Q2 and Q4 are opened and Q3 is closed. Click the “Reset” button in the screen to clear the Q3 closed / Q3 opened alarm information.

8. When maintaining the UPS, if the rectifier input has external distribution circuit breaker, you need to open this circuit breaker and put the fuse FB3 to open status. Otherwise, you need to put fuse FB1, FB2 and fuses FB3.

9. Close all the cabinet doors. At this time, all the internal power supplies are closed and the LCD displays closed status.

Fig.5- 5 LCD display in maintenance bypass mode

At this time, the load is powered on the maintenance bypass and the UPS totally shuts down.

WARNING

At this time, the mains voltage presents at all the rectifier and bypass input terminals and the output terminal of output switch Q4..



Transfer from Maintenance Bypass Mode to Normal Mode

The following procedure transfers the load from maintenance bypass mode to normal mode.

1. Open the outer door and inner door of rectifier cabinet. Close the fuses FB1, FB2, FB3 and FB4 .

2. After the LCD displays that the startup is completed, confirm whether the bypass input power frame is in green and close the bypass input circuit breaker Q2 and output circuit breaker Q4. Click “STARTUP”-> Enter “manual Start” menu to display the dialog of “Click OK button to turn on the bypass or skip the bypass to turn on the rectifier”. Click

OK button and another dialog shows up, that is, “click OK button to send ‘Turn on BPSS command’”. Click “OK” button again and the bypass starts up. The UPS then operates in bypass mode and at this time the power flow displayed by LCD is as shown in Figure 5-3,图与实际不对应，这是 maintenance 和 bypass 是同时导通的.

WARNING

You must turn on the bypass first and then open the maintenance bypass switch, otherwise load power failure will happen.

3. Open internal maintenance bypass switch Q3.

4. Close the input switch Q1.

At this time, you need to check if the LCD displays that the rectifier input power frame is in green color. Otherwise check if the switch Q1 is closed. The LCD displays a dialog of “Click ‘OK’ button to send the command of turning on the rectifier”. Click “OK”, the rectifier performs soft-start and the rectifier frame is in flashing green color. After several seconds, the rectifier starts stable operation, and then the rectifier frame become normally lighting and is in green and

DC bus voltage reaches the rated voltage.

5. Then, the LCD displays a dialog of “Click ‘OK’ button to send the command of turning on the inverter”. Click “OK” to start the inverter and the inverter frame become normally lighting and the inverter starts normal operation. After the system detects the battery, the battery frame becomes green.

6. The LCD displays a dialog of “Click ‘OK’ button to send the command of enabling the MBD”. Verify if the bus voltage and the battery polarities are correct. Click OK if the battery charging is needed, and close the external battery circuit breaker. If no battery is connected, click “Skip” to enter the next step. The battery circuit breaker is located in the battery cabinet.

7. The LCD displays a dialog of “Click ‘OK’ button to send the command of transferring”. If the bypass is in the synchronization range of inverter, click OK and the UPS transfers from bypass mode to inverter mode.

At this time the bypass frame becomes dark and the output static switch frame becomes normally lighting and is in green. The UPS has entered in normal mode.

8. Close all the cabinet doors. Check if there is any alarm shown in the active event window in the LCD. Check if the power flow displayed in LCD is as shown in Figure 5-4.

If there is any alarm information, handle the fault according to Table 4-3.

At this time, UPS has re-transferred to normal mode

Shutdown Procedure (Complete UPS And Load Shutdown)

This procedure must be followed to completely power off the UPS and load. All power switches, isolators and circuit breakers will be opened and UPS does not power the load.

Caution

The following procedure will cut all power supply to the load equipment.

1. Select “SHUTDOWN” menu in the UPS LCD and the shutdown interface as shown in Figure 4-20. Select and click the “System” button to pop up the dialog as shown in Figure 4-22, that is, “click OK button to shut down the UPS and the power to the load will be switched off”. Click OK button



This operation will turn off the rectifier, inverter and bypass static switch and disconnect battery, and the load is powered off.

2. Open the front doors, open the power switches Q1, external battery circuit breaker(BCB), bypass switch Q2, and output switch Q4 one by one.

3. Ensure that the maintenance bypass switch Q3 is open. Confirm that all the switches displayed on the power flow diagram in the LCD are opened.

4. To completely isolate the UPS from the AC supplies, if the rectifier and bypass inputs have external switches, you need to turn off these switches respectively. Otherwise, you need to put the FB1, FB2 and FB3 to open status and attach the WARNING labels.

5. Turn off the external output switches.

With all the internal power sources driven by external power supplies turned off, all the frames in the LCD become dark.

EPO Procedure

The UPS provides an EPO button on the front door of the rectifier cabinet. The EPO button is designed to switch off the UPS in emergency conditions (that is, fire, flood, etc.). To achieve this, just press the EPO button, and the system will turn off the rectifier, inverter and stop powering the load immediately (including the inverter and bypass), and the battery stops charging or discharging.

If the input utility is present, the UPS control circuit will remain active; however, the output will be turned off. To remove all power from the UPS, refer to step 2 to step 5 in 5.6 Shutdown Procedure (Complete UPS And Load

Shutdown)

.

UPS Reset Procedure after EPO Procedure

After using EPO to shut down the UPS and clearing all the faults according to the prompt information displayed in screen, carry out this procedure to restore the UPS to normal operation.

After confirming that the fault is cleared and there is no remote EPO signal:

1. The control display LCD panel pops up a dialog “Click OK button to reset EPO latch signal”. Click the OK button to make the system exit the EPO status.

2. Click “STARTUP->Mannual Start” menu in the LCD screen.

3. Follow the procedure described in 5.2 Start-Up Procedure (Into Normal Mode.)

WARNING

If the maintenance bypass switch Q3 is closed and the bypass input is available, the UPS has output.

Auto Restart

When the mains power is failure, the UPS draws power from the battery system to supply the load until the battery voltage reaches the end of discharge voltage (EOD), and the UPS will shut down.

The UPS will automatically restart and enable output power if following requirements are satisfied:

After the mains power is restored

If the Auto restart is enabled, and if the Auto Restart Type has been set up (default is charging only). There are three kinds of Auto Recovery: bypass mode only, charging only and full system enabled.

After the Auto Restart Delay

After the Auto Restart, if the Auto Restart is set to charging only or full system enabled, the UPS charges the battery to avoid the power failure risk to the load due to the next time of mains power failure.

Note



In Auto Restart process, manual start is disabled. Auto Restart function must be set through host computer.

Language Selection

The LCD menus and data display are available in two languages: Chinese and English.

Proceed the following procedure to select a language needed:

1. Enter the “CONFIG/User Settings/System Parameters” menu and a dialog as shown in Figure 5-6 is popped up.

Fig.5- 6 Dialog of selecting language and modifying the current date/time

2. Click the button “Language”, then two available languages are displayed , Chinese and English.

3. Select the display language and click “OK” to return to the dialog as shown in Figure 5-6.

4. After the above setting is made, click “Save” and a dialog for password verification is popped up.

5. Enter the password and click “OK” to confirm the entry of password.

Changing The Current Date And Time

To change the system date and time:

1. Enter the “CONFIG/User Settings/System Parameters” menu and a dialog as shown in Figure 5-6 is popped up.

2. Click the button “Date”. The dialog of “Month/Day/Year” is popped up.

3. After changing the “Month/Day/Year”, click OK to return to the dialog as shown in Figure 5-6.

4. Click the button before the “Time”. The dialog of “Hour/Minute/Second” is popped up.

5. After changing the “Hour/Minute/Second”, click OK to return to the dialog as shown in Figure 5-6.

6. Click “Save” and a dialog for password verification is popped up.

7. Enter the password and click “OK” to confirm the entry of password.

Change Password

The system is password protected to limit the operating. The default password is “NXL”, which is case-sensitive. You can only operate and test the UPS and battery after entering correct password.

To change the password:

1. Enter the “CONFIG/User Settings/System Parameters” , and a dialog as shown in Figure 5-6 is popped up.



2. Click the button “Password”. The dialog of “Change Password” is popped up.

3. Enter the current password, and then enter new password and enter the new password again. Click OK to return to the dialog as shown in Figure 5-6.

4. Click “Save” to complete the setting.


66 Chapter 6 Battery

6. Battery

This chapter introduces the battery, including the battery safety, installation and maintenance information, and the battery protection function, as well as the connections of the optional BCB box (cabinet) and battery temperature sensor.

Introduction

The UPS battery consists of battery blocks connected in series to provide a nominal DC input voltage for the UPS inverter. The required autonomy time (the time that the battery can maintain supply to the load in the event of a mains failure) is limited by the ampere-hour size of the individual battery blocks and in some cases this could mean several strings need to be connected in parallel.

In order to facilitate the HIPULSE-NXL 500/800kVA UPS installation, generally the batteries are installed in specially designed BCB cabinet or battery rack.

Be sure to disconnect the battery from the UPS module when undertaking maintenance or service procedures. This is facilitated by means of a suitably rated battery circuit breaker, which must be located as close as possible to the battery terminals, and the power and control cables connected to the UPS using the most direct route possible.

If multiple sets of batteries connected in parallel are used to increase battery autonomy time, the extension must be fitted with a sectioning device to permit work to be performed on one set of batteries while the others remain in service.

For external battery assembly, Emerson offers an optional battery cabinet (the features of which depend on the size of the UPS). Normally, you must select a corresponding battery circuit breaker for each UPS, in order to disconnect the battery from the UPS when the UPS requires maintenance or repair. The BCB cabinet includes a battery interface board. For 500kVA UPS, this BCB cabinet is designed to be wall-mounted; For 800kVA UPS, this BCB cabinet is designed to be floor mounted and is connected between the UPS and the battery. Refer to 6.9 Battery Cabinet

(Optional Parts) for more information.

Safety

Special care should be taken when working with the batteries associated with the HIPULSE-NXL 500/800kVA UPS.

When all the cells are connected together, the battery terminal voltage will exceed 540V and is potentially lethal.

Please observe the safety codes for high voltage operation. Only qualified person can install and maintain the batteries. A primary safety consideration is to install the cells in a key-lockable cabinet or a purpose-designed, dedicated battery room so as to isolate the batteries from other personnel except the qualified maintenance engineers.


Chapter 6 Battery 67

WARNING

1. The battery must be reliably connected. After connecting the batteries, be sure to calibrate the connections between all the wiring terminals and batteries. The torque requirements specified in battery user manuals provided by battery manufacturer must be met. The connections between all the wiring terminals and batteries must be checked once a year. Otherwise fire accident will occur!

Correct connection

Tighten the terminal bolt of the battery with specified torque.

Wrong connection

Both bigger and smaller torques will cause poor connection of terminal. Under certain condition, electric arc or heat concentration may occur in the terminals, which finally results in fire accident.



2. Before accepting and using the goods, be sure to check the battery appearance. If the package is broken or battery terminal is dirty, eroded, and rusted or the case has cracks, distortion and leakage, be sure to replace the battery. Otherwise, the battery capacity will be lowered, and current leakage and fire accident will happen.

Battery damaged in transportation

Condition of battery that has been discharged for one week

3. Since the battery is heavy, please use correct methods to carry or lift the batteries to avoid human injury or battery terminal damage. In severe condition, the battery may caught fire.

4. The battery connection terminal should not be applied with any external force such as the pulling or twisting force from the cable. Otherwise the internal connection of the battery may be damaged, or even fire accident may be caused.

5. The batteries should be installed in a clean, cool and dry environment. Do not install the batteries in a sealed battery chamber or sealed room. The battery ventilation should meet the requirement of EN50272-2001, otherwise the battery may swell, catch fire or result in human injury.

6. The battery installation location should be far away from the heating sources such as transformer. Do not use and keep the batteries in the place close to the fire source. Do not burn the battery or heat the battery in fire, otherwise the battery will leak, swell, catch fire or explode.

7. Do not connect any conductor between the positive and negative terminals of the battery. When operating the battery, be sure to remove the metallic objects such as ring, watch, necklace and other metallic decorating objects. Make sure the operating tools such as wrench are wrapped with insulation tapes otherwise the battery may catch fire, cause human injure or result in explode.

8. Please do not dissemble, modify and damage the battery. Otherwise the battery may have short circuit, leakage or result in human injure.

9. Use a wet cloth that has been twisted to clean the battery case. Do not use a dry cloth or other dry tool to clean the battery case so as to avoid ESD or spark. Do not use organic solution such as gasoline or evaporating oil to clean the battery case otherwise the battery case may be broken, and the worst consequence may be the fire accident.

10. The battery contains sulfuric acid. In normal operation, all the sulfuric acid is attached to the separation board and plate in the battery. However, when the battery case is broken, the acid will leak from the battery. Therefore, be sure to wear a pair of protective glasses, rubber gloves and skirt when operating the battery. Otherwise, you may become blind if acid enters your eyes and your skin may be damaged by the acid.

11. At the end of battery life, the battery may have internal short circuit, dry of electrolytic and erosion of positive/negative plates.

If this condition continues, the battery may have temperature out of control, swell or leak. Be sure to replace the battery before these phenomena happen.

UPS Batteries

It is a common practice in UPS installations to use valve-regulated cells. The term ‘valve regulated’ is used currently in place of either ‘sealed’ or ‘maintenance free’ both of which have been used in the past.

Valve-regulated cells are not ‘sealed,’ and will release gas, particularly on overcharge. The amount of gas given off is less than for a flooded cell. However, considering the temperature rise in the design of the battery installation, be sure to reserve adequate clearance for good ventilation of the cells.

Similarly, valve-regulated cells cannot be regarded as maintenance-free, as they must be kept clean and their connections checked periodically for tightness and free of corrosion. Refer to battery maintenance section for details.

The number of battery strings connected in parallel should not exceed four. Do not mix the batteries of different types, name and ages, otherwise, some batteries may be over discharged and some batteries may be under discharged due to the inconsistent battery parameters, which results in the earlier failure of some batteries and in adequate battery capacity.



Batteries are fully charged in storage; However, some capacity of the batteries may be lost due to self-discharging in storage and transportation processes. Therefore, be sure to re-charge the batteries before using them. When storing

25 .

In order to compensate the self-discharging of the batteries during battery storage process, re-charge the battery every 3 months. The time for different battery is also different, so please re-charge the battery according to the manufacturer’s instructions.

It is especially important that the battery is fully charged before attempting a field test of the autonomy time. This may require several days to complete; therefore any field test concerning the batteries should take place only after the battery has been on uninterrupted float charge for at least one week.

Cell performance typically improves after a few weeks in service or after two or three discharge and recharge cycles.

In order to avoid over charging or under charging to the battery, please set the battery management parameters according to the float charging voltage and temperature compensation coefficient specified in the user manual provided by the battery manufacturer. Charge the battery immediately after it has discharged.

Installation Design Considerations

Note

Full safety instructions concerning the use and maintenance of UPS batteries are provided in the appropriate battery manufacturers’ manuals. The battery safety information contained in this section relates to key considerations which must be taken into account during the installation design process and might affect the design outcome depending on local conditions.

Battery Installation Environment and Number of Batteries Needed

Installation Environment

Fresh air flow volume (EN50272-2001)

The battery application environment must be well ventilated. During the battery operating process, the requirement for fresh air ventilation is as follows:

Q = 0.05 × n × Igas ×Crt × 10–3 [m3/h]

Where:

Q― Fresh air flow per hour and the unit is m3/h n― Number of battery cells

Igas― Gassing current density in battery float charging or equalize charging status, unit: mA/Ah

Igas=1 at 2.27V/cell float charging condition

Igas=8 at 2.35V/ cell float charging condition

Crt―20hr battery rated capacity

Temperature

Table 6- 1 Using temperature range

Temperature

Category Remark value

Recommended optimum temperature

Short time acceptable temperature

The battery operating temperature can be neither high nor low.

20ºC~25 ºC

-15 ºC~45 ºC

If the average battery operating temperature rises from 25 ºC to 35 ºC, so the battery life will be reduced by 50%; If the battery operating temperature is higher than 40 ºC, the battery service life will decrease each day in the exponent level.

The higher the temperature, the shorter the battery service life. The lower the temperature, the lower the battery charging and discharging capabilities.



The battery must be installed in cool and dry environment that is free of heating source and sunshine with ambient humidity less than 90%.

Ambient temperature, ventilation, spacing, float charge voltage and ripple current all affect the battery temperature.

Uneven temperature distribution through the battery string will cause the voltage distribution to be uneven which can also lead to problems — it is therefore important to maintain an even temperature across the whole battery string.

The temperature difference between different layers of batteries should be less than 3°C. Valve-regulated cells are very sensitive to temperature and should be operated at a temperature between 15°C and 25°C. When batteries are cabinet-mounted adjacent to the UPS module, it is the battery which dictates the designed maximum ambient temperature, not the UPS. That is, in the case of valve-regulated cells, the ambient room temperature should be kept between 15°C and 25°C, but not the main equipment operating temperature range. Temperature deviations are acceptable for short periods of time provided the average temperature does not exceed 25°C.

Number of Batteries Needed

The nominal DC bus voltage, and therefore battery float voltage, is set according the module’s rated input and output voltages, and usually set to 540Vdc, and the expected float charging voltage for a cell is 2.25V. The number of battery cells, end of discharge voltage, and float charging voltage under 380V/400V/415V are the same. See Table 6-2 for details.

Parameter

Number of cells used (standard)

End-of-discharge voltage

Float charging voltage

Table 6- 2 Number of Batteries Needed

380V/400V/415V

228 to 246, 240 is recommended

1.60 to 1.88 Vdc/Cell, 1.62 is recommended, that is 389V

2.15 to 2.3 Vdc/Cell, 2.25 is recommended, that is 540V

Battery Protection

Attention

It is recommended to use the battery circuit breaker provided by Emerson to avoid risk.

The battery is connected to the UPS through a BCB which is manually closed and electronically tripped through the

UPS control circuitry. If the cells are rack-mounted (or located remote from the main UPS cabinet), the BCB must be mounted as close as possible to the batteries themselves, and the power and control cables connected to the UPS using the most direct route possible.

Features of the BCB include:

Isolation from battery to achieve safety and reliability

Short circuit protection

Automatic opening in the event of inverter lockup due to battery under voltage to prevent battery damage caused by over discharge

Tripping by remote emergency power off (EPO) button if installed

Operation error protection

To achieve the required autonomy time, it may be necessary to parallel battery strings. In which case, the battery circuit breaker should be placed downstream of all parallel battery strings.

Attention

All equipment servicing procedures should be carried out only by trained personnel.



Battery Connection

Fitting The Batteries

1. Prior to installation, be sure to check if the appearance of the batteries has been damaged and if the spare parts are complete. In addition, read the user manual or installation instructions provided by battery manufacturer carefully.

2. A minimum space of 10 mm must be reserved on all vertical sides of the battery block to permit free air movement around the cells.

3. A certain clearance should be reserved between the top of the cells and the underside of the shelf above, as this is necessary for monitoring and servicing the cells.

4. When installing the batteries always work from the bottom shelf upwards to prevent raising the center of gravity.

Install the batteries reliably and avoid vibration and mechanical bumping.

Connecting The Battery

1. All cabinets or racks must be connected together and must be well earthed.

2. When using multi battery strings, connect the cells / blocks in series first and then in parallel. Do not connect power until the total voltage of the battery string is verified correct through measurement. Be sure to connect the positive/negative terminals of the batteries to those of the UPS respectively with reference to the markings of positive/negative terminals. Reverse connection of battery polarities will result in explosion, fire accident, the damage of batteries and UPS, and human injure.

3. Each battery terminal should be insulated after its connection has been made.

4. When connecting the cables between the battery terminals and the circuit breaker always connect the circuit breaker terminal first.

5. The bending radius of cable should be more than 10D, where "D" is the outer diameter of cable.

6. After connecting the cables of battery, it is absolutely prohibited to pull the battery cable or cable terminal.

7. When connecting the cable, do not cross the battery cables and do not bind the battery cables together.

Battery Installation

Whatever the type of mounting system selected, the following conditions should be noted (Refer to Figure 6-1):

X Layout of cells:

Whatever battery mounting system is used, the batteries should be laid out in such a manner as to make simultaneous contact with two exposed live parts having a potential greater than 150V impossible. Where this is not possible, insulated terminal shields must be installed and insulated cables must be used for connections.

Y Service platform

The service platform (or duckboard) must be slip-proof, insulated from the floor and be at least one meter wide.

Z Connections:

All connections must be as short as possible.

[ Battery circuit breaker:

The Battery Circuit Breaker is generally installed in the wall-mounted box close to the battery. The connection of BCB cabinet available for the 'HIPULSE-NXL UPS' is described in the following paragraph.



Fig.6- 1 Battery room design

Battery Cabinet (Optional)

The BCB box of NXL500kVA UPS is wall-mounted, and the installation holes and dimensions are shown in Figure 6-2.

The BCB cabinet of NXL800kVA UPS is floor-mounted. The installation holes and dimensions are shown in Figure

6-3 and Figure 6-4.

A Detail

Fig.6- 2 Installation hole dimensions for battery cabinet of 500kVA UPS (Unit: mm)



800

642

4-14.5×24.5

Fig.6- 3 Installation hole dimensions for floor-mounted of battery cabinet (Unit: mm)

Fig.6- 4 Dimensions of BCB cabinet

The battery cabinet contains a BCB and a BIB (battery interface board, Model: 02-806811).

The battery cabinet is fitted as close as possible to the battery. The battery CAN cable is connected to the EIB

(external interface board) of UPS rectifier cabinet via the TB1154 interface on the BIB, as shown in Figure 6-5. The battery temperature sensor is connected to the P1153 interface on the BIB.



UPS EIB

TB1154A

BATT +24V

GND

BATT CANH

BATT CANL

1

2

3

4

7

8

5

6

3

4

1

2

TB1158

1

2

3

4

TB1154

BIB

1

2

TB1156

TB1151

1 2 3 4 5 6 7

TB1150

3

4

5

1

2

P1152

1

2

E2 (POS)

＋

E1 (NEG)

—

P1153

1 2

P1159

3

4

1

2

接电池温度传感

Fig.6- 5 Battery cabinet connection

Note: The control cables from the UPS to the BIB must be made using the accessory cable of the BCB cabinet, which is a shielded cable located in a separate conduit to that containing the battery power cables. The cable shield must be earthed to prevent induced EMI affecting the control operation, and both the UPS and BCB cabinet must be earthed separately.



Battery Temperature Detecting Resistor

A battery temperature detecting resistor (NTC) is provided to detect the battery temperature. This resistor is closely attached to the surface of the battery that is close to the battery circuit breaker. Another end of the detecting resistor is plugged into the P1153 interface of BIB, and then connected to the UPS logic circuits through BIB. See Figure 6-5 for detailed connections.

With this feature fitted, the nominal float voltage supplied to the battery is adjusted so as to be inversely proportional to the ambient battery cabinet/room temperature. This prevents the battery being over charged at high ambient temperatures.

Note

If there are multi battery strings, each string should be mounted with a temperature detecting resistor.

Battery Maintenance

Refer to IEEE-Std-1188-2005 and the user manual provided by the battery manufacturer for the battery maintenance and maintenance cautions.

Note

Please check the battery connection screw periodically. Check whether the screws are tightened or become loose. If there is any loose screw, be sure to tighten it.

Test and ensure all the applied safety devices are installed and operate normally. Pay particular attention to if the battery management parameter settings are correct.

Measure and record the air temperature inside battery room.

Check if the battery terminals have been damaged or have any heating phenomena. Check if the battery case or cover has been damaged.

Recycle of Batteries

If battery leakage or damage happens, please place the battery in the container that is resistive to acid and dispose the battery according to local codes.

The waste lead-acid battery is a kind of hazardous waste and is one of the major contaminants controlled by government. Therefore, its storage, transportation, using and disposal must comply with the national or local regulations and laws about the disposal of hazardous waste and waste batteries or other standards.

According to the national laws, the waste lead-acid battery should be recycled and reused, and it is prohibited to dispose the batteries in other ways except recycling. Throwing away the waste lead-acid batteries at will or other improper disposal methods will cause severe environment pollution, and the person who does this will bear the corresponding legal responsibilities.

As a lead-acid battery supplier, Emerson Network Power Co., Ltd. has set up a perfect service network and a recycling system for waste batteries so as to help the customers to dispose the waste batteries properly. Please obtain the recycling system of Emerson Network Power Co., Ltd. from the local Emerson office or nearest Emerson office. If the customer does not accept this requirement or does not use the waste batteries recycling system set up by Emerson Network Power Co., Ltd., Emerson Network Power Co., Ltd. will not bear any responsibility due to improper dispose of the waste batteries.


76 Chapter 7 1+N Parallel System Installation

7. 1+N Parallel System Installation

Configuration

The HIPULSE-NXL UPS mainly has two kinds of configurations: z Single (expandable) z N+1

Single module is applicable for: z Single module system (composed of single UPS module) z 1+1 redundant system z 1+N parallel system (with static switch that has a distributed bypass)

N+1 configuration is used for: z N+1 system (with a integrated bypass static switch)

This manual will introduce the single module and parallel system. Another manual will be dedicated for N+1 parallel system.

1+N system is composed of two or more than two (up to 8) UPS modules with same capacity, and each module shares the UPS load.1+N system has following two types: z Parallel for capacity expansion: The system is composed of minimum number of UPS modules that can meet the system load requirements. z Redundant The system is composed of the number of UPS modules that is larger than the load capacity.

The basic installation procedures of 1+N parallel system are the same with those of the UPS single module system.

In this section, only the installation procedures related to the parallel system are introduced.

Note

The parallel system that is composed of two or more than two UPS modules needs external maintenance bypass if the load capacity is larger than that of single UPS module. When using 1+N system, use certain measures to avoid using the

UPS internal maintenance bypass switch (Q3), and you can achieve this by removing the handle of the switch and placing a warning label for maintenance persons.

Overview

A parallel system that is composed of single UPS modules is equivalent to a large capacity UPS with higher reliability.

To ensure that all the UPS modules are used equally and meet the relevant wiring rules, be sure to observe the following requirements:

1) The rated power, voltage and frequency of all the UPS modules should be the same.

2) The output of all the UPS modules must be connected to the same output bus.

3) For the redundant parallel system composed of more than 3 modules (or the capacity-expanded system composed of two or more than two modules), the bypass load sharing inductor should be installed. Refer to Optional Parts

1+N parallel system needs the parallel control signal to control the load sharing, synchronization and bypass transfer of the UPS modules. The “Parallel Control Cable” in Figure 7-1“Principal Diagram of 1+N System with Separate


Chapter 7 1+N Parallel System Installation 77

Batteries” provides this function. The parallel control cable is the multi-conductor ribbon cable that connects between the UPS modules.

External Protective Devices

1) Refer to the instructions supplied in the first part of this manual ⎯ Big leakage current alarm

2) If the rectifier and bypass do not share the same power source and each UPS module has its own batteries, and if a differential switch is needed at the UPS input, the differential switch is only needed at the system bypass input.

3) In the system where all the UPS modules share the same battery, if the rectifier and bypass share the same power source and if the UPS input uses differential switch, every power input source should be installed with a differential switch. If the rectifier and bypass do not share the same power source, all bypass input source needs to be installed with a differential switch.

Install Cabinet

All the UPS modules should be installed side by side, and the cables should be connected according to Chapter 3

Electrical Installation .

Fig.7- 1 Principal Diagram of 1+N System with Separate Batteries

To make it easier for the maintenance and system test, the optional parts of external maintenance bypass cabinet are recommended to be used in the installation.

Power Cables

The connection of the power cables of each UPS module is described in 3.1 Power Cable Connection.

In the parallel system, the tolerance of the length of power cables connected between the UPS modules should be within ±20%.



Parallel Communication Board (IMC)

The IMC board can realize the communication between the UPS modules in 1+N parallel system. Each UPS module has an IMC board that realizes the communication with the 1+N parallel system and other UPS modules. The IMC board offers three communication buses between the UPS modules: CAN bus, power sharing CAN bus and separated I/O bus.

Fig.7- 2 Parallel Communication Board (IMC)

You can use a RS232 cable to connect to the PC and UPS serial communication port to configure the IMC.

Fig.7- 3 Illustration of Parallel Communication Board (IMC)



Control Cable

As shown in Figure 7-4“Connections of Parallel Signal”, the connection between the single UPS modules is chain-type redundant connection. This kind of connection method ensures the high reliable control, that is, even if one cable among N PCS of cables is broken, the system control signal transmission, synchronization among UPS modules, load sharing, battery charging current sharing (shared battery configuration), load transfer and other common control and alarms will not be affected.

The IMC board is located in I/O area.

Fig.7- 4 Parallel Signal Connection

Note 1: The I/O of P1301 and P1303 is connected via “T type” connector I/O. z Basic connection: Use the parallel cable that is a 7-conductor twisted cable (14-wires) to connect the UPS#1

(P3101) to UPS#2 (P3101), and then connect UPS#2 (P3101) to the next UPS module. z Redundant connection: Use the parallel cable that is a 7-conductor twisted cable (14-wires) to connect the

UPS#1 (P3101) to UPS#2 (P3103), and then connect UPS#2 (P3103) to the next UPS module. z The circuit in the last IMC board in the chain connection must have a CAN termination resistor. z Set the CAN termination jumper: P9, P22, P7, P19, P5, P17, P4, P12, P3, P11, P1, and P10

Pin 1-2= there is resistance in the circuit; Pin 2-3=there is no resistance in the circuit. When there are more than 2 UPS modules in the parallel system, set the jumper to pin 1-2 only the in the modules at two ends of the parallel system.

Note: For every single UPS module in the parallel system, be sure to change the setting from “SMS” to “1+N” from the operator control panel.

The maximum length of the parallel communication cable is 280m.Therefore, the maximum length of the cable between UPS modules in the parallel system with 8 UPS modules (the distance between every two neighboring UPS modules is the same) is 40m.

The system provides these optional parts of cables.

Remote EPO

Besides the EOP button on the front panel of the UPS, which can be used to shut down the local UPS, the UPS also supports remote EPO that can shut down several UPS modules.

Note: z The remote EPO switch must be normally open or normally close reactive switch z The open circuit voltage is 12Vdc, and the current is less than 10mA. z The external EPO provides second sets of contacts, which can turn off the user input mains circuit breaker or the bypass input circuit breaker, if they are fitted with remote tripping mechanism. z Normally closed LEPO-J0806-1-2 terminals: Has been connected in factory and located on the external interface board (EIB).



Fig.7- 5 EPO Connection

Hot Standby System

The hot standby system is composed of two UPS modules with the same capacity and connected in series, One of the UPS module is set as the host (low level) and another UPS is set as the slave (high level). The master and slave units are connected via power cables and are set via software. Normally, both the slave and master operate in normal mode. The output of the high level unit (slave) is the bypass input source of the low level unit (master).The output of the low level UPS (master) connects to the load and synchronizes with the output of the high level (slave) UPS. If the inverter that connects to the load fails, the inverter of the high level UPS (slave) powers the load via the bypass of the low level UPS (master).You can set the system in this mode: The low level UPS (master) operates alternatively in normal mode and bypass , so that two UPS are utilized equally.

Note: In hot standby system, the master unit must be started first.

External Protection Devices

Refer to Chapter 3 Electrical Installation

Install Cabinet

Place the UPS modules side by side and connect the cables according to the following drawing:



Fig.7- 6 Hot standby system

Power Cables

Besides that the high level UPS output powers the bypass of the low level UPS, and the inverter or bypass of the low level UPS powers the load, the power cable connection of the hot standby system is similar to that of the system with single UPS module.


Control Cables

Except the single UPS module control cables, no other control cable is needed.

Dual-bus System

The dual bus system (DBS) is consisted of two independent UPS systems and each UPS system is consisted of one or more than one UPS module. The dual bus system is configured for high availability and is suitable for powering the load with multi inputs. If the load is single-input load, the static transfer switch is needed and the LBS system of the

UPS should be enabled. The LBS makes the outputs of two independent UPS modules (or parallel system) keep synchronized. One system is set as the master unit and another system is set as slave unit. The LBS can enable the load to have two independent UPS sources.

External Protection Devices




Install Cabinet

Place the UPS modules side by side and connect the cables according to Figure 7-7 Dual Bus System.

Fig.7- 7 Dual Bus System

Power Cables

The power cable connection of the dual-bus system is similar to that of the system with single UPS module. Refer to

Chapter 3 Electrical Installation

Control Cables

7.3.4.1 Dual Bus Configuration of HIPULSE-NXL and HIPULSE-NXL

Refer to Figure 7-8 “Dual Bus System: Cable Connection of Single UPS Module”, and use the optional LBS cables to connect any two digital LBS interfaces that connect two UPS systems.



Fig.7- 8 Dual bus system: Cable connection of single UPS module

1. The capacity, voltage and frequency of two UPS systems must be the same.

2. The load cannot be larger than the rated capacity of single UPS system.


84 Chapter 8 Specifications

8. Specifications

This chapter provides the specifications of the HIPULSE-NXL 500/800kVA UPS.

Conformity And Standard

Description

Safety requirements

Year

2005

EMC 2005

Design and test methods 1999

Environmental Requirements

Table 8- 1 Conformity and standard

Normative references

IEC60950-1, IEC62040-1-1

IEC/EN62040-2

IEC62040-3

Item

Operating Temperature

Altitude of operation

Storage temperature and transport temperature

Mechanical Characteristics

Table 8- 2 Environmental requirements

Unit Power rating

℃ 0~40

0~35 (output PF: 0.9)

0~40 (output PF: 0.85) m

≤1500m, derated according to GB/T 3859.2-1993 for altitude higher than 1500m

℃ battery)

Table 8- 3 HIPULSE-NXL 500/800kVA Mechanical characteristics

Components

Item Unit

Height mm

Rectifier cabinet

500kVA 800kVA

Inverter cabinet

Rectifier cabinet

Inverter cabinet Switch cabinet

1950

Width

Depth

Weight mm mm

1250 1585 1585

1090

1570 800

Ventilation

Cable entry

-

-

By internal intake fans

Top or bottom of cabinet

Note:

1. The volume (height/width/depth) and weight does not include the packaging materials.


Chapter 8 Specifications 85

UPS Electrical Characteristics (Input Rectifier)

Table 8- 4 Electrical characteristics (input rectifier)

Power rating

Supply

Input harmonic current

Item

Input voltage tolerance 1

Power factor

Unit

Power rating

500kVA 800kVA

Vac 380/400/415 (line-to-line voltage)

- Three phase without neutral

380V system:-23%~+15%, 291V~438V (line-to-line voltage), recovery point (low limit: 352V high

% limit: 427V)

400V system:-25%~+15%, 300V~460V (line-to-line voltage), recovery point (low limit: 370V high limit: 450V)

415V system:-25%~+15%, 310V~477V (line-to-line voltage), recovery point (low limit: 385V high limit: 467V)

-

-

<10% (No filter)

<5% (with Trap filer)

<3% (with Active filer)

≥0.8 (lag) (No filter)

≥0.89 (lag) (with Trap filer)

≥0.98 (lag) (with Active filer)

Condition: Rated input voltage, output 100%KW

Hz 50/60

Hz 45~55(50Hz),54~66(60Hz)

Frequency

Frequency

Rated input apparent power 2

Rated input current

2 kVA 611

A 929

1086

1650

Maximal input apparent Power 3

Maximal input current 3 kVA 754

A

1145

1303

1832

Duration of progressive power walk-in 4 s 3～30 3～30

Note:

1. With mains at -20% and suggested number of cells the UPS can maintain the output rated voltage at rated load, and the battery does not discharge but cannot guarantee float charge to battery;.

2. IEC62040-3(5.2.2): UPS, rated load, input rated voltage 380V, no current to battery.

3. IEC62040-3(5.2.2): UPS, rated load, input rated voltage 380V, battery on boost charge with maximal allowed current.

4. Set by dedicated software installed in host computer

UPS Electrical Characteristics (DC Intermediate Circuit)

Item

DC bus voltage range

Recommended number of lead-acid cells 1, 2

Float charge voltage

Boost charge voltage

End-of-discharge voltage

Battery protectiion voltage

2.45 Vdc/Cell 1

Max boost charge duration 3

Boost-float threshold current 3

Ripple voltage 4

Table 8- 5 Electrical characteristics (DC intermediate circuit)

Unit

Vdc 490~566

Power rating (500/800kVA)

PCS 228~246, Recommended number is 240

Vdc/Cell

Vdc/Cell

Vdc/Cell

2.15~2.3, Recommended value is 2.25

2.30~2.45, Recommended value is 2.35

1.60~1.88

Vdc 588


86 Chapter 8 Specifications

Item Unit Power rating (500/800kVA)

Note:

1. (According to rated voltage)

2. Different cells number and voltage per cell may be set by configuration software.

3. Set by software.

4. Battery disconnected, RMS percentage value referred to DC voltage

UPS Electrical Characteristics (Inverter Output)

Table 8- 6 Electrical characteristics (inverter output)

Item Unit

Power rating

500kVA 800kVA

Rated output voltage 1

Output supply

Rated Power at cos = 0.9

Rated Power at cos = 1

- kVA kW

Three-phase four-wire, that is, with neutral

500 800

450

60, 110%

720

Three-phase overload time 2

1, 150%

Maximal non linear load allowed 3

Voltage stability, steady State test 2

Voltage stability, transient test

4

THD(linear load) 5

THD(non linear load) 3

- 100kVA

%

±1% (balanced load)

±2% (imbalance load)

% ±5%RMS

THD(non linear load)

%

%

-

2% (line-to-neutrl voltage)

2.5% (line-to-neutrl voltage)

120±0.5º (balanced load)

120±1º (imbalance load)

Frequency range

Frequency slewrate 6

Hz

Hz/s

Synchronous status, track the bypass input, bypass synchronous window:

0.3Hz to 5Hz settable(0.1Hz step)

0. 1Hz/s to 3Hz/s(settable, step: 0.1Hz/s)

Bypass transfer time ms

Inverter synchronizes with bypass, transfer time is 0;

Inverter does not synchronize with bypass, transfer time is less than 20ms

0 Battery transfer time ms

Note:

1. Factory set 380V 400 or 415 voltages settable through software.

2. IEC62040-3 (5.3.2)

3. Reference non-linear load requirement specified by IEC62040-3(ANNEX E)

4. IEC62040-3(5.3.1), including 0~100~0% load transient, restore time 20 ms with resolution of 1%

5. Load is from 0 to 110%

6. Factory setting is 1 Hz/s, settable through software


Chapter 8 Specifications 87

UPS Electrical Characteristics (Bypass Input)

Table 8- 7 Electrical characteristics (bypass input)

Item

Rated mains voltage

Supply

Rated current

380 Vac

400 Vac

415 Vac

*

Unit

Vac

-

A

Power rating (800kVA)

380/400/415

Three-phase four-wire, that is, with neutral

500kVA 800kVA

760 1216

722 1155

696 1113

Bypass voltage tolerance

Delay time to acknowledge returned to window

Inverter output voltage window

Frequency

Input frequency tolerance

Maximum frequency slew rate

% -20%~+15% s 2

% ±1

Hz 50/60

% ±10

Hz/s 3

Current rating of neutral cable

Protection, bypass line

Transient overload

- 1.1In

- ms

I/In

The bypass line should be protected using an external device in the input distribution system.

This device should be sized for statisfying different load protection needs.

10

11.5

20

10.5

50

9.25

Note:

Factory set 380V, 400 or 415 voltages settable through software.

100

7.75

200

7.5

500

6.38

1000

5.88

2000

5.38

5000

4.63

UPS Electrical Characteristics (System Performance)

Item

No load losses

Full load losses (100%)

Table 8- 8 Electrical characteristics (system performance)

Unit kW kW

Power rating

500kVA 800kVA

9.5

40.5

14.9

56.5


88 Chapter 9 Service & Maintenance

9. Service & Maintenance

Regular service and maintenance are required during the long term operation of the UPS system (including the associated battery). The battery maintenance has been described in chapter 6. This chapter deals with the life characteristics of the key components of the UPS, and provides recommendation for the regular check and service of the key components. Proper service and maintenance of the UPS system can extend the UPS life and reduce the risk of system malfunction.

Safety

WARNING

The daily patrol check of the UPS system can be conducted by trained personnel, while the check and replacement of the UPS components should be done by authorized professionals.

UPS Key Components And Their Lives

During the UPS operation, some UPS components’ lives are shorter than the UPS life due to wear in working. To ensure the safe power supply of the UPS system, regular check and replacement of these components are required.

This section introduces the key components of the HIPULSE-NXL 500/800kVA UPS and their reference working lives.

For systems working in different conditions (environment, load, and so on), you may ask professionals to assess the components and provide advices whether to replace the components by referring to the information provided in this section.

Magnetic Components: Transformer, Inductor

The design life of the magnetic components is 20 years. The key factors affecting the life of the magnetic components are the insulation system and the temperature increase in operation. The HIPULSE-NXL 500/800kVA UPS adopts

H-level insulation system and can withstand up to 220°C working temperature. Normally, the UPS works in forced air convection cooling condition.

Power Semiconductor Devices

The power semiconductor devices include SCR (silicon-controlled rectifier) and IGBT (insulated gate bipolar transistor). In normal UPS working condition, there is no rated life of the power semiconductor devices. The SCR and

IGBT failures are always caused by other problems, as they do not have the problem of life expiration. However, in system service and maintenance, you should check on an annual basis the appearances of the power semiconductor devices for erosion and damage in package. If you spot any risk of failure, replace the device.

Electrolytic Capacitors

The life of the electrolytic capacitors depend on the DC bus voltage, ripple current and ambient temperature of the

UPS.

To ensure safe and stable UPS operation, it is recommended to check the operation status of the electrolytic capacitors on an annual basis. The electrolytic capacitors must be replaced before their life expires, advisably, within

5 to 6 years of operation.

AC Capacitors

It is recommended to replace the AC capacitors within 5 to 6 years of continuous operation, and to check the AC capacitors on a half year basis. Replace the AC capacitor if spotting any deformation.


Chapter 9 Service & Maintenance 89

Dust Filter

The dust filter must be checked and replaced periodically. The checking and replacing interval is dependent on the environmental conditions of UPS. Under general environmental conditions, the dust filter should be cleaned or replaced every two months. If the environment has more dusts or is more severe, clean and replace dust filter more frequently even in a new building. The dust filter of NXL UPS is mounted on the front door of the cabinet and can be replaced when the UPS is operating.

Lives And Recommended Replacement Time Of Key Components

The key components listed in Table 8-1 are used in the UPS. To prevent system malfunction caused by failure of key components due to wear during working, you are recommended to check them regularly, and replace them within their life expectancy.

Table 9- 1 Lives and recommended replacement time of key components

Key components Life expectancy

AC capacitor

Electrolytic capacitor

Fan

Dust filter

Valve-regulated lead-acid battery ( 5 years of life)

Valve-regulated lead-acid battery ( 10 years of life)

≥7 years (~62, 000 hours)



1~3 years

5 years

10 years

Replacing Fuses

Recommended replacement time

5~6 years

5~6 years

5~6 years

1~2 years

Recommended check period

6 months

1 year

1 year

2 months

3~4 years 6 months

6~8 years 6 months

When replacing the fuse on the high-voltage interface board or the fuse in the fuse box, use a fuse of the same model, avoid being misled by the parameter screen-print on the fuse box.In the systems, do not exchange the AC fuse with

DC fuse.

Maintenance

Some routine maintenance works for UPS:

1. Keep good record. Good history record is helpful to solve some difficult problems.

2. Keep clean. Keep the UPS from dust and moisture.

3. Keep suitable ambient temperature, and the most suitable temperature is 20ºC to 25ºC. Too low temperature will reduce the battery capacity and too high temperature will reduce battery life.

4. Check connections. All the connection screws should be tightened and should be calibrated once a year.

5. Check periodically. Periodically check if there is any abnormal condition in the upstream and downstream of the

UPS so as to cut the input or output when over current happens.

The maintenance engineer should be familiar with the typical environmental conditions of the UPS so as to find out which environmental condition is abnormal. He should also be familiar with the location of the UPS control and display panel.

For the battery maintenance, refer to 6.11 Battery Maintenance


90 Appendix 1 Transportation Restraints Removing Procedures

Appendix 1 Transportation Restraints Removing Procedures

1. Rectifier Input Transformer Transportation Restraints Removing

Procedures

1. There is a small metallic cover at the left bottom part of the rectifier cabinet, remove this cover to expose the transportation restraints at the bottom part of the input transformer, as shown in Figure 1. Keep the removed screws.

Appendix- 1 Removing the input transformer transportation restraints

2. There is a transportation restraint respectively in the left and right sides at the bottom of the input transformer. First, remove the two M16 screws at the bottom part of the transportation restraint shown in Figure 1.

Note

Only remove the screw underneath the transportation restraint, the screw on the top of the transportation restraint needs not to be removed.

3. Remove the right cover of the rectifier cabinet to expose the metallic cover at the location as shown above. Keep the removed screws.

4. Remove the metallic cover to expose the transportation restraints on another side of the transformer. Keep the removed screws.

5. Remove the two M16 screws at the bottom part of the transportation restraint.

6. Re-install the metallic covers at two sides of the rectifier cabinet to their original positions.

7. Re-install the right panel of the rectifier cabinet to its original position. Execute this step after equipment commissioning is completed.


Appendix 1 Transportation Restraints Removing Procedures 91

2. Inverter Output Transformer Transportation Restraints Removing

Procedures

1. There is a small metallic cover at the left bottom part of the inverter cabinet, remove this cover to expose the transportation restraints at the bottom part of the input transformer, as shown in Figure 2. Keep the removed screws.

Appendix- 2 Removing the output transformer transportation restraints

2. There is a transportation restraint respectively in the two sides at the bottom of the output transformer. First, remove the two M16 screws at the bottom part of the transportation restraint shown in Figure 2.

Note

Only remove the screw underneath the transportation restraint, the screw on the top of the transportation restraint needs not to be removed.

3. Remove the metallic cover at the right bottom part (in the same location as described above) of the inverter cabinet to expose the transportation restraints at another side of the transformer. Keep the removed screws.

Note: On the left side of the metallic cover, there is a metallic base plate of a discharging resistor (for bus capacitor), and this plate blocks the metallic cover. Move this plate 30 cm to the left and then remove the metallic cover.

4. Remove the two M16 screws at the bottom part of the transportation restraint.

5. Re-install the metallic covers at two sides of the Inverter cabinet to their original positions, and move the metallic base plate of the discharging resistor to its original position.


92 Appendix 2 : Hazardous Substances or Elements Announcement

Appendix 2 : Hazardous Substances or Elements Announcement

Parts

Hazardous Substances

Plumbum Hydrargyru Cadmium Chrome

6+

PBB PBDE

Pb Hg Cd Cr

6+

PBB PBDE

Cabinet/ Enclosure /

Copper busbar

Metallic parts / fixing parts

Plastic parts

Heatsink

PCBA

○

○

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×

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○

○

○

○

○

AC capcitor

DC capacitor

Fan

Cables

LCD

Sensors

Large-medium power magnetic components

Distribution switches

(circuit breaker /

○

○

○

×

○

×

○

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○

○

○ contactor)

Fuse

Contactor (when applicable)

○

○

○

○

○

○

○

○

○

○

○

○

Semiconductors ○ ○ ○ ○ ○ ○

○: Means the content of the hazardous substances in all the average quality materials of the part is within the limits specified in SJ/T-11363-2006

×: Means the content of the hazardous substances in at least one of the average quality materials of the part is outside the limits specified in SJ/T11363-2006

Emerson Network Power Co., Ltd. has been committed to the design and manufacturing of environment-friendly products. It will reduce and eventually eliminate the harzardous substances in the products through unremitting efforts in research. However, limited by the current technical level, the following parts still contain harzardous substances due to the lack of reliable substitute or mature solution:

1. All solders in the products contain plumbum

2. Copper alloy contains plumbum

3. Backlight bulb contains Hydrargyrum

About Environment Protection Period: The Environment Protection Period of the product is marked on the product.

Under normal working condtions and normal use of the products observing relevant safety precautions, the hazardous substances in the product will not seriously affect the environment, personnel safety or property in the

Environment Protection Period starting from the manufacturing date.

Applicable product:Liebert HIPULSE-NXL 500/800kVA


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